HYBRID CONTROL SYSTEM, Diagnostic DTC:P321D17

DTC Code DTC Name
P321D17 Charger Circuit Voltage Above Threshold

DTC SUMMARY


  1. MALFUNCTION DESCRIPTION

    If overvoltage of the VCHG capacitor is detected due to an internal or external malfunction of the electric vehicle charger assembly, the electric vehicle charger assembly will be turned off as a protection function and a DTC will be stored.

    The cause of this malfunction may be one of the following:


      Low-voltage circuit (12 V) malfunction

    • Charge relay operation command circuit malfunction (between the battery ECU assembly and HV battery junction block assembly (CHRB-CHRG))


      High voltage system malfunction

    • Charging circuit malfunction

      - High voltage circuit malfunction in the electric vehicle charger assembly (open circuit/temporary interruption)

      - High voltage circuit between the electric vehicle charger assembly and HV battery junction block assembly (open circuit/temporary interruption) *1

      - High voltage circuit between the electric vehicle charger assembly and solar energy control unit (open circuit/temporary interruption) *2

      - High voltage circuit malfunction in the solar energy control unit (open circuit/temporary interruption) *2

      - High voltage circuit between the solar energy control unit and HV battery junction block assembly (open circuit/temporary interruption) *2

    • HV battery junction block assembly malfunction (CHRB, CHRG)

      - HV battery junction block assembly (CHRB-CHRG) (open circuit/temporary interruption)

      - High voltage circuit between the HV battery and HV battery junction block assembly (open circuit/temporary interruption)

    *1: w/o Solar Charging System

    *2: w/ Solar Charging System

  2. INSPECTION DESCRIPTION

    B006HQDE02
    System Diagram Range Inspection Content Reason
    *a Check the connection condition of the connectors and the continuity of the wire harness between the battery ECU assembly and HV battery junction block assembly. Improperly connected connectors and open in CHRB and CHRG excitation line.
    *b Check whether the HV battery junction block assembly connector is connected. Improperly connected HV battery junction block assembly connector.
    *c Check the connection condition and the continuity of the high-voltage cable between the electric vehicle charger assembly and HV battery junction block assembly. Improperly connected connectors and open circuit confirmation.
    *d Inspect the electric vehicle charger assembly internal circuit. Open in the electric vehicle charger assembly.
    *e Inspect the HV battery junction block assembly internal circuit. Open in the HV battery junction block assembly.
    B006I18E03
    System Diagram Range Inspection Content Reason
    *a Check the connection condition of the connectors and the continuity of the wire harness between the battery ECU assembly and HV battery junction block assembly. Improperly connected connectors and open in CHRB and CHRG excitation line.
    *b Check whether the HV battery junction block assembly connector is connected. Improperly connected HV battery junction block assembly connector.
    *c Check the connection condition and the continuity of the high-voltage cable between the electric vehicle charger assembly and solar energy control unit. Improperly connected connectors and open circuit confirmation.
    *d Inspect the electric vehicle charger assembly internal circuit. Open in the electric vehicle charger assembly.
    *e Check the connection condition and the continuity of the high-voltage cable between the solar energy control unit and HV battery junction block assembly. Improperly connected connectors and open circuit confirmation.
    *f Inspect the solar energy control unit internal circuit. Open in the solar energy control unit.
    *g Inspect the HV battery junction block assembly internal circuit. Open in the HV battery junction block assembly.

DESCRIPTION

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P321D17 Charger Circuit Voltage Above Threshold

The charging voltage increases rapidly due to a charging circuit malfunction during charging.

(1 trip detection logic)

  • Electric vehicle charger assembly

  • Battery ECU assembly

  • No. 1 HV battery junction block assembly

  • No. 2 HV battery junction block assembly

  • HV battery charger wire

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
Related Data List
DTC No. Data List
P321D17

  • AC Charging Precharge Relay Drive Request

  • AC Charging Precharge Relay Status

  • AC Charging Positive Relay Drive Request

  • AC Charging Positive Relay Status

  • AC Charging Negative Relay Drive Request

  • AC Charging Negative Relay Status

  • Charging Voltage for Hybrid Battery

  • Charger Start Request by Hybrid Control ECU

  • Charger Input Power

  • AC Input Current

  • Charger Start Request by Hybrid Control ECU

  • Charging Permission Signal by Sub CPU

  • Charging Permission Answerback Signal from Plug-in Control ECU

CONFIRMATION DRIVING PATTERN

Tech Tips

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click here


  1. Connect the GTS to the DLC3.

  2. Turn the power switch on (IG) and turn the GTS on.

  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

  4. Enter the following menus: Powertrain / Hybrid Control / Data List.

  5. Check that "Hybrid Battery SOC" shows 70% or less.

  6. Turn the power switch off and wait for 2 minutes or more.

  7. Connect the electric vehicle charger cable assembly, and plug-in charge the vehicle for at least 30 seconds.

  8. Disconnect the electric vehicle charger cable assembly and wait for 10 seconds or more.

  9. Turn the power switch on (IG) and turn the GTS on.

  10. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

  11. Check the DTC judgment result.

    Tech Tips


    • If the judgment result shows NORMAL, the system is normal.

    • If the judgment result shows ABNORMAL, the system has a malfunction.

    • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P308F49.

Click here

CAUTION / NOTICE / HINT

CAUTION:


  • B006HUP

    Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.


    • Inspecting the high-voltage system

    • Disconnecting the low voltage connector of the inverter with converter assembly

    • Disconnecting the low voltage connector of the HV battery

    • Disconnecting the low voltage connector of the electric vehicle charger assembly

    • Disconnecting the low voltage connector of the solar energy control unit

  • B006IQP

    To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

  • B006HQC

    After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • B006IVPC02
    *a Without waiting for 10 minutes

    After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

    Click here

    Tech Tips

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

Note

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL, HV BATTERY, PLUG-IN CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control, HV Battery and Plug-in Control / Trouble Codes.

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Powertrain > HV Battery > Trouble Codes
      Powertrain > Plug-in Control > Trouble Codes
      Result
      Result Proceed to
      P321D17 only is output, or DTCs except the ones in the table below are also output. A
      DTCs of hybrid control system in the tables below are output. B
      DTCs of hybrid battery system in the tables below are output. C
      DTCs of plug-in charge control system in the tables below are output. D
      Malfunction Content System Relevant DTC
      Microcomputer malfunction Hybrid control system P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
      P060694 Hybrid/EV Powertrain Control Module Processor Unexpected Operation
      P060A29 Hybrid/EV Powertrain Control Module Monitoring Processor Signal Invalid
      P060A44 Hybrid/EV Powertrain Control Module Monitoring Processor Data Memory Failure
      P060A45 Hybrid/EV Powertrain Control Module Monitoring Processor Program Memory Failure
      P060A47 Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure
      P060A49 Hybrid/EV Powertrain Control Module Monitoring Processor Internal Electronic Failure
      P060A94 Hybrid/EV Powertrain Control Module Monitoring Processor Unexpected Operation
      P1CE31C Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Voltage Out of Range
      P1CE349 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Internal Electronic Failure
      P1CE371 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Actuator Stuck
      Hybrid battery system P060687 Hybrid/EV Battery Energy Control Module Processor to Monitoring Processor Missing Message
      P060A47 Hybrid/EV Battery Energy Control Module Monitoring Processor Watchdog / Safety MCU Failure
      P060A87 Hybrid/EV Battery Energy Control Module Processor from Monitoring Processor Missing Message
      P060B16 Hybrid/EV Battery Energy Control Module A/D Processing Circuit Voltage Below Threshold
      P060B49 Hybrid/EV Battery Energy Control Module A/D Processing Internal Electronic Failure
      Plug-in charge control system P060B49 Plug-in Control Module A/D Processing Internal Electronic Failure
      P1C1F49 Hybrid/EV Battery Charger Control Module A/D Processing Internal Electronic Failure
      Power source circuit malfunction Hybrid control system P06881F ECM/PCM Power Relay Sense Circuit Intermittent
      Hybrid battery system P056014 System Voltage (BATT) Circuit Short to Ground or Open
      P1CBB12 Hybrid/EV Battery Current Sensor Power Supply Circuit Short to Auxiliary Battery
      P1CBB14 Hybrid/EV Battery Current Sensor Power Supply Circuit Short to Ground or Open
      Communication system malfunction Hybrid control system P060687 Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message
      P060A87 Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message
      U011187 Lost Communication with Hybrid/EV Battery Energy Control Module "A" Missing Message
      U019B87 Lost Communication with Hybrid/EV Battery Charger Control Module Missing Message
      Hybrid battery system U029387 Lost Communication with Hybrid/EV Powertrain Control Module Missing Message
      U115087 Lost Communication with Hybrid Powertrain Control Module (Hybrid/EV Battery Local Bus) Missing Message
      Plug-in charge control system U115087 Lost Communication with Hybrid Powertrain Control Module (Hybrid/EV Battery Local Bus) Missing Message
      Sensor and actuator circuit malfunction Hybrid battery system P0ABF11 Hybrid/EV Battery Current Sensor "A" Circuit Short to Ground
      P0ABF15 Hybrid/EV Battery Current Sensor "A" Circuit Short to Auxiliary Battery or Open
      P0ABF28 Hybrid/EV Battery Current Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure
      P0ABF2A Hybrid/EV Battery Current Sensor "A" Signal Stuck In Range
      P0B0E11 Hybrid/EV Battery Current Sensor "B" Circuit Short to Ground
      P0B0E15 Hybrid/EV Battery Current Sensor "B" Circuit Short to Auxiliary Battery or Open
      P0B1362 Hybrid/EV Battery Current Sensor "A"/"B" Signal Compare Failure
      P0D0A15 Hybrid/EV Battery Charging System Positive Contactor Control Circuit Short to Auxiliary Battery or Open
      P0D1115 Hybrid/EV Battery Charging System Negative Contactor Control Circuit Short to Auxiliary Battery or Open
      Plug-in charge control system P0D4C12 Hybrid/EV Battery Charger Hybrid/EV Battery Input Voltage Sensor Circuit Short to Auxiliary Battery
      P0D4C14 Hybrid/EV Battery Charger Hybrid/EV Battery Input Voltage Sensor Circuit Short to Ground or Open
      System malfunction Hybrid control system P1AC413 Hybrid/EV Battery Stack 1 Current Interrupt Device Circuit Open
      P0A0A92 High Voltage System Interlock Performance or Incorrect Operation
      P0A1F94 Hybrid/EV Battery Energy Control Module Unexpected Operation
      Hybrid battery system P1AC413 Hybrid/EV Battery Stack 1 Current Interrupt Device Circuit Open
      P1AC49E Hybrid/EV Battery Stack 1 Current Interrupt Device Stuck On
      P1AC513 Hybrid/EV Battery Stack 2 Current Interrupt Device Circuit Open
      P1AC59E Hybrid/EV Battery Stack 2 Current Interrupt Device Stuck On
      P1AC613 Hybrid/EV Battery Stack 3 Current Interrupt Device Circuit Open
      P1AC69E Hybrid/EV Battery Stack 3 Current Interrupt Device Stuck On
      P1AC713 Hybrid/EV Battery Stack 4 Current Interrupt Device Circuit Open
      P1AC79E Hybrid/EV Battery Stack 4 Current Interrupt Device Stuck On
      P1AC813 Hybrid/EV Battery Stack 5 Current Interrupt Device Circuit Open
      P1AC89E Hybrid/EV Battery Stack 5 Current Interrupt Device Stuck On

      Tech Tips


      • P321D17 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    D

    GO TO DTC CHART (PLUG-IN CHARGE CONTROL SYSTEM) Click here

    A

  2. CHECK CONNECTOR CONNECTION CONDITION (BATTERY ECU ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006J82N09

      Check the connector connection for the t14 battery ECU assembly connector.

    4. Disconnect the t14 battery ECU assembly connector.

    5. Check the contact pressure of each terminal of the t14 battery ECU assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the t14 battery ECU assembly connector.

    7. Install the upper hybrid battery cover sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  3. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006HEMN10

      Check the connector connection for the t4 No. 2 HV battery junction block assembly connector.

    4. Disconnect the t4 No. 2 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the t4 No. 2 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the t4 No. 2 HV battery junction block assembly connector.

    7. Install the upper hybrid battery cover sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  4. CHECK CONNECTOR CONNECTION CONDITION (NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006IO9N13

      Check the connector connection for the t8 No. 1 HV battery junction block assembly connector.

    4. Disconnect the t8 No. 1 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the t8 HV No. 1 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the t8 No. 1 HV battery junction block assembly connector.

    7. Install the upper hybrid battery cover sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  5. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006J82N09

      Disconnect the t14 battery ECU assembly connector.

    4. B006HEMN10

      Disconnect the t4 No. 2 HV battery junction block assembly connector.

    5. B006HO8C05
      *a

      Front view of wire harness connector

      (to Battery ECU Assembly)
      *b

      Front view of wire harness connector

      (to No. 2 HV Battery Junction Block Assembly)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      t14-52 (CHRB) - t4-2 (CHRB) IG OFF Below 1 Ω
      t14-52 (CHRB) and t4-2 (CHRB) - Body ground and other terminals IG OFF 10 kΩ or higher

    6. Reconnect the t4 No. 2 HV battery junction block assembly connector.

    7. Reconnect the t14 battery ECU assembly connector.

    8. Install the upper hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006J82N09

      Disconnect the t14 battery ECU assembly connector.

    4. B006IO9N13

      Disconnect the t8 No. 1 HV battery junction block assembly connector.

    5. B006HWBC03
      *a

      Front view of wire harness connector

      (to Battery ECU Assembly)
      *b

      Front view of wire harness connector

      (to No. 1 HV Battery Junction Block Assembly)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      t14-51 (CHRG) - t8-1 (CHRG) IG OFF Below 1 Ω
      t14-51 (CHRG) and t8-1 (CHRG) - Body ground and other terminals IG OFF 10 kΩ or higher

    6. Reconnect the t8 No. 1 HV battery junction block assembly connector.

    7. Reconnect the t14 battery ECU assembly connector.

    8. Install the upper hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. CHECK HARNESS AND CONNECTOR (NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006HEMN10

      Disconnect the t4 No. 2 HV battery junction block assembly connector.

    4. B006IJ4C07
      *a

      Front view of wire harness connector

      (to No. 2 HV Battery Junction Block Assembly)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      t4-1 (GNDB) - Body ground IG OFF Below 1 Ω

    5. Reconnect the t4 No. 2 HV battery junction block assembly connector.

    6. Install the upper hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. CHECK HARNESS AND CONNECTOR (NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006IO9N13

      Disconnect the t8 No. 1 HV battery junction block assembly connector.

    4. B006IKGC11
      *a

      Front view of wire harness connector

      (to No. 1 HV Battery Junction Block Assembly)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      t8-2 (GND) - Body ground IG OFF Below 1 Ω

    5. Reconnect the t8 No. 1 HV battery junction block assembly connector.

    6. Install the upper hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  9. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006J1WN01

      Check the connector connection for the j1 No. 2 HV battery junction block assembly connector.

    4. Disconnect the j1 No. 2 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the j1 No. 2 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the j1 No. 2 HV battery junction block assembly connector.

    7. Install the upper hybrid battery cover sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  10. CHECK CONNECTOR CONNECTION CONDITION (NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

      Click here

    3. B006HBGN01

      Check the connector connection for the i1 No. 1 HV battery junction block assembly connector.

    4. Disconnect the i1 No. 1 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the i1 No. 1 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the i1 No. 1 HV battery junction block assembly connector.

    7. Install the upper hybrid battery cover sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  11. CHECK CONNECTOR CONNECTION CONDITION (ELECTRIC VEHICLE CHARGER ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear under side cover RH.

      Click here

    3. B006HUKN01

      Check the connector connection for the U12 electric vehicle charger assembly connector.

    4. Disconnect the U12 electric vehicle charger assembly connector.

    5. Check the contact pressure of each terminal of the U12 electric vehicle charger assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the U12 electric vehicle charger assembly connector.

    7. Install the rear under side cover RH.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  12. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear under side cover RH.

      Click here

    3. B006HUKN01

      Check the connector connection for the U12 electric vehicle charger assembly connector.

    4. B006IY0C02
      *a

      Component without harness connected

      (Electric Vehicle Charger Assembly)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      U12-1 (DCHB) - U12-2 (DCHG) IG OFF Below 700 kΩ

      Note

      Read the resistance after the value has stabilized.

    5. Reconnect the U12 electric vehicle charger assembly connector.

    6. Install the rear under side cover RH.

      Result
      Result Proceed to
      OK (w/o Solar Charging System) A
      OK (w/ Solar Charging System) B
      NG C

    B

    CHECK CONNECTOR CONNECTION CONDITION (SOLAR ENERGY CONTROL UNIT CONNECTOR) Click here

    C

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

    A

  13. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 1 HV battery shield panel.

      Click here

    3. B006J5HN03

      Check the connector connection for the U9 No. 2 HV battery junction block assembly connector.

    4. Disconnect the U9 No. 2 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the U9 No. 2 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the U9 No. 2 HV battery junction block assembly connector.

    7. Install the No. 1 HV battery shield panel.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  14. CHECK CONNECTOR CONNECTION CONDITION (NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 1 HV battery shield panel.

      Click here

    3. B006HM6N03

      Check the connector connection for the U10 No. 1 HV battery junction block assembly connector.

    4. Disconnect the U10 No. 1 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the U10 No. 1 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the U10 No. 1 HV battery junction block assembly connector.

    7. Install the No. 1 HV battery shield panel.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  15. CHECK HV BATTERY CHARGER WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear under side cover RH.

      Click here

    3. B006HUKN01

      Check the connector connection for the U12 electric vehicle charger assembly connector.

    4. Remove the No. 1 HV battery shield panel.

      Click here

    5. B006HDGN07

      Disconnect the U9 and U10 HV battery junction block assembly connectors.

    6. Measure the resistance according to the value(s) in the table below.

      B006IHRC04
      *a

      HV Battery Charger Wire

      (Electric Vehicle Charger Assembly Side)

      		 *b

      HV Battery Charger Wire

      (HV Battery Junction Block Assembly Side)
      Standard Resistance
      Tester Connection Condition Specified Condition
      U12-1 (DCHB) - U9-1 (DCHB) IG OFF Below 1 Ω
      U12-2 (DCHG) - U10-1 (DCHG) IG OFF Below 1 Ω

    7. Reconnect the U9 and U10 HV battery junction block assembly connectors.

    8. Install the No. 1 HV battery shield panel.

    9. Reconnect the U12 electric vehicle charger assembly connector.

    10. Install the rear under side cover RH.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY CHARGER WIRE Click here

    OK

  16. INSPECT NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY (CHRB)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 HV battery junction block assembly.

      Click here

    3. Measure the resistance according to the value(s) in the table below.

      B006HW4C09
      *a

      Component without harness connected

      (No. 2 HV Battery Junction Block Assembly)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      j1-1 (+) - U9-1 (DCHB) Auxiliary battery voltage applied between terminals t4-2 (CHRB) and t4-1 (GNDB) Below 1 Ω

    4. Install the No. 2 HV battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

  17. CHECK CONNECTOR CONNECTION CONDITION (SOLAR ENERGY CONTROL UNIT CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear seat console box assembly.

      Click here

    3. B006IB2N02

      Disconnect the N73 solar energy control unit connector.

    4. B006IM3N02

      Disconnect the N71 and N72 solar energy control unit connectors.

    5. B006HUMN04

      Check the connector connection for the U11 solar energy control unit connector.

    6. Disconnect the U11 solar energy control unit connector.

    7. Check the contact pressure of each terminal of the U11 solar energy control unit connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    8. Reconnect the U11 solar energy control unit connector.

    9. Reconnect the N73 solar energy control unit connector.

    10. Reconnect the N71 and N72 solar energy control unit connectors.

    11. Install the rear seat console box assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  18. CHECK HV BATTERY CHARGER WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear seat console box assembly.

      Click here

    3. B006HUKN01

      Check the connector connection for the U12 electric vehicle charger assembly connector.

    4. B006IB2N02

      Disconnect the N73 solar energy control unit connector.

    5. B006IM3N02

      Disconnect the N71 and N72 solar energy control unit connectors.

    6. B006HUMN04

      Disconnect the U11 solar energy control unit connector.

    7. B006IDZC02
      *a

      HV Battery Charger Wire

      (Electric Vehicle Charger Assembly Side)
      *b

      HV Battery Charger Wire

      (Solar Energy Control Unit Side)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      U12-1 (DCHB) - U11-1 (DPLB) IG OFF Below 1 Ω
      U12-2 (DCHG) - U11-2 (DPLG) IG OFF Below 1 Ω

    8. Reconnect the U11 solar energy control unit connector.

    9. Reconnect the U12 electric vehicle charger assembly connector.

    10. Reconnect the N73 solar energy control unit connector.

    11. Reconnect the N71 and N72 solar energy control unit connectors.

    12. Install the rear seat console box assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY CHARGER WIRE Click here

    OK

  19. CHECK CONNECTOR CONNECTION CONDITION (SOLAR ENERGY CONTROL UNIT CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear seat console box assembly.

      Click here

    3. B006IB2N02

      Disconnect the N73 solar energy control unit connector.

    4. B006IM3N02

      Disconnect the N71 and N72 solar energy control unit connectors.

    5. B006J62N06

      Check the connector connection for the U13 solar energy control unit connector.

    6. Disconnect the U13 solar energy control unit connector.

    7. Check the contact pressure of each terminal of the U13 solar energy control unit connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    8. Reconnect the U13 solar energy control unit connector.

    9. Reconnect the N73 solar energy control unit connector.

    10. Reconnect the N71 and N72 solar energy control unit connectors.

    11. Install the rear seat console box assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  20. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 1 HV battery shield panel.

      Click here

    3. B006J5HN03

      Check the connector connection for the U9 No. 2 HV battery junction block assembly connector.

    4. Disconnect the U9 No. 2 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the U9 No. 2 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the U9 No. 2 HV battery junction block assembly connector.

    7. Install the No. 1 HV battery shield panel.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  21. CHECK CONNECTOR CONNECTION CONDITION (NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 1 HV battery shield panel.

      Click here

    3. B006HM6N03

      Check the connector connection for the U10 No. 1 HV battery junction block assembly connector.

    4. Disconnect the U10 No. 1 HV battery junction block assembly connector.

    5. Check the contact pressure of each terminal of the U10 No. 1 HV battery junction block assembly connector and check for foreign matter or arc marks on the terminals.

      Click here

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There is neither foreign matter nor ark marks. A
      The terminals are not connected securely and there is a contact problem. There is any of foreign matter or ark marks. B
      The terminals are not connected securely and there is a contact problem. There is neither foreign matter nor ark marks. C
      The terminals are connected securely and there are no contact problems. There is any of foreign matter or ark marks. B

    6. Reconnect the U10 No. 1 HV battery junction block assembly connector.

    7. Install the No. 1 HV battery shield panel.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  22. CHECK HV BATTERY CHARGER WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear seat console box assembly.

      Click here

    3. B006IB2N02

      Disconnect the N73 solar energy control unit connector.

    4. B006IM3N02

      Disconnect the N71 and N72 solar energy control unit connectors.

    5. B006J62N06

      Disconnect the U13 solar energy control unit connector.

    6. Remove the No. 1 HV battery shield panel.

      Click here

    7. B006HDGN07

      Disconnect the U9 and U10 HV battery junction block assembly connectors.

    8. Measure the resistance according to the value(s) in the table below.

      B006HRNC06
      *a

      HV Battery Charger Wire

      (Solar Energy Control Unit Side)

      		 *b

      HV Battery Charger Wire

      (HV Battery Junction Block Assembly Side)
      Standard Resistance
      Tester Connection Condition Specified Condition
      U13-1 (DCHB) - U9-1 (DCHB) IG OFF Below 1 Ω
      U13-2 (DCHG) - U10-1 (DCHG) IG OFF Below 1 Ω

    9. Reconnect the U9 and U10 HV battery junction block assembly connectors.

    10. Install the No. 1 HV battery shield panel.

    11. Reconnect the U13 solar energy control unit connector.

    12. Reconnect the N73 solar energy control unit connector.

    13. Reconnect the N71 and N72 solar energy control unit connectors.

    14. Install the rear seat console box assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY CHARGER WIRE Click here

    OK

  23. CHECK SOLAR ENERGY CONTROL UNIT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the rear seat console box assembly.

      Click here

    3. B006IB2N02

      Disconnect the N73 solar energy control unit connector.

    4. B006IM3N02

      Disconnect the N71 and N72 solar energy control unit connectors.

    5. B006HMJN04

      Disconnect the U11 and U13 solar energy control unit connector.

    6. B006HEEC08
      *a

      Component without harness connected

      (Solar Energy Control unit)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      U13-1 (DCHB) - U11-1 (DPLB) IG OFF Below 1 Ω
      U13-2 (DCHG) - U11-2 (DPLG) IG OFF Below 1 Ω

    7. Reconnect the U11 and U13 solar energy control unit connector.

    8. Reconnect the N73 solar energy control unit connector.

    9. Reconnect the N71 and N72 solar energy control unit connectors.

    10. Install the rear seat console box assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE SOLAR ENERGY CONTROL UNIT Click here

    OK

  24. INSPECT NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY (CHRB)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 HV battery junction block assembly.

      Click here

    3. Measure the resistance according to the value(s) in the table below.

      B006HW4C09
      *a

      Component without harness connected

      (No. 2 HV Battery Junction Block Assembly)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      j1-1 (+) - U9-1 (DCHB) Auxiliary battery voltage applied between terminals t4-2 (CHRB) and t4-1 (GNDB) Below 1 Ω

    4. Install the No. 2 HV battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here