HYBRID CONTROL SYSTEM HV Battery High-voltage Line Circuit

DESCRIPTION

The cause of the malfunction may be the HV battery high-voltage line circuit.

Check the continuity in the high-voltage line from the HV battery to the inverter.

Check the connection condition and for an open circuit in the frame wire from the service plug grip, EV electric battery fuse and HV battery to the inverter and perform a function check of the system main relay.

Related Parts Check
Area Inspection Step
High-voltage circuit from HV battery to inverter Check connection condition and for open circuit. 1, 5, 6
Service plug grip Check connection condition and for open circuit. 2, 3
EV electric battery fuse Check for open circuit. 4
System Main Relay Check operation condition as relay. 7, 8

SYSTEM DESCRIPTION

The HV battery high voltage is supplied to the inverter via the system main relay operation.

WIRING DIAGRAM

B006J6PE03

CAUTION / NOTICE / HINT

This step is referenced from the procedures for each DTC.

If the inspection results below are normal, perform the next procedure for the referenced DTC.

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 INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER 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. B006ISO

      Check that the bolts for the HV floor under wire is tightened to the specified torque, the HV floor under wire is connected securely, and there are no contact problems.

      Specified Condition
      T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

    3. Disconnect the HV floor under wire from the inverter with converter assembly.

    4. Check for arc marks on the terminals for the HV floor under wire and inverter with converter assembly.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    5. Reconnect the HV floor under wire.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  2. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK
      Dirt or foreign matter has not entered the connectors, and there is no evidence of contamination.

    2. Install the service plug grip.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  3. INSPECT SERVICE PLUG GRIP

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the service plug grip.

      Click here

    2. B006IHBC01
      *1 Service Plug Grip

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω

    3. Install the service plug grip.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  4. CHECK HYBRID BATTERY TERMINAL BLOCK

    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. B006IWYN01

      Disconnect the s1 and r1 HV battery high voltage connectors from the hybrid battery terminal block.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    4. B006IKUC05
      *a

      Component without harness connected

      (Hybrid Battery Terminal Block)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      s1-1 - r1-1 Always Below 1 Ω

    5. Reconnect the s1 and r1 HV battery high voltage connectors to the hybrid battery terminal block.

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

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    OK

  5. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER 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 No. 1 HV battery shield panel.

      Click here

    3. B006J4MN02

      Check that the HV floor under wire is connected securely, and there are no contact problems.

    4. Disconnect the S2 and S3 HV floor under wire connectors from the HV battery junction block assembly.

    5. Check for arc marks on the terminals of the HV floor wire and the HV battery junction block assembly.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Reconnect the S2 and S3 HV floor under wire connectors.

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


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  6. CHECK HV FLOOR UNDER 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 No. 1 HV battery shield panel.

      Click here

    3. B006J4MN02

      Disconnect the S2 and S3 HV floor under wire connectors from the HV battery junction block assembly.

    4. B006H8X

      Disconnect the HV floor under wire connector from the inverter with converter assembly.

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

      B006HFFC03
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      		 *b

      HV Floor Under Wire

      (No. 2 HV Battery Junction Block Assembly Side)
      *c

      HV Floor Under Wire

      (No. 1 HV Battery Junction Block Assembly Side)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - S3-1 (CBI) Power switch off Below 1 Ω
      S1-2 (CEI) - S2-1(CEI) Power switch off Below 1 Ω

      Note

      Be sure not to damage or deform the terminal being inspected.

    6. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) or S3-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-2 (CEI) or S2-1(CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-1 (CBI) - S1-2 (CEI) Power switch off 10 MΩ or higher
      S3-1 (CBI) - S2-1(CEI) Power switch off 10 MΩ or higher

    7. Reconnect the HV floor under wire connector to the inverter with converter assembly.

    8. Reconnect the S2 and S3 HV floor under wire connectors to the HV battery junction block assembly.

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

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV FLOOR UNDER WIRE Click here

    OK

  7. INSPECT NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    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.

      B006HW4C10
      *a

      Component without harness connected

      (No. 2 HV Battery Junction Block Assembly)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      j1-1 (+) - S3-1 (CBI) Auxiliary battery voltage not applied between terminals t4-3 (SMRB) and t4-1 (GNDB) 10 kΩ or higher
      j1-1 (+) - S3-1 (CBI) Auxiliary battery voltage applied between terminals t4-3 (SMRB) and t4-1 (GNDB) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      t4-3 (SMRB) - t4-1 (GNDB) -40 to 80°C (-40 to 176°F) 20.6 to 40.8 Ω

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

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  8. INSPECT NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

    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. 1 HV battery junction block assembly.

      Click here

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

      B006J14C40
      *a

      Component without harness connected

      (No. 1 HV Battery Junction Block Assembly)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      i1-1 (-) - S2-1 (CEI) Auxiliary battery voltage not applied between terminals t8-3 (SMRG) and t8-2 (GND) 10 kΩ or higher
      i1-1 (-) - S2-1 (CEI) Auxiliary battery voltage applied between terminals t8-3 (SMRG) and t8-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      t8-3 (SMRG) - t8-2 (GND) -40 to 80°C (-40 to 176°F) 20.6 to 40.8 Ω

    5. Install the No. 1 HV battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    OK

    HV BATTERY HIGH-VOLTAGE LINE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

    NG

    REPLACE NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here