HV BATTERY RECOVERY INSPECTION

CAUTION:


  • When disposing of HV batteries or hybrid vehicle supply stack sub-assemblies, make sure to return them through an authorized collection agent who is capable of handling them safely. If they are returned via the manufacturer specified route, they will be returned properly and in a safe manner by an authorized collection agent.

  • Before returning a HV battery or hybrid vehicle supply stack sub-assembly, make sure to perform a recovery inspection.

  • Accidents such as electric shock or fire may result if the HV battery or a hybrid vehicle supply stack sub-assembly is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries or hybrid vehicle supply stack sub-assemblies through an authorized collection agent.

  • To reduce the risk of fire, HV batteries and vehicle supply stack sub-assemblies must not be stored in an area where they will be exposed to fire or high temperatures.

  • If the temperature of the HV battery and hybrid vehicle supply stack sub-assemblies is high, leave the vehicle until the temperature drops.

Tech Tips

In order to return the HV batteries and hybrid vehicle supply stack sub-assemblies in a safe manner, discharge it as necessary. By performing a recovery inspection, whether discharging the HV batteries and hybrid vehicle supply stack sub-assemblies will be required or not and the discharge method can be checked.


  1. INSPECT FOR ELECTROLYTE LEAK

    CAUTION:

    Wear insulated gloves.


    1. A0041REE01
      Text in Illustration
      *a 155 mm (6.10 in.) or more

      Tilt the HV battery as shown in the illustration and leave it for 5 minutes.

    2. Check that no electrolyte is leaking from the HV battery.

      OK
      There is no electrolyte leaking from the HV battery.

      CAUTION:


      • Perform this procedure in an area where the battery will not be exposed to fire.

      • Do not touch the HV battery, unless absolutely necessary, as electrolyte may be leaking.

      Note

      If there is an electrolyte leak, make sure to wear insulated gloves and goggles and clean it using a piece of cloth. Do not leave electrolyte-contaminated cloths unattended. Dispose of them according to law or local regulations.


      NG

      DISCHARGING (WHEN USING THE SALT WATER SOLUTION)
      OK

  2. CHECK FOR DTCS


    1. Check the previously recorded DTCs which resulted in replacement of the HV battery or a hybrid vehicle supply stack sub-assembly.

      Result
      Result Proceed to
      DTC record not available. A
      The HV battery was replaced due to one of the DTCs listed in the following table. B
      The HV battery was replaced due to a reason other than the DTCs listed in the following table. C
      DTC No. Relevant Diagnosis
      P1A60-123 Hybrid Battery Cell High Voltage Stack "B"
      P1A63-123 Hybrid Battery Cell High Voltage Stack "C"
      P1A66-123 Hybrid Battery Cell High Voltage Stack "D"
      P31AA-123 Hybrid Battery Cell High Voltage
      P1A61-123 Hybrid Battery Cell Low Voltage Stack "B"
      P1A64-123 Hybrid Battery Cell Low Voltage Stack "C"
      P1A67-123 Hybrid Battery Cell Low Voltage Stack "D"
      P31AB-123 Hybrid Battery Cell Low Voltage
      P1A62-123 Hybrid Battery Cell Extreme High Voltage Stack "B"
      P1A65-123 Hybrid Battery Cell Extreme High Voltage Stack "C"
      P1A68-123 Hybrid Battery Cell Extreme High Voltage Stack "D"
      P31AC-123 Hybrid Battery Cell Extreme High Voltage
      P31B3-123 Hybrid Battery Voltage High
      P0AA6-612 Hybrid Battery Voltage System Isolation Fault

      B

      Go to step 7
      C

      Go to step 5
      A

  3. CHECK HV BATTERY VOLTAGE

    CAUTION:

    Wear insulated gloves.


    1. A0043SME01
      Text in Illustration
      *1 No. 1 Hybrid Vehicle Battery Pack Cable
      *2 No. 2 Hybrid Vehicle Battery Pack Cable
      *3 Electric Vehicle Battery Plug Assembly

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      o8-1(-) - Service plug grip connecting terminal 1 Power switch off Below 114.8 V
      f8-1(+) - Service plug grip connecting terminal 2 Power switch off Below 114.8 V

      CAUTION:

      Make sure not to cross the electrodes of an electrical tester measurement terminals.


      NG

      Go to step 7
      OK

  4. INSULATION INSPECTION OF HV BATTERY

    CAUTION:

    Wear insulated gloves.


    1. A0040MSE01
      Text in Illustration
      *1 Battery outer case insulation inspection area

      Using a megohmmeter set to 500 V, measure the insulation 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
      f8-1(+) - Battery Outer Case Always 1 MΩ or higher
      o8-1(-) - Battery Outer Case Always 1 MΩ or higher

      NG

      Go to step 7
      OK

  5. HV BATTERY VISUAL CHECK

    CAUTION:

    Wear insulated gloves.


    1. Check that there is no deformation or discoloration of the HV battery.

      OK
      There is no deformation or discoloration of the HV battery.

      NG

      Go to step 7
      OK

  6. RETURN HV BATTERY

  7. HV BATTERY CONNECTORS VISUAL CHECK


    1. Check that there are no deformations or abnormalities in the orange connectors connected to the battery smart unit.

      Tech Tips

      If any of the connectors are damaged, a Li-ion battery discharger will not be able to be connected to the HV battery. Soak the HV battery in a saltwater solution to discharge it.

      OK
      There are no deformations or abnormalities in the connectors.

      NG

      DISCHARGING (WHEN USING THE SALT WATER SOLUTION)
      OK
      DISCHARGING (WHEN USING THE LI-ION BATTERY DISCHARGER)