HV BATTERY STACK 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 may result if a HV battery or hybrid vehicle supply stack sub-assembly is disposed of improperly or abandoned. Therefore, make sure to return all HV battery or hybrid vehicle supply stack sub-assemblies through an authorized collection agent.
To reduce the risk of fire, HV batteries and hybrid 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.

INSPECT FOR ELECTROLYTE LEAK

CAUTION:

Wear insulated gloves.
1. Inspect for electrolyte leaks after removing a hybrid vehicle supply stack sub-assembly.
  
  OK
  
  No leak was found on the lower part of the battery outer case.
  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

OK
No leak was found on the lower part of the battery outer case.

CHECK FOR DTCS

Check the previously recorded DTCs which resulted in replacement of the hybrid vehicle supply stack sub-assembly.

Result

Result	Proceed to
DTC record not available.	A
The hybrid vehicle supply stack sub-assembly was replaced due to one of the DTCs listed in the following table.	B
The hybrid vehicle supply stack sub-assembly 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

Go to step 7

Go to step 5

CHECK HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY VOLTAGE

CAUTION:

Wear insulated gloves.

Text in Illustration
*1	No. 1 Hybrid Vehicle Supply Stack Sub-assembly
*2	No. 2 Hybrid Vehicle Supply Stack Sub-assembly
*3	No. 3 Hybrid Vehicle Supply Stack Sub-assembly
*4	No. 4 Hybrid Vehicle Supply Stack Sub-assembly

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

Standard Voltage

Tester Connection	Condition	Specified Condition
f7-1 - P4-1	Power switch off	Below 57.4 V
P3-1 - A-1	Power switch off	Below 57.4 V
B-1 -P6-1	Power switch off	Below 57.4 V
P5-1 - o7-1	Power switch off	Below 57.4 V

CAUTION:

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

Tech Tips

Measure the voltage of the hybrid vehicle supply stack sub-assembly that will be replaced.

Go to step 7

INSULATION INSPECTION OF HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Wear insulated gloves.

Text in Illustration
*1	Insulation inspection area of the bracket

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
f7-1 - Insulation inspection area of the bracket	Always	1 MΩ or higher
A-1 - Insulation inspection area of the bracket	Always	1 MΩ or higher
B-1 - Insulation inspection area of the bracket	Always	1 MΩ or higher
o7-1 - Insulation inspection area of the bracket	Always	1 MΩ or higher

Tech Tips

Measure the resistance of the hybrid vehicle supply stack sub-assembly that will be replaced.

Go to step 7

HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY VISUAL CHECK

CAUTION:

Wear insulated gloves.
1. Check that there is no deformation or discoloration of the hybrid vehicle supply stack sub-assembly.
  
  OK
  
  There is no deformation or discoloration of the hybrid vehicle supply stack sub-assembly.
  
  NG
  Go to step 7
  
  OK
RETURN HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY
HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY 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)