PRECAUTIONS FOR INSPECTING HYBRID CONTROL SYSTEM
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, turn the ignition switch off and take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
Note
After turning the ignition 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.
After removing the service plug grip, turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the ignition switch to ON (READY) unless instructed by the repair manual.
After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.
Tech Tips
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
Check the voltage at the terminals in the inspection point in the inverter with converter assembly.
CAUTION:
Be sure to wear insulated gloves.
Note
Do not allow any foreign objects or water to enter the inverter with converter assembly.
*1 | Inverter Terminal Cover |
*2 | Interlock Connector |
Remove the 2 bolts and inverter terminal cover Click here.
CAUTION:
An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.
Note
Make sure to pull the inverter terminal cover straight up to remove it, because an interlock connector is connected to the bottom of the inverter terminal cover.
Remove the 7 bolts and inverter cover.
CAUTION:
An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.
Measure the voltage according to the value(s) in the table below.
Tech Tips
Set the tester to DC750 V or more to measure the voltage.
When turning the ignition switch to ON (IG) during inspections, do not turn the ignition switch with the brake pedal depressed.
CAUTION:
Turning the ignition switch with the brake pedal depressed causes the system to enter the READY-on state. This is very dangerous because high voltage may be applied to the inspection area.
Turn the ignition switch off, wear insulated gloves, and disconnect the cable from the negative (-) terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system.
Note
After turning the ignition 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.
Turn the ignition switch off before performing any resistance checks.
Turn the ignition switch off before disconnecting or reconnecting any connectors.
When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or a insulated tool.
When high-voltage connectors are removed, wrap the connectors with insulation tape to prevent them from contacting foreign objects.
NOTICE FOR HYBRID CONTROL SYSTEM ACTIVATION
When the warning light is illuminated, or the auxiliary battery has been disconnected and reconnected, attempting to turn the ignition switch to ON (READY) may not start the system (the system may not enter the READY-on state) on the first attempt. If so, turn the ignition switch off and reattempt to start the hybrid system.
Note
After turning the ignition 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.
PRECAUTIONS FOR DISCONNECTING AMD TERMINAL
Tech Tips
The AMD terminal is connected to the positive terminal of the auxiliary battery. To prevent damage when the AMD terminal is being disconnected, use the following procedure.
*1 | AMD Terminal |
Be sure to disconnect the cable from the negative (-) terminal of the auxiliary battery before disconnecting the AMD terminal from the engine room relay block.
Note
After turning the ignition 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.
After disconnecting the AMD terminal, wrap the terminal with insulation tape.
Be sure to reconnect the AMD terminal to the engine room relay block before reconnecting the cable of the negative (-) terminal of the auxiliary battery.
Note
A short circuit to ground may occur if the AMD terminal is disconnected before the cable is disconnected from the negative (-) terminal of the auxiliary battery. If a short circuit to ground occurs, it can result in an open circuit in a fusible link or fuse.
COOLING FAN SYSTEM
Note
Regardless of which position the ignition switch is in, the cooling fans way continue to operate after the engine stops, so make sure to keep hands and objects away from the fans when they are operating.
Tech Tips
If all of the following are met for a certain period of time during a few minutes immediately before the engine stops, the cooling fans will continue to operate for a maximum of 2 minutes after the engine is stopped. This is performed to ensure restartability.
The GTS indicates a very high coolant temperature.
The GTS indicates a high outside air temperature.
DISPOSING OF AN HV BATTERY
When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.
CAUTION:
Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.
After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.
DISCONNECTING AND RECONNECTING NEGATIVE AUXILIARY BATTERY CABLE
*1 | Cable |
*2 | Negative (-) Auxiliary Battery Terminal |
Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or electrical components.
Before disconnecting and reconnecting the auxiliary battery cable, turn the ignition switch off and the headlight switch off. Then loosen the terminal nut completely. Do not damage the cable or terminal.
When the auxiliary battery cable is disconnected, the clock and radio settings and stored DTCs are cleared. Therefore, before disconnecting the auxiliary battery cable, make a note of them.
Note
After turning the ignition 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.
IGNITION SWITCH EXPRESSIONS
Tech Tips
The type of ignition switch used on this model differs depending on specifications of the vehicle.
The expressions listed in the table below are used in this section.
Expression | Ignition Switch (Position) | Power Switch (Condition) |
---|---|---|
Ignition switch off | LOCK | Off (Lock) |
Ignition switch ACC | ACC | On (ACC) |
Ignition switch ON (IG) | ON (IG) | On (IG) |
Ignition switch ON (READY) | ON (READY) | On (Ready) |