Component Inspection
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- The removed service plug must always be carried in a pocket of the responsible worker or placed in the tool box during the procedure to prevent the plug from being connected by mistake.
- Be sure to wear insulating protective equipment before beginning work on the high voltage system.
- Never allow workers other than the responsible person to touch the vehicle containing high voltage parts. To keep others from touching the high voltage parts, these parts must be covered with an insulating sheet except when using them.
- Refer to HIGH VOLTAGE PRECAUTIONS .
Never bring the vehicle into the READY status with the service plug removed unless otherwise instructed in the Service Information. A malfunction may occur if this is not observed.
- PRECONDITIONINGWARNING:
Follow the instructions below before starting the procedure.
- Disconnect high voltage circuit. Refer to HOW TO DISCONNECT HIGH VOLTAGE .
- Check voltage in high voltage circuit. Refer to CHECK VOLTAGE IN HIGH VOLTAGE CIRCUIT .
GO TO STEP 2 .
- CHECK LI-ION BATTERY INSULATION RESISTANCECAUTION:
Unlike the ordinary tester, the insulation resistance tester applies 500V when measuring. If used incorrectly, there is the danger of electric shock. If used in the vehicle 12V system, there is the danger of damage to electronic devices. Read the insulation resistance tester instruction information carefully and be sure to work safely.
- Remove Li-ion battery. Refer to REMOVAL AND INSTALLATION .
- Disconnect Li-ion battery controller harness connector.WARNING:
Immediately insulate disconnected high voltage connectors and terminals with insulating tape.
- Remove front battery cover from Li-ion battery. Refer to EXPLODED VIEW WITH TORQUE SPECIFICATIONS .
- Reconnect service plug.
- Check insulation resistance between Li-ion battery negative terminal
/positive terminal
and lower battery cover metallic part
, using an insulation resistance tester.
CAUTION:- Be sure to set the insulation resistance tester to 500V when performing this test.
- Using a setting higher than 500V can result in damage to the component being inspected.
Li-ion battery terminals Ground Resistance + Lower battery cover metallic part 21 MΩ or more -
Is the inspection result normal?
YES
INSPECTION END
NO
Replace Li-ion battery (battery pack). Refer to REMOVAL AND INSTALLATION .