Diagnosis Procedure
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.
- CHECK DTC PRIORITY
If DTC P0AE2 is displayed with DTC UXXXX, P0ADF, P0AE0, P0AE6, P0AE7, P3179, P317A, P317B, or P31A7, first perform the confirmation procedure (trouble diagnosis) for DTC UXXXX, P0ADF, P0AE0, P0AE6, P0AE7, P3179, P317A, P317B, or P31A7.
Is applicable DTC detected?
YES
Perform diagnosis of applicable. Refer to DTC INDEX .
NO
GO TO STEP 2 .
- CHECK SYSTEM MAIN RELAY 2 OUTPUT SIGNAL CIRCUIT
With CONSULT
- Select "HV N MAIN RLY ACTIV" and "HV PRE CHG RLY ACTIV" in "DATA MONITOR" mode of "EV/HEV" using CONSULT.
- Check that monitor indication as per the following condition.
Monitor item Condition Indication HV N MAIN RLY ACTIV Ignition switch: ON Off READY On HV PRE CHG RLY ACTIV Ignition switch: ON Off Ignition switch: ON → READY On READY Off
Without CONSULT
Check the voltage between HPCM harness connector and ground as per the following condition.
+ - Condition Voltage
(Approx.)HPCM Connector Terminal B14 15 Ground Ignition switch: ON Less than 2.0 V READY More than battery voltage - 2.0 V 3 Ignition switch: ON Less than 2.0 V Ignition switch: ON → READY More than battery voltage - 2.0 V READY Less than 2.0 V Is the inspection result normal?
YES-1
With CONSULT: GO TO STEP 3 .
YES-2
Without CONSULT: GO TO STEP 4 .
NO
Perform the trouble diagnosis for power supply and ground circuit of HPCM. Refer to DIAGNOSIS PROCEDURE .
- CHECK SYSTEM MAIN RELAY 2 OPERATION
With CONSULT
- Select "HV N MAIN RLY ACTIV", "HV PRE CHG RLY ACTIV", "HV N MAIN RLY ACTIV MONI", and "PRE-CHG RLY ACTIV MONI" in" DATA MONITOR" mode of "EV/HEV" using CONSULT.
- Check that monitor indication as per the following condition.
Monitor item Condition Indication HV N MAIN RLY ACTIV Ignition switch: ON Off READY On HV PRE CHG RLY ACTIV Ignition switch: ON Off Ignition switch: ON → READY On READY Off HV N MAIN RLY ACTIV MONI Ignition switch: ON On READY Off PRE-CHG RLY ACTIV MONI Ignition switch: ON Off Ignition switch: ON → READY On READY Off
Is the inspection result normal?
YES
Perform INTERMITTENT INCIDENT .
NO
GO TO STEP 4 .
- 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 5 .
- CHECK SYSTEM MAIN RELAY 2 CIRCUIT-1
- Disconnect HPCM harness connector.
- Disconnect Li-ion battery harness connector.
- Check the continuity between HPCM harness connector and Li-ion battery harness connector.
+ - Continuity HPCM Li-ion battery Connector Terminal Connector Terminal B14 15 T28 23 Existed - Also check harness for short to ground and to power.
Is the inspection result normal?
YES
GO TO STEP 6 .
NO
Repair or replace error-detected parts.
- CHECK PRE-CHARGE RELAY SIGNAL CIRCUIT-1
- Check the continuity between HPCM harness connector and Li-ion battery harness connector.
+ - Continuity HPCM Li-ion battery Connector Terminal Connector Terminal B14 3 T28 9 Existed - Also check harness for short to ground and to power.
Is the inspection result normal?
YES
GO TO STEP 7 .
NO
Repair or replace error-detected parts.
- Check the continuity between HPCM harness connector and Li-ion battery harness connector.
- CHECK SYSTEM MAIN RELAY 2 CIRCUIT-2
- Check the continuity between Li-ion battery harness connector terminals.
Li-ion battery Continuity Connector + - Terminal LB39 23 24 Existed - Also check harness for short to ground and to power.
Is the inspection result normal?
YES
GO TO STEP 8 .
NO
GO TO STEP 12 .
- Check the continuity between Li-ion battery harness connector terminals.
- CHECK PRE-CHARGE RELAY CIRCUIT-2
- Check the continuity between Li-ion battery harness connector terminals.
Li-ion battery Continuity Connector + - Terminal LB39 9 24 Existed - Also check harness for short to ground and to power.
Is the inspection result normal?
YES
GO TO STEP 9 .
NO
GO TO STEP 15 .
- Check the continuity between Li-ion battery harness connector terminals.
- CHECK SYSTEM MAIN RELAY GROUND CIRCUIT-1
Check the continuity between Li-ion battery harness connector and ground.
+ - Continuity Li-ion battery Connector Terminal LB39 24 Ground Existed Is the inspection result normal?
YES
GO TO STEP 10 .
NO
Repair or replace error-detected parts.
- CHECK SYSTEM MAIN RELAY 2
Check system main relay 2. Refer to COMPONENT INSPECTION (SYSTEM MAIN RELAY 2) .
Is the inspection result normal?
YES
GO TO STEP 11 .
NO
Repair or replace error-detected parts.
- CHECK PRE-CHARGE RELAY
Check pre-charge relay. Refer to COMPONENT INSPECTION (PRE-CHARGE RELAY) .
Is the inspection result normal?
YES
Perform INTERMITTENT INCIDENT .
NO
Repair or replace error-detected parts.
- CHECK SYSTEM MAIN RELAY 2 CIRCUIT-3
- Disconnect battery junction box harness connector.
- Check the continuity between Li-ion battery harness connector and battery junction box harness connector.
+ - Continuity Li-ion battery Battery junction box Connector Terminal Connector Terminal LB39 23 LB33 7 Existed - Also check harness for short to ground and to power.
Is the inspection result normal?
YES
GO TO STEP 13 .
NO
Repair or replace error-detected parts.
- CHECK SYSTEM MAIN RELAY GROUND CIRCUIT-2
- Check the continuity between battery junction box harness connector and Li-ion battery harness connector.
+ - Continuity Battery junction box Li-ion battery Connector Terminal Connector Terminal LB33 8 LB39 24 Existed - Also check harness for short to power.
Is the inspection result normal?
YES
GO TO STEP 14 .
NO
Repair or replace error-detected parts.
- Check the continuity between battery junction box harness connector and Li-ion battery harness connector.
- CHECK SYSTEM MAIN RELAY 2
Check system main relay 2. Refer to COMPONENT INSPECTION (SYSTEM MAIN RELAY 2) .
Is the inspection result normal?
YES
Perform INTERMITTENT INCIDENT .
NO
Repair or replace error-detected parts.
- CHECK PRE-CHARGE RELAY CIRCUIT-3
- Disconnect battery junction box harness connector.
- Check the continuity between Li-ion battery harness connector and battery junction box harness connector.
+ - Continuity Li-ion battery Battery junction box Connector Terminal Connector Terminal LB39 9 LB33 24 Existed - Also check harness for short to ground and to power.
Is the inspection result normal?
YES
GO TO STEP 16 .
NO
Repair or replace error-detected parts.
- CHECK PRE-CHARGE RELAY
Check pre-charge relay. Refer to COMPONENT INSPECTION (PRE-CHARGE RELAY) .
Is the inspection result normal?
YES
Perform INTERMITTENT INCIDENT .
NO
Repair or replace error-detected parts.