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 CONNECTION STATUS OF SERVICE PLUG
Check the connection of service plug.
Is the inspection result normal?
YES
GO TO STEP 2 .
NO
Repair the connection of harness.
- 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 3 .
- CHECK CONNECTION STATUS OF BUS BAR
- Remove Li-ion battery. Refer to REMOVAL AND INSTALLATION .
- Check the connection of bus bar.
Is the inspection result normal?
YES
GO TO STEP 4 .
NO
Repair the connection of harness.
- CHECK THE CONNECTION OF ALL WIRING RELATED TO HIGH VOLTAGE
Check the connection of all wiring related to high voltage.
Is the inspection result normal?
YES
GO TO STEP 5 .
NO
Repair the connection of harness.
- CHECK CELL VOLTAGE DETECTION HARNESS
Check continuity between Li-ion battery controller harness connector and all cell (cell voltage detection harness) harness connector.
Module No. Cell No. Module Li-ion battery controller Continuity Connector Terminal Connector Terminal module 1 Cell 1 LB8 1 LB3 50 Existed Cell 3 3 51 Cell 5 5 52 Cell 7 7 53 Cell 2 LB7 2 LB3 34 Cell 4 4 35 Cell 6 6 36 Cell 8 8 37 module 2 Cell 9 LB10 1 LB3 54 Existed Cell 11 3 55 Cell 13 5 56 Cell 15 7 57 Cell 10 LB9 2 LB3 38 Cell 12 4 39 Cell 14 6 40 Cell 16 8 42 module 3 Cell 17 LB12 1 LB3 58 Existed Cell 19 3 59 Cell 21 5 60 Cell 23 7 61 Cell 18 LB11 2 LB3 43 Cell 20 4 44 Cell 22 6 45 Cell 24 8 46 module 4 Cell 25 LB14 1 LB3 62 Existed Cell 27 3 63 Cell 29 5 LB4 77 Cell 31 7 78 Cell 26 LB13 2 LB3 47 Cell 28 4 48 Cell 30 6 LB4 65 Cell 32 8 66 module 5 Cell 33 LB16 1 LB4 80 Existed Cell 35 3 81 Cell 37 5 82 Cell 39 7 83 Cell 34 LB15 2 LB4 69 Cell 36 4 70 Cell 38 6 71 Cell 40 8 72 module 6 Cell 41 LB18 1 LB4 84 Existed Cell 43 3 85 Cell 45 5 86 Cell 47 7 87 Cell 42 LB17 2 LB4 73 Cell 44 4 74 Cell 46 6 75 Cell 48 8 76 module 7 Cell 49 LB20 1 LB5 110 Existed Cell 51 3 111 Cell 53 5 112 Cell 55 7 113 Cell 50 LB19 2 LB5 90 Cell 52 4 91 Cell 54 6 92 Cell 56 8 93 module 8 Cell 57 LB22 1 LB5 114 Existed Cell 59 3 115 Cell 61 5 116 Cell 63 7 117 Cell 58 LB21 2 LB5 94 Cell 60 4 95 Cell 62 6 96 Cell 64 8 97 module 9 Cell 65 LB24 1 LB5 118 Existed Cell 67 3 119 Cell 69 5 120 Cell 71 7 121 Cell 66 LB23 2 LB5 99 Cell 68 4 100 Cell 70 6 101 Cell 72 8 102 module 10 Cell 73 LB26 1 LB5 122 Existed Cell 75 3 123 Cell 77 5 124 Cell 79 7 125 Cell 74 LB25 2 LB5 103 Cell 76 4 104 Cell 78 6 105 Cell 80 8 106 module 11 Cell 81 LB28 1 LB5 127 Existed Cell 83 3 128 Cell 85 5 LB6 137 Cell 87 7 138 Cell 82 LB27 2 LB5 107 Cell 84 4 108 Cell 86 6 LB6 130 Cell 88 8 131 module 12 Cell 89 LB30 1 LB6 140 Existed Cell 91 3 141 Cell 93 5 142 Cell 95 7 143 Cell 90 LB29 2 LB6 132 Cell 92 4 133 Cell 94 6 134 Cell 96 8 135 Is the inspection result normal?
YES
Replace Li-ion battery (battery pack). Refer to REMOVAL AND INSTALLATION .
NO
Replace cell voltage detection harness.