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 BATTERY COOLING FAN OPERATION
WITH CONSULT
- Turn ignition switch ON.
- Perform "HV BATTERY COOLING FAN" with the "ACTIVE TEST" mode.
Is the battery cooling fan activated?
YES
GO TO STEP 2 .
NO
GO TO STEP 5 .
- CHECK BATTERY COOLING FAN MOTOR INPUT SIGNAL CIRCUIT-1
- Turn ignition switch OFF.
- Check continuity between battery cooling fan motor harness connector and Li-ion battery harness connector.
Battery cooling fan motor Li-ion battery Continuity Connector Terminal Connector Terminal T11 2 T28 1 Existed - Also check harness for short to ground.
Is the inspection result normal?
YES
GO TO STEP 3 .
NO
Repair harness or connector.
- 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 4 .
- CHECK BATTERY COOLING FAN MOTOR INPUT SIGNAL CIRCUIT-2
- Remove Li-ion battery. Refer to REMOVAL AND INSTALLATION .
- Disconnect Li-ion battery controller harness connector.
- Check continuity between Li-ion battery harness connector and Li-ion battery controller harness connector.
Li-ion battery Li-ion battery controller Continuity Connector Terminal Connector Terminal LB39 1 LB1 20 Existed - Also check harness for short to ground.
Is the inspection result normal?
YES
Replace Li-ion battery controller. Refer to DISASSEMBLY AND ASSEMBLY .
NO
Repair harness or connector.
- CHECK FUSE
- Turn ignition switch OFF.
- Pull out 20A fuse (No. 75) and check that the fuse is not blown (open).NOTE:
Refer to FUSE AND FUSIBLE LINK ARRANGEMENT for fuse layout.
Is the inspection result normal?
YES
GO TO STEP 6 .
NO
Replace the fuse after repairing the applicable circuit.
- CHECK BATTERY COOLING FAN POWER SUPPLY CIRCUIT-1
- Disconnect battery cooling fan harness connector.
- Turn ignition switch ON.
- Check voltage between battery cooling fan harness connector and ground.
(+) (-) Voltage Battery cooling fan Connector Terminal Ground Battery voltage T11 1
Is the inspection result normal?
YES
GO TO STEP 7 .
NO
GO TO STEP 12 .
- CHECK BATTERY COOLING FAN GROUND CIRCUIT
- Disconnect Li-ion battery harness connector.
- Check continuity between Li-ion battery harness connector and battery cooling fan harness connector.
Li-ion battery Battery cooling fan Continuity Connector Terminal Connector Terminal LB39 1 T11 2 Existed
Is the inspection result normal?
YES
GO TO STEP 8 .
NO
Repair harness or connector.
- CHECK LI-ION BATTERY CONTROLLER OUTPUT SIGNAL-1
WITH CONSULT
- Connect Li-ion battery controller harness connector, Li-ion battery harness connector and battery cooling fan harness connector.
- Turn ignition switch ON.
- Perform "HV BATTERY COOLING FAN" in "ACTIVE TEST" mode.
- Check voltage between battery cooling fan harness connector and ground.
(+) (-) Condition Voltage Battery cooling fan Connector Terminal Ground ACTIVE TEST: Hi Approx. 12 V T11 3
Is the inspection result normal?
YES
Replace battery cooling fan. Refer to REMOVAL AND INSTALLATION .
NO
GO TO STEP 9 .
- CHECK LI-ION BATTERY CONTROLLER OUTPUT SIGNAL-2
WITH CONSULT
- Turn ignition switch ON.
- Perform "HV BATTERY COOLING FAN" in "ACTIVE TEST" mode.
- Check voltage between Li-ion battery harness connector and ground.
(+) (-) Condition Voltage Li-ion battery Connector Terminal Ground ACTIVE TEST: Hi Approx. 12 V T28 13
Is the inspection result normal?
YES
Repair harness or connector.
NO
GO TO STEP 10 .
- PRECONDITIONINGWARNING:
Shut off high voltage circuit. Refer to HOW TO DISCONNECT HIGH VOLTAGE .
Remove Li-ion battery. Refer to REMOVAL AND INSTALLATION .
GO TO STEP 11 .
- CHECK OUTPUT SIGNAL CIRCUIT
- Disconnect Li-ion battery controller harness connector.
- Check continuity between Li-ion battery controller harness connector and Li-ion battery harness connector.
Li-ion battery controller Li-ion battery Continuity Connector Terminal Connector Terminal LB1 19 T28 13 Existed - Also check harness for short to ground.
Is the inspection result normal?
YES
Replace Li-ion battery controller. Refer to DISASSEMBLY AND ASSEMBLY .
NO
Repair harness or connector.
- CHECK BATTERY COOLING FAN POWER SUPPLY CIRCUIT-2
- Remove battery cooling fan relay.
- Check voltage between battery cooling fan relay harness connector and ground.
(+) (-) Voltage Battery cooling fan relay Connector Terminal Ground Battery voltage T36 1 5
Is the inspection result normal?
YES
GO TO STEP 13 .
NO
Repair harness or connector.
- CHECK BATTERY COOLING FAN RELAY
Check battery cooling fan relay.
Is the inspection result normal?
YES
GO TO STEP 14 .
NO
Replace Battery cooling fan relay.
- CHECK BATTERY COOLING FAN RELAY GROUND CIRCUIT-1
Check continuity between battery cooling fan relay harness connector and Li-ion battery harness connector.
Battery cooling fan relay Li-ion battery Continuity Connector Terminal Connector Terminal T36 2 T28 17 Existed Is the inspection result normal?
YES
GO TO STEP 15 .
NO
Repair harness or connector.
- PRECONDITIONINGWARNING:
Shut off high voltage circuit. Refer to HOW TO DISCONNECT HIGH VOLTAGE .
Remove Li-ion battery. Refer to REMOVAL AND INSTALLATION .
GO TO STEP 16 .
- CHECK BATTERY COOLING FAN RELAY GROUND CIRCUIT-2
- Disconnect Li-ion battery controller harness connector.
- Check continuity between battery cooling fan relay harness connector and Li-ion battery harness connector.
Li-ion battery Li-ion battery controller Continuity Connector Terminal Connector Terminal LB39 17 LB1 16 Existed Is the inspection result normal?
YES
Replace Li-ion battery controller. Refer to DISASSEMBLY AND ASSEMBLY .
NO
Repair harness or connector.