DTC P0E2D-00: Hybrid/EV Battery Energy Control Module Hybrid/EV Battery Monitor Performance [08/2023 - ]: Procedure

Pre-procedure1

1. None.

   Procedure1

2. Check for DTCs.

   Powertrain > HV Battery > Trouble Codes 

   Result

   Result	Proceed to
   "P0E2D-00" only is output, or DTCs except the ones in the table below are also output.	A
   DTCs of hybrid battery system in the table below are output.	B

   System	Relevant DTC
   Hybrid battery system	P1A00-1C	Hybrid Battery Stack 2 Cell Voltage Detection Voltage Out of Range
   	P1A05-1C	Hybrid Battery Stack 3 Cell Voltage Detection Voltage Out of Range
   	P1A0A-1C	Hybrid Battery Stack 4 Cell Voltage Detection Voltage Out of Range
   	P1AC4-13	Hybrid/EV Battery Stack 1 Current Interrupt Device Circuit Open
   	P1AC4-9E	Hybrid/EV Battery Stack 1 Current Interrupt Device Stuck On
   	P1AC5-13	Hybrid/EV Battery Stack 2 Current Interrupt Device Circuit Open
   	P1AC5-9E	Hybrid/EV Battery Stack 2 Current Interrupt Device Stuck On
   	P1AC6-13	Hybrid/EV Battery Stack 3 Current Interrupt Device Circuit Open
   	P1AC6-9E	Hybrid/EV Battery Stack 3 Current Interrupt Device Stuck On
   	P1AC7-13	Hybrid/EV Battery Stack 4 Current Interrupt Device Circuit Open
   	P1AC7-9E	Hybrid/EV Battery Stack 4 Current Interrupt Device Stuck On
   	P301A-1C	Hybrid Battery Stack 1 Cell Voltage Detection Voltage Out of Range

   Post-procedure1

3. Turn the ignition switch off.

Result: 

B 

GO TO DTC CHART (HYBRID BATTERY SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2023 - ] 

Result: 

A 

See step  2

Pre-procedure1

1. None.

   Procedure1

2. Read the value of freeze frame data items "Lost Communication with Hybrid/EV Battery Monitoring IC", "Hybrid/EV Battery Monitoring IC 1 Internal Malfunction (Determinable)" through "Hybrid/EV Battery Monitoring IC 4 Internal Malfunction (Determinable)", "Hybrid/EV Battery Monitoring IC Internal Malfunction (Unidentifiable)", "Hybrid/EV Battery Monitoring IC 1 Power Supply Malfunction" through "Hybrid/EV Battery Monitoring IC 4 Power Supply Malfunction" and "Hybrid/EV Battery Monitoring IC 1 Cell Voltage Detection Malfunction" through "Hybrid/EV Battery Monitoring IC 4 Cell Voltage Detection Malfunction" for DTC P0E2D-00 and make a note.

   HINT: 

   • The chart above is listed in inspection order of priority.
   • Check items that are ON at the same time by following the listed order.

   Result

   Result	Proceed to
   The freeze frame data item "Hybrid/EV Battery Monitoring IC Internal Malfunction (Unidentifiable)" is ON.	A
   Either freeze frame data item "Hybrid/EV Battery Monitoring IC 1 Internal Malfunction (Determinable)" through "Hybrid/EV Battery Monitoring IC 4 Internal Malfunction (Determinable)" is ON.	B
   Any of the freeze frame data items "Hybrid/EV Battery Monitoring IC 1 Power Supply Malfunction" through "Hybrid/EV Battery Monitoring IC 4 Power Supply Malfunction" is ON.	C
   The freeze frame data item "Lost Communication with Hybrid/EV Battery Monitoring IC" is ON.	D
   Any of the freeze frame data items "Hybrid/EV Battery Monitoring IC 1 Cell Voltage Detection Malfunction" through "Hybrid/EV Battery Monitoring IC 4 Power Supply Malfunction" is ON.	E

   Powertrain > HV Battery > Trouble Codes 

   Post-procedure1

3. Turn the ignition switch off.

Result: 

A 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

B 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

D 

See step  4

Result: 

E 

See step  5

Result: 

C 

See step  3

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery ECU assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

3. Disconnect the o8 battery voltage sensor connector.
   WARNING:

   When disconnecting connector o8 of the battery voltage sensor, first disconnect connectors z19, z20, z21, z22, z23 and z24 from the battery voltage sensor.

   NOTE:

   • Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.
   • Before disconnecting the connector, check that it is not loose or disconnected.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Procedure1

4. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   o3-1 (VG0) - o8-1 (VG0)	Ignition switch off	Below 1 Ω
   o3-2 (VG1) - o8-19 (VG1)	Ignition switch off	Below 1 Ω
   o3-23 (GDV0) - o8-3 (GDV0)	Ignition switch off	Below 1 Ω
   o3-24 (GDV1) - o8-21 (GDV1)	Ignition switch off	Below 1 Ω

   Result

   Proceed to
   OK
   NG

   Post-procedure1

5. Reconnect the o8 battery voltage sensor connector.
   WARNING:

   When connecting connectors z19, z20, z21, z22, z23 and z24 of the battery voltage sensor, first connect connector o8 to the battery voltage sensor.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. Reconnect the battery ECU assembly connector.

Result: 

OK 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery ECU assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

3. Disconnect the o8 battery voltage sensor connector.
   WARNING:

   When disconnecting connector o8 of the battery voltage sensor, first disconnect connectors z19, z20, z21, z22, z23 and z24 from the battery voltage sensor.

   NOTE:

   • Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.
   • Before disconnecting the connector, check that it is not loose or disconnected.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Procedure1

4. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   o3-27 (SCOH) - o8-9 (SCIH)	Ignition switch off	Below 1 Ω
   o3-28 (SCOL) - o8-26 (SCIL)	Ignition switch off	Below 1 Ω
   o3-29 (SCIH) - o8-8 (SCOH)	Ignition switch off	Below 1 Ω
   o3-30 (SCIL) - o8-25 (SCOL)	Ignition switch off	Below 1 Ω

   Result

   Proceed to
   OK
   NG

   Post-procedure1

5. Reconnect the o8 battery voltage sensor connector.
   WARNING:

   When connecting connectors z19, z20, z21, z22, z23 and z24 of the battery voltage sensor, first connect connector o8 to the battery voltage sensor.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. Reconnect the battery ECU assembly connector.

Result: 

OK 

REPLACE BATTERY ECU ASSEMBLY AND BATTERY VOLTAGE SENSOR 

Battery ECU assembly: Refer to REMOVAL [08/2023 - ]

Battery voltage sensor: Refer to REMOVAL [08/2023 - ]

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

   Procedure1

2. Check the connections of the battery voltage sensor connector.

   HINT: 

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [10/2022 - ]

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The connector is connected securely and there are no contact problems.

   Result

   Result		Proceed to
   OK		A
   Not connected securely	The terminals are not damaged or corroded	B
   Connector z19 is not connected securely	The terminals are damaged or corroded	C
   Connector z21 is not connected securely	The terminals are damaged or corroded	D
   Connector z20 is not connected securely	The terminals are damaged or corroded	E
   Connector z23 is not connected securely	The terminals are damaged or corroded	F
   Connector z22 is not connected securely	The terminals are damaged or corroded	G
   Connector z24 is not connected securely	The terminals are damaged or corroded	H

   Post-procedure1

3. None.

Result: 

B 

CONNECT SECURELY 

Result: 

C 

REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

D 

REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

E 

REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

F 

REPLACE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

G 

REPLACE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

H 

REPLACE NO. 4 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

A 

See step  6

Pre-procedure1

1. None.

   Procedure1

2. Read the value of freeze frame data items "Hybrid/EV Battery Cell 1 Voltage" through "Hybrid/EV Battery Cell 96 Voltage" for DTC P0E2D-00 and make a note if the value of any is 1.6 V or less.

   Powertrain > HV Battery > Trouble Codes 

   Result

   Result	Proceed to
   The value of any of the freeze frame data items "Hybrid/EV Battery Cell 1 Voltage" through "Hybrid/EV Battery Cell 12 Voltage" is 1.6 V or less.	A
   The value of any of the freeze frame data items "Hybrid/EV Battery Cell 13 Voltage" through "Hybrid/EV Battery Cell 24 Voltage" is 1.6 V or less.	B
   The value of any of the freeze frame data items "Hybrid/EV Battery Cell 25 Voltage" through "Hybrid/EV Battery Cell 48 Voltage" is 1.6 V or less.	C
   The value of any of the freeze frame data items "Hybrid/EV Battery Cell 49 Voltage" through "Hybrid/EV Battery Cell 72 Voltage" is 1.6 V or less.	D
   The value of any of the freeze frame data items "Hybrid/EV Battery Cell 73 Voltage" through "Hybrid/EV Battery Cell 80 Voltage" is 1.6 V or less.	E
   The value of any of the freeze frame data items "Hybrid/EV Battery Cell 81 Voltage" through "Hybrid/EV Battery Cell 96 Voltage" is 1.6 V or less.	F
   Other than above	G

   Post-procedure1

3. Turn the ignition switch off.

Result: 

B 

See step  10

Result: 

C 

See step  14

Result: 

D 

See step  17

Result: 

E 

See step  20

Result: 

F 

See step  24

Result: 

G 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

A 

See step  7

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Procedure1

3. Measure the voltage according to the value(s) in the table below.

   HINT: 

   Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.6 V or less only.

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition
   1	z19-11 (GA0) (-) - z19-9 (VA1) (+)	Always
   2	z19-9 (VA1) (-) - z19-8 (VA2) (+)	Always
   3	z19-8 (VA2) (-) - z19-17 (VA3) (+)	Always
   4	z19-17 (VA3) (-) - z19-7 (VA4) (+)	Always
   5	z19-7 (VA4) (-) - z19-16 (VA5) (+)	Always
   6	z19-16 (VA5) (-) - z19-6 (VA6) (+)	Always
   7	z19-6 (VA6) (-) - z19-5 (VA7) (+)	Always
   8	z19-5 (VA7) (-) - z19-15 (VA8) (+)	Always
   9	z19-15 (VA8) (-) - z19-4 (VA9) (+)	Always
   10	z19-4 (VA9) (-) - z19-1 (VA10) (+)	Always
   11	z19-1 (VA10) (-) - z19-3 (VA11) (+)	Always
   12	z19-3 (VA11) (-) - z19-14 (VA12) (+)	Always

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Front view of wire harness connector (to Battery Voltage Sensor)

   WARNING:

   Make sure not to cross the electrodes of an electrical tester measurement terminals.

   NOTE:

   Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

   Result

   Result	Proceed to
   The voltage between the terminals is 1.6 V or less.	A
   Other than above	B

   Post-procedure1

4. Reconnect the battery voltage sensor connector.

Result: 

B 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

A 

See step  8

Pre-procedure1

1. Remove the battery voltage sensor.

   HINT: 

   Refer to REMOVAL [08/2023 - ]

   Procedure1

2. Measure the resistance according to the value(s) in the table below.

   HINT: 

   Only inspect the terminals of the battery voltage sensor which correspond to the HV battery cells which measured 1.6 V or less in the previous step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (Battery Voltage Sensor)

   -

   -

   Standard Resistance

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition	Specified Condition
   1	z19-11 (GA0) (-) - z19-9 (VA1) (+)	Always	50 kΩ or more
   2	z19-9 (VA1) (-) - z19-8 (VA2) (+)	Always	50 kΩ or more
   3	z19-8 (VA2) (-) - z19-17 (VA3) (+)	Always	50 kΩ or more
   4	z19-17 (VA3) (-) - z19-7 (VA4) (+)	Always	50 kΩ or more
   5	z19-7 (VA4) (-) - z19-16 (VA5) (+)	Always	50 kΩ or more
   6	z19-16 (VA5) (-) - z19-6 (VA6) (+)	Always	50 kΩ or more
   7	z19-6 (VA6) (-) - z19-5 (VA7) (+)	Always	50 kΩ or more
   8	z19-5 (VA7) (-) - z19-15 (VA8) (+)	Always	50 kΩ or more
   9	z19-15 (VA8) (-) - z19-4 (VA9) (+)	Always	50 kΩ or more
   10	z19-4 (VA9) (-) - z19-1 (VA10) (+)	Always	50 kΩ or more
   11	z19-1 (VA10) (-) - z19-3 (VA11) (+)	Always	50 kΩ or more
   12	z19-3 (VA11) (-) - z19-14 (VA12) (+)	Always	50 kΩ or more

   NOTE:

   • Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.
   • Read the resistance after the value has stabilized.
   • In order to avoid damaging the terminals of the battery voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

   Result

   Result	Proceed to
   The resistance between the terminals is 50 kΩ or more.	A
   Other than above	B

   Post-procedure1

3. Install the battery voltage sensor.

Result: 

A 

REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

B 

See step  9

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Procedure1

3. Measure the voltage according to the value(s) in the table below.

   HINT: 

   Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.6 V or less only.

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition
   13	z21-27 (GA1) (-) - z21-17 (VA13) (+)	Always
   14	z21-17 (VA13) (-) - z21-4 (VA14) (+)	Always
   15	z21-4 (VA14) (-) - z21-16 (VA15) (+)	Always
   16	z21-16 (VA15) (-) - z21-3 (VA16) (+)	Always
   17	z21-3 (VA16) (-) - z21-15 (VA17) (+)	Always
   18	z21-15 (VA17) (-) - z21-25 (VA18) (+)	Always
   19	z21-25 (VA18) (-) - z21-14 (VA19) (+)	Always
   20	z21-14 (VA19) (-) - z21-13 (VA20) (+)	Always
   21	z21-13 (VA20) (-) - z21-12 (VA21) (+)	Always
   22	z21-12 (VA21) (-) - z21-23 (VA22) (+)	Always
   23	z21-23 (VA22) (-) - z21-11 (VA23) (+)	Always
   24	z21-11 (VA23) (-) - z21-10 (VA24) (+)	Always

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Front view of wire harness connector (to Battery Voltage Sensor)

   WARNING:

   Make sure not to cross the electrodes of an electrical tester measurement terminals.

   NOTE:

   Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

   Result

   Result	Proceed to
   The voltage between the terminals is 1.6 V or less.	A
   Other than above	B

   Post-procedure1

4. Reconnect the battery voltage sensor connector.

Result: 

B 

See step  13

Result: 

A 

See step  11

Pre-procedure1

1. Remove the battery voltage sensor.

   HINT: 

   Refer to REMOVAL [08/2023 - ]

   Procedure1

2. Measure the resistance according to the value(s) in the table below.

   HINT: 

   Only inspect the terminals of the battery voltage sensor which correspond to the HV battery cells which measured 1.6 V or less in the previous step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (Battery Voltage Sensor)

   -

   -

   Standard Resistance

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition	Specified Condition
   13	z21-27 (GA1) (-) - z21-17 (VA13) (+)	Always	50 kΩ or more
   14	z21-17 (VA13) (-) - z21-4 (VA14) (+)	Always	50 kΩ or more
   15	z21-4 (VA14) (-) - z21-16 (VA15) (+)	Always	50 kΩ or more
   16	z21-16 (VA15) (-) - z21-3 (VA16) (+)	Always	50 kΩ or more
   17	z21-3 (VA16) (-) - z21-15 (VA17) (+)	Always	50 kΩ or more
   18	z21-15 (VA17) (-) - z21-25 (VA18) (+)	Always	50 kΩ or more
   19	z21-25 (VA18) (-) - z21-14 (VA19) (+)	Always	50 kΩ or more
   20	z21-14 (VA19) (-) - z21-13 (VA20) (+)	Always	50 kΩ or more
   21	z21-13 (VA20) (-) - z21-12 (VA21) (+)	Always	50 kΩ or more
   22	z21-12 (VA21) (-) - z21-23 (VA22) (+)	Always	50 kΩ or more
   23	z21-23 (VA22) (-) - z21-11 (VA23) (+)	Always	50 kΩ or more
   24	z21-11 (VA23) (-) - z21-10 (VA24) (+)	Always	50 kΩ or more

   NOTE:

   • Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.
   • Read the resistance after the value has stabilized.
   • In order to avoid damaging the terminals of the battery voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

   Result

   Result	Proceed to
   The resistance between the terminals is 50 kΩ or more.	A
   Other than above	B

   Post-procedure1

3. Install the battery voltage sensor.

Result: 

A 

REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

B 

See step  12

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connector.
   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Disconnect the B No. 2 HV supply stack sub-assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Procedure1

4. Measure the resistance according to the value(s) in the tables below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   B-11 (GA1) - z21-27 (GA1)	Ignition switch off	Below 1 Ω
   B-22 (VA13) - z21-17 (VA13)	Ignition switch off	Below 1 Ω
   B-10 (VA14) - z21-4 (VA14)	Ignition switch off	Below 1 Ω
   B-21 (VA15) - z21-16 (VA15)	Ignition switch off	Below 1 Ω
   B-9 (VA16) - z21-3 (VA16)	Ignition switch off	Below 1 Ω
   B-20 (VA17) - z21-15 (VA17)	Ignition switch off	Below 1 Ω
   B-8 (VA18) - z21-25 (VA18)	Ignition switch off	Below 1 Ω
   B-19 (VA19) - z21-14 (VA19)	Ignition switch off	Below 1 Ω
   B-7 (VA20) - z21-13 (VA20)	Ignition switch off	Below 1 Ω
   B-18 (VA21) - z21-12 (VA21)	Ignition switch off	Below 1 Ω
   B-6 (VA22) - z21-23 (VA22)	Ignition switch off	Below 1 Ω
   B-17 (VA23) - z21-11 (VA23)	Ignition switch off	Below 1 Ω
   B-16 (VA24) - z21-10 (VA24)	Ignition switch off	Below 1 Ω
   B-11 (GA1) or z21-27 (GA1) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-22 (VA13) or z21-17 (VA13) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-10 (VA14) or z21-4 (VA14) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-21 (VA15) or z21-16 (VA15) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-9 (VA16) or z21-3 (VA16) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-20 (VA17) or z21-15 (VA17) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-8 (VA18) or z21-25 (VA18) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-19 (VA19) or z21-14 (VA19) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-7 (VA20) or z21-13 (VA20) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-18 (VA21) or z21-12 (VA21) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-6 (VA22) or z21-23 (VA22) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-17 (VA23) or z21-11 (VA23) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   B-16 (VA24) or z21-10 (VA24) - Body ground and other terminals	Ignition switch off	10 kΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Front view of wire harness connector (to No. 1 HV Supply Stack Sub-assembly)
   *b	Front view of wire harness connector (to Battery Voltage Sensor)

   Result

   Proceed to
   OK
   NG

   Post-procedure1

5. Reconnect the No. 2 HV supply stack sub-assembly connector.
6. Reconnect the battery voltage sensor connector.

Result: 

OK 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

NG 

REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connectors.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Procedure1

3. Measure the voltage according to the value(s) in the table below.

   HINT: 

   Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.6 V or less only.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Front view of wire harness connector (to Battery Voltage Sensor)

   -

   -

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition
   25	z21-5 (GA2) (-) - z21-18 (VA25) (+)	Always
   26	z21-18 (VA25) (-) - z20-27 (VA26) (+)	Always
   27	z20-27 (VA26) (-) - z20-17 (VA27) (+)	Always
   28	z20-17 (VA27) (-) - z20-4 (VA28) (+)	Always
   29	z20-4 (VA28) (-) - z20-16 (VA29) (+)	Always
   30	z20-16 (VA29) (-) - z20-3 (VA30) (+)	Always
   31	z20-3 (VA30) (-) - z20-15 (VA31) (+)	Always
   32	z20-15 (VA31) (-) - z20-25 (VA32) (+)	Always
   33	z20-25 (VA32) (-) - z20-14 (VA33) (+)	Always
   34	z20-14 (VA33) (-) - z20-13 (VA34) (+)	Always
   35	z20-13 (VA34) (-) - z20-12 (VA35) (+)	Always
   36	z20-12 (VA35) (-) - z20-23 (VA36) (+)	Always
   37	z20-11 (GA3) (-) - z20-10 (VA37) (+)	Always
   38	z20-10 (VA37) (-) - z20-21 (VA38) (+)	Always
   39	z20-21 (VA38) (-) - z20-9 (VA39) (+)	Always
   40	z20-9 (VA39) (-) - z20-8 (VA40) (+)	Always
   41	z20-8 (VA40) (-) - z20-20 (VA41) (+)	Always
   42	z20-20 (VA41) (-) - z20-7 (VA42) (+)	Always
   43	z20-7 (VA42) (-) - z20-19 (VA43) (+)	Always
   44	z20-19 (VA43) (-) - z20-2 (VA44) (+)	Always
   45	z20-2 (VA44) (-) - z20-6 (VA45) (+)	Always
   46	z20-6 (VA45) (-) - z20-1 (VA46) (+)	Always
   47	z20-1 (VA46) (-) - z20-5 (VA47) (+)	Always
   48	z20-5 (VA47) (-) - z20-18 (VA48) (+)	Always

   WARNING:

   Make sure not to cross the electrodes of an electrical tester measurement terminals.

   NOTE:

   Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

   Result

   Result	Proceed to
   The voltage between the terminals is 1.6 V or less.	A
   Other than above	B

   Post-procedure1

4. Reconnect the battery voltage sensor connectors.

Result: 

B 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

A 

See step  15

Pre-procedure1

1. Remove the battery voltage sensor.

   HINT: 

   Refer to REMOVAL [08/2023 - ]

   Procedure1

2. Measure the resistance according to the value(s) in the table below.

   HINT: 

   Only inspect the terminals of the battery voltage sensor which correspond to the HV battery cells which measured 1.6 V or less in the previous step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (Battery Voltage Sensor)

   -

   -

   Standard Resistance

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition	Specified Condition
   25	z21-5 (GA2) (-) - z21-18 (VA25) (+)	Always	50 kΩ or more
   26	z21-18 (VA25) (-) - z20-27 (VA26) (+)	Always	50 kΩ or more
   27	z20-27 (VA26) (-) - z20-17 (VA27) (+)	Always	50 kΩ or more
   28	z20-17 (VA27) (-) - z20-4 (VA28) (+)	Always	50 kΩ or more
   29	z20-4 (VA28) (-) - z20-16 (VA29) (+)	Always	50 kΩ or more
   30	z20-16 (VA29) (-) - z20-3 (VA30) (+)	Always	50 kΩ or more
   31	z20-3 (VA30) (-) - z20-15 (VA31) (+)	Always	50 kΩ or more
   32	z20-15 (VA31) (-) - z20-25 (VA32) (+)	Always	50 kΩ or more
   33	z20-25 (VA32) (-) - z20-14 (VA33) (+)	Always	50 kΩ or more
   34	z20-14 (VA33) (-) - z20-13 (VA34) (+)	Always	50 kΩ or more
   35	z20-13 (VA34) (-) - z20-12 (VA35) (+)	Always	50 kΩ or more
   36	z20-12 (VA35) (-) - z20-23 (VA36) (+)	Always	50 kΩ or more
   37	z20-11 (GA3) (-) - z20-10 (VA37) (+)	Always	50 kΩ or more
   38	z20-10 (VA37) (-) - z20-21 (VA38) (+)	Always	50 kΩ or more
   39	z20-21 (VA38) (-) - z20-9 (VA39) (+)	Always	50 kΩ or more
   40	z20-9 (VA39) (-) - z20-8 (VA40) (+)	Always	50 kΩ or more
   41	z20-8 (VA40) (-) - z20-20 (VA41) (+)	Always	50 kΩ or more
   42	z20-20 (VA41) (-) - z20-7 (VA42) (+)	Always	50 kΩ or more
   43	z20-7 (VA42) (-) - z20-19 (VA43) (+)	Always	50 kΩ or more
   44	z20-19 (VA43) (-) - z20-2 (VA44) (+)	Always	50 kΩ or more
   45	z20-2 (VA44) (-) - z20-6 (VA45) (+)	Always	50 kΩ or more
   46	z20-6 (VA45) (-) - z20-1 (VA46) (+)	Always	50 kΩ or more
   47	z20-1 (VA46) (-) - z20-5 (VA47) (+)	Always	50 kΩ or more
   48	z20-5 (VA47) (-) - z20-18 (VA48) (+)	Always	50 kΩ or more

   NOTE:

   • Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.
   • Read the resistance after the value has stabilized.
   • In order to avoid damaging the terminals of the battery voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

   Result

   Result	Proceed to
   The resistance between the terminals is 50 kΩ or more.	A
   Other than above	B

   Post-procedure1

3. Install the battery voltage sensor.

Result: 

A 

REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

B 

See step  16

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connectors.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Procedure1

3. Measure the voltage according to the value(s) in the table below.

   HINT: 

   Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.6 V or less only.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Front view of wire harness connector (to Battery Voltage Sensor)

   -

   -

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition
   49	z23-11 (GA4) (-) - z23-9 (VA49) (+)	Always
   50	z23-9 (VA49) (-) - z23-8 (VA50) (+)	Always
   51	z23-8 (VA50) (-) - z23-17 (VA51) (+)	Always
   52	z23-17 (VA51) (-) - z23-7 (VA52) (+)	Always
   53	z23-7 (VA52) (-) - z23-16 (VA53) (+)	Always
   54	z23-16 (VA53) (-) - z23-6 (VA54) (+)	Always
   55	z23-6 (VA54) (-) - z23-5 (VA55) (+)	Always
   56	z23-5 (VA55) (-) - z23-15 (VA56) (+)	Always
   57	z23-15 (VA56) (-) - z23-4 (VA57) (+)	Always
   58	z23-4 (VA57) (-) - z23-1 (VA58) (+)	Always
   59	z23-1 (VA58) (-) - z23-3 (VA59) (+)	Always
   60	z23-3 (VA59) (-) - z23-14 (VA60) (+)	Always
   61	z22-30 (GA5) (-) - z22-19 (VA61) (+)	Always
   62	z22-19 (VA61) (-) - z22-29 (VA62) (+)	Always
   63	z22-29 (VA62) (-) - z22-5 (VA63) (+)	Always
   64	z22-5 (VA63) (-) - z22-18 (VA64) (+)	Always
   65	z22-18 (VA64) (-) - z22-4 (VA65) (+)	Always
   66	z22-4 (VA65) (-) - z22-28 (VA66) (+)	Always
   67	z22-28 (VA66) (-) - z22-17 (VA67) (+)	Always
   68	z22-17 (VA67) (-) - z22-16 (VA68) (+)	Always
   69	z22-16 (VA68) (-) - z22-27 (VA69) (+)	Always
   70	z22-27 (VA69) (-) - z22-15 (VA70) (+)	Always
   71	z22-15 (VA70) (-) - z22-14 (VA71) (+)	Always
   72	z22-14 (VA71) (-) - z22-26 (VA72) (+)	Always

   WARNING:

   Make sure not to cross the electrodes of an electrical tester measurement terminals.

   NOTE:

   Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

   Result

   Result	Proceed to
   The voltage between the terminals is 1.6 V or less.	A
   Other than above	B

   Post-procedure1

4. Reconnect the battery voltage sensor connectors.

Result: 

B 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

A 

See step  18

Pre-procedure1

1. Remove the battery voltage sensor.

   HINT: 

   Refer to REMOVAL [08/2023 - ]

   Procedure1

2. Measure the resistance according to the value(s) in the table below.

   HINT: 

   Only inspect the terminals of the battery voltage sensor which correspond to the HV battery cells which measured 1.6 V or less in the previous step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (Battery Voltage Sensor)

   -

   -

   Standard Resistance

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition	Specified Condition
   49	z23-11 (GA4) (-) - z23-9 (VA49) (+)	Always	50 kΩ or more
   50	z23-9 (VA49) (-) - z23-8 (VA50) (+)	Always	50 kΩ or more
   51	z23-8 (VA50) (-) - z23-17 (VA51) (+)	Always	50 kΩ or more
   52	z23-17 (VA51) (-) - z23-7 (VA52) (+)	Always	50 kΩ or more
   53	z23-7 (VA52) (-) - z23-16 (VA53) (+)	Always	50 kΩ or more
   54	z23-16 (VA53) (-) - z23-6 (VA54) (+)	Always	50 kΩ or more
   55	z23-6 (VA54) (-) - z23-5 (VA55) (+)	Always	50 kΩ or more
   56	z23-5 (VA55) (-) - z23-15 (VA56) (+)	Always	50 kΩ or more
   57	z23-15 (VA56) (-) - z23-4 (VA57) (+)	Always	50 kΩ or more
   58	z23-4 (VA57) (-) - z23-1 (VA58) (+)	Always	50 kΩ or more
   59	z23-1 (VA58) (-) - z23-3 (VA59) (+)	Always	50 kΩ or more
   60	z23-3 (VA59) (-) - z23-14 (VA60) (+)	Always	50 kΩ or more
   61	z22-30 (GA5) (-) - z22-19 (VA61) (+)	Always	50 kΩ or more
   62	z22-19 (VA61) (-) - z22-29 (VA62) (+)	Always	50 kΩ or more
   63	z22-29 (VA62) (-) - z22-5 (VA63) (+)	Always	50 kΩ or more
   64	z22-5 (VA63) (-) - z22-18 (VA64) (+)	Always	50 kΩ or more
   65	z22-18 (VA64) (-) - z22-4 (VA65) (+)	Always	50 kΩ or more
   66	z22-4 (VA65) (-) - z22-28 (VA66) (+)	Always	50 kΩ or more
   67	z22-28 (VA66) (-) - z22-17 (VA67) (+)	Always	50 kΩ or more
   68	z22-17 (VA67) (-) - z22-16 (VA68) (+)	Always	50 kΩ or more
   69	z22-16 (VA68) (-) - z22-27 (VA69) (+)	Always	50 kΩ or more
   70	z22-27 (VA69) (-) - z22-15 (VA70) (+)	Always	50 kΩ or more
   71	z22-15 (VA70) (-) - z22-14 (VA71) (+)	Always	50 kΩ or more
   72	z22-14 (VA71) (-) - z22-26 (VA72) (+)	Always	50 kΩ or more

   NOTE:

   • Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.
   • Read the resistance after the value has stabilized.
   • In order to avoid damaging the terminals of the battery voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

   Result

   Result	Proceed to
   The resistance between the terminals is 50 kΩ or more.	A
   Other than above	B

   Post-procedure1

3. Install the battery voltage sensor.

Result: 

A 

REPLACE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

B 

See step  19

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connectors.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Procedure1

3. Measure the voltage according to the value(s) in the table below.

   HINT: 

   Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.6 V or less only.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Front view of wire harness connector (to Battery Voltage Sensor)

   -

   -

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition
   73	z22-3 (GA6) (-) - z22-8 (VA73) (+)	Always
   74	z22-8 (VA73) (-) - z22-2 (VA74) (+)	Always
   75	z22-2 (VA74) (-) - z22-7 (VA75) (+)	Always
   76	z22-7 (VA75) (-) - z22-1 (VA76) (+)	Always
   77	z22-1 (VA76) (-) - z22-21 (VA77) (+)	Always
   78	z22-21 (VA77) (-) - z22-6 (VA78) (+)	Always
   79	z22-6 (VA78) (-) - z22-20 (VA79) (+)	Always
   80	z22-20 (VA79) (-) - z24-26 (VA80) (+)	Always

   WARNING:

   Make sure not to cross the electrodes of an electrical tester measurement terminals.

   NOTE:

   Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

   Result

   Result	Proceed to
   The voltage between the terminals is 1.6 V or less.	A
   Other than above	B

   Post-procedure1

4. Reconnect the battery voltage sensor connectors.

Result: 

B 

See step  23

Result: 

A 

See step  21

Pre-procedure1

1. Remove the battery voltage sensor.

   HINT: 

   Refer to REMOVAL [08/2023 - ]

   Procedure1

2. Measure the resistance according to the value(s) in the table below.

   HINT: 

   Only inspect the terminals of the battery voltage sensor which correspond to the HV battery cells which measured 1.6 V or less in the previous step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (Battery Voltage Sensor)

   -

   -

   Standard Resistance

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition	Specified Condition
   73	z22-3 (GA6) (-) - z22-8 (VA73) (+)	Always	50 kΩ or more
   74	z22-8 (VA73) (-) - z22-2 (VA74) (+)	Always	50 kΩ or more
   75	z22-2 (VA74) (-) - z22-7 (VA75) (+)	Always	50 kΩ or more
   76	z22-7 (VA75) (-) - z22-1 (VA76) (+)	Always	50 kΩ or more
   77	z22-1 (VA76) (-) - z22-21 (VA77) (+)	Always	50 kΩ or more
   78	z22-21 (VA77) (-) - z22-6 (VA78) (+)	Always	50 kΩ or more
   79	z22-6 (VA78) (-) - z22-20 (VA79) (+)	Always	50 kΩ or more
   80	z22-20 (VA79) (-) - z24-26 (VA80) (+)	Always	50 kΩ or more

   NOTE:

   • Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.
   • Read the resistance after the value has stabilized.
   • In order to avoid damaging the terminals of the battery voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

   Result

   Result	Proceed to
   The resistance between the terminals is 50 kΩ or more.	A
   Other than above	B

   Post-procedure1

3. Install the battery voltage sensor.

Result: 

A 

REPLACE NO. 4 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

B 

See step  22

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON, unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connector.
   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Disconnect the A No. 3 HV supply stack sub-assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Procedure1

4. Measure the resistance according to the value(s) in the tables below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   A-4 (GA6) - z22-3 (GA6)	Ignition switch off	Below 1 Ω
   A-15 (VA73) - z22-8 (VA73)	Ignition switch off	Below 1 Ω
   A-3 (VA74) - z22-2 (VA74)	Ignition switch off	Below 1 Ω
   A-14 (VA75) - z22-7 (VA75)	Ignition switch off	Below 1 Ω
   A-2 (VA76) - z22-1 (VA76)	Ignition switch off	Below 1 Ω
   A-13 (VA77) - z22-21 (VA77)	Ignition switch off	Below 1 Ω
   A-1 (VA78) - z22-6 (VA78)	Ignition switch off	Below 1 Ω
   A-12 (VA79) - z22-20 (VA79)	Ignition switch off	Below 1 Ω
   A-4 (GA6) or z22-3 (GA6) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A-15 (VA73) or z22-8 (VA73) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A-3 (VA74) or z22-2 (VA74) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A-14 (VA75) or z22-7 (VA75) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A-2 (VA76) or z22-1 (VA76) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A-13 (VA77) or z22-21 (VA77) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A-1 (VA78) or z22-6 (VA78) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A-12 (VA79) or z22-20 (VA79) - Body ground and other terminals	Ignition switch off	10 kΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Front view of wire harness connector (to No. 4 HV Supply Stack Sub-assembly)
   *b	Front view of wire harness connector (to Battery Voltage Sensor)

   Result

   Proceed to
   OK
   NG

   Post-procedure1

5. Reconnect the No. 3 HV supply stack sub-assembly connector.
6. Reconnect the battery voltage sensor connector.

Result: 

OK 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

NG 

REPLACE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery voltage sensor connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Before disconnecting the connector, check that it is not loose or disconnected.

   Procedure1

3. Measure the voltage according to the value(s) in the table below.

   HINT: 

   Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.6 V or less only.

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition
   81	z24-26 (VA80) (-) - z24-27 (VA81) (+)	Always
   82	z24-27 (VA81) (-) - z24-17 (VA82) (+)	Always
   83	z24-17 (VA82) (-) - z24-4 (VA83) (+)	Always
   84	z24-4 (VA83) (-) - z24-16 (VA84) (+)	Always
   85	z24-3 (GA7) (-) - z24-15 (VA85) (+)	Always
   86	z24-15 (VA85) (-) - z24-14 (VA86) (+)	Always
   87	z24-14 (VA86) (-) - z24-24 (VA87) (+)	Always
   88	z24-24 (VA87) (-) - z24-13 (VA88) (+)	Always
   89	z24-13 (VA88) (-) - z24-12 (VA89) (+)	Always
   90	z24-12 (VA89) (-) - z24-23 (VA90) (+)	Always
   91	z24-23 (VA90) (-) - z24-11 (VA91) (+)	Always
   92	z24-11 (VA91) (-) - z24-22 (VA92) (+)	Always
   93	z24-22 (VA92) (-) - z24-10 (VA93) (+)	Always
   94	z24-10 (VA93) (-) - z24-9 (VA94) (+)	Always
   95	z24-9 (VA94) (-) - z24-21 (VA95) (+)	Always
   96	z24-21 (VA95) (-) - z24-7 (VA96) (+)	Always

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Front view of wire harness connector (to Battery Voltage Sensor)

   WARNING:

   Make sure not to cross the electrodes of an electrical tester measurement terminals.

   NOTE:

   Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

   Result

   Result	Proceed to
   The voltage between the terminals is 1.6 V or less.	A
   Other than above	B

   Post-procedure1

4. Reconnect the battery voltage sensor connector.

Result: 

B 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ] 

Result: 

A 

See step  25

Pre-procedure1

1. Remove the battery voltage sensor.

   HINT: 

   Refer to REMOVAL [08/2023 - ]

   Procedure1

2. Measure the resistance according to the value(s) in the table below.

   HINT: 

   Only inspect the terminals of the battery voltage sensor which correspond to the HV battery cells which measured 1.6 V or less in the previous step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (Battery Voltage Sensor)

   -

   -

   Standard Resistance

   Hybrid Battery Cell	Tester Connection (Tester Probe Polarity)	Condition	Specified Condition
   81	z24-26 (VA80) (-) - z24-27 (VA81) (+)	Always	50 kΩ or more
   82	z24-27 (VA81) (-) - z24-17 (VA82) (+)	Always	50 kΩ or more
   83	z24-17 (VA82) (-) - z24-4 (VA83) (+)	Always	50 kΩ or more
   84	z24-4 (VA83) (-) - z24-16 (VA84) (+)	Always	50 kΩ or more
   85	z24-3 (GA7) (-) - z24-15 (VA85) (+)	Always	50 kΩ or more
   86	z24-15 (VA85) (-) - z24-14 (VA86) (+)	Always	50 kΩ or more
   87	z24-14 (VA86) (-) - z24-24 (VA87) (+)	Always	50 kΩ or more
   88	z24-24 (VA87) (-) - z24-13 (VA88) (+)	Always	50 kΩ or more
   89	z24-13 (VA88) (-) - z24-12 (VA89) (+)	Always	50 kΩ or more
   90	z24-12 (VA89) (-) - z24-23 (VA90) (+)	Always	50 kΩ or more
   91	z24-23 (VA90) (-) - z24-11 (VA91) (+)	Always	50 kΩ or more
   92	z24-11 (VA91) (-) - z24-22 (VA92) (+)	Always	50 kΩ or more
   93	z24-22 (VA92) (-) - z24-10 (VA93) (+)	Always	50 kΩ or more
   94	z24-10 (VA93) (-) - z24-9 (VA94) (+)	Always	50 kΩ or more
   95	z24-9 (VA94) (-) - z24-21 (VA95) (+)	Always	50 kΩ or more
   96	z24-21 (VA95) (-) - z24-7 (VA96) (+)	Always	50 kΩ or more

   NOTE:

   • Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.
   • Read the resistance after the value has stabilized.
   • In order to avoid damaging the terminals of the battery voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

   Result

   Result	Proceed to
   The resistance between the terminals is 50 kΩ or more.	A
   Other than above	B

   Post-procedure1

3. Install the battery voltage sensor.

Result: 

A 

REPLACE NO. 4 HV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

Result: 

B 

See step  26

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [08/2023 - ]