Inspection [12/2023 - ]: Procedure

HINT: 

• The purpose of the external inspection is to determine the condition of the HV Supply Battery Assembly.
• Perform the external inspection after first cleaning away any dust or mud on the HV Supply Battery Assembly and ensuring an appropriate level of cleanliness.

1. Remove the service plug grip.

   Refer to REMOVAL [12/2023 - ]

   Inspection Item	Inspection Method	Important Points to Check
   Abnormal Odor	Smell for Odors	Get under the vehicle and check for odors (sweet, acrid, or burnt odors)
   HV Supply Battery Assembly External Wire Harness/Connector	Visual Inspection	Check the high voltage wire harness and connector condition. Also check for water entry when disconnected.
   		Check the low voltage wire harness and connector condition. Also check for water entry when disconnected.
   HV Supply Battery Assembly - Frame Bolt Fastening Inspection	Visual Inspection	Check the fastening points with the body for looseness, falling out, damage, or twisting.
   HV Supply Battery Assembly Lower Side External Inspection	Visual Inspection	Check the condition of the paint on the lower side. Check that there is no deformation or rust. Check that the HV Supply Battery Assembly has no abrasion or other damage. Check that there are no signs of flooding or submersion.
   Service Plug Grip Inspection	Visual Inspection	Check that the service plug grip has no deformation or abrasion damage, and that the No. 2 traction battery cover and service plug grip are clean and without foreign matter contamination.
   Coolant Line Supply/Outlet Inspection	Visual Inspection	Check that the coolant line (refrigerant line) hoses, No. 2 discharge hose sub-assembly and No. 1 discharge hose sub-assembly connecting portions have no fluid leakage.
   HV Supply Battery Assembly Upper Side Inspection HINT:  Use a mirror and perform inspection in the areas that are visible.	Visual Inspection	Check that there are no cracks, and that the painted surfaces have no bubbling or swelling. Check that the pressure release valve and pressure equalization membrane have no looseness with the body, and that there is no sludge accumulation, deformation, or cracking. Check that there are no signs of flooding or submersion. Check for damage to the No. 1 traction battery carrier and No. 1 traction battery cover (splitting or deformation of the lower and upper seal surfaces, etc.)

2. If the visual inspection of the HV Supply Battery Assembly reveals deformation/cracking that results in clearly apparent penetration, replace the HV Supply Battery Assembly.

   Refer to REMOVAL [12/2023 - ] 

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  2

See step  2

Result

Result: 

A 

END 

Result: 

B 

See step  3

Refer to REMOVAL [12/2023 - ] 

Result

Result: 

NEXT 

See step  4

See step  2

Result

Result: 

NEXT 

See step  5

Refer to PROCEDURE - Step 2

Result

Result: 

NEXT 

See step  6

1. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Main Battery Cable(A)
   *2	Main Battery Cable(B)
   *a	Exterior Case Insulation Resistance Inspection Point

   NOTE:

   Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   A - Exterior Case	Always	1 MΩ or higher
   B - Exterior Case	Always	1 MΩ or higher

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  7

Result: 

OK 

See step  7

HINT: 

Make sure that no foreign matter or water has entered the HV battery.

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

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

2. Remove the No. 1 traction battery cover.

   Refer to PROCEDURE - Step 2

3. Disconnect the battery voltage sensor connectors.
   NOTE:

   Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
   NOTE:

   Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   1 - Body ground	Ignition switch off	10 MΩ or higher
   2 - Body ground	Ignition switch off	10 MΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Traction Battery Plug Cable Grip (Service Plug Grip Connecting Terminals)

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  9

Result: 

OK 

See step  8

• Battery ECU assembly:

  Refer to REMOVAL [12/2023 - ]

• Battery voltage sensor:

  Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  16

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

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

2. Disconnect the traction battery plug cable (No. 3 HV supply stack sub-assembly) connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
   NOTE:

   Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   1 - Body ground	Ignition switch off	10 MΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Traction Battery Plug Cable Grip (Service Plug Grip Connecting Terminals)

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  22

Result: 

OK 

See step  10

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

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

2. Disconnect the high voltage cable connector of the HV battery from the No. 2 traction battery device box assembly.
   NOTE:

   Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
   NOTE:

   Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Component without harness connected (No. 2 Traction Battery Device Box Assembly)

   -

   -

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   z14-1 (+) - Body ground	Ignition switch off	10 MΩ or higher
   z16-1 (+) - Body ground	Ignition switch off	10 MΩ or higher
   z13-1 (-) - Body ground	Ignition switch off	10 MΩ or higher
   z15-1 (-) - Body ground	Ignition switch off	10 MΩ or higher

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  16

Result: 

OK 

See step  11

1. Check that no electrolyte is leaking from each HV supply battery sub-assembly.

   Refer to PROCEDURE - Step 1

   Result

   Result	Proceed to
   Electrolyte is not leaking from the HV supply battery sub-assembly.	A
   Electrolyte is leaking from the HV supply battery sub-assembly.	B

Result: 

B 

See step  23

Result: 

A 

See step  12

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

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

2. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
   NOTE:

   Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   z16-1 (+) - Body ground	Ignition switch off	10 MΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	No. 4 HV Supply Stack Sub-assembly Connector (No. 4 HV Supply Stack Sub-assembly Side)

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  19

Result: 

OK 

See step  13

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

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

2. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
   NOTE:

   Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   z15-1 (+) - Body ground	Ignition switch off	10 MΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	NO. 3 HV Supply Stack Sub-assembly Connector (NO. 3 HV Supply Stack Sub-assembly Side)

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  20

Result: 

OK 

See step  14

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

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

2. Disconnect the traction battery plug cable (No. 2 HV supply stack sub-assembly) connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
   NOTE:

   Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   z14-1 (+) - Body ground	Ignition switch off	10 MΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	No. 2 HV Supply Stack Sub-assembly Connector (No. 2 HV Supply Stack Sub-assembly Side)

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  21

Result: 

OK 

See step  15

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  16

1. Check the following items to determine whether there has been water entry into the HV supply battery assembly. If problems are found, replace the malfunctioning components.

   Procedure	Inspection Method	Important Points to Check
   Inspect for condensation on the inside of the upper cover.	Visual Inspection	Check that the inside of the upper cover has a good appearance, has no condensation, and has no signs that water droplets were present.
   Inspect for water entry inside the HV supply battery assembly.	Visual Inspection	Check the condition of the top and sides of the HV battery stack.
   		Check the condition of the heater relay.
   		Check the condition of the junction block.
   		Check the condition of the lower case.
   		Check the ECU and SBM condition.
   Inspect the appearance and connector connection status of the low voltage wire harness inside the HV supply battery assembly.	Visual Inspection	Check that the external appearance is good, there is no wear or degradation, and the connector is not loose. Check that the harness insulation does not have wear, and has no abnormal discoloration or blackening.
   Inspect the high voltage wire harness (including electrical connector) inside the HV supply battery assembly.	Visual Inspection	Check that the external appearance is good, there is no wear or degradation, and the connector is not loose. Check that the harness insulation does not have wear, and has no abnormal discoloration or blackening.
   Inspect the torque of the brass high voltage bolts.	Inspection Using Tools	Check for looseness in the torque of all bus bar fastening locations. Tighten to the specified torque.
   Inspect the external appearance of the water cooling plate.	Visual Inspection	Check that the coolant line (refrigerant line) hoses/hard type connections are in good condition.
   		Check that the water cooling plate (refrigerant) has no deformation.
   Inspect the cleanliness of the HV supply battery assembly.	Visual Inspection	Check that the cleanliness of the interior is good, and that there is no foreign matter remaining.
   Replace the No. 2 HV battery seal.	Component Replacement	Replace the No. 2 HV battery seal.
   Inspect the lower surface of the No. 1 traction battery carrier.	Visual Inspection	Check for rust on the lower surface of the No. 1 traction battery carrier.
   Inspect the lower surface of the first stage HV battery stack.	Visual Inspection	Check for rust on the lower surface of the first stage HV battery stack.

2. If any abnormalities are found, replace the affected part(s).

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE REPAIR OR REPLACE MALFUNCTIONING PARTS 

Result: 

OK 

See step  17

1. After replacing the airtightness check problem location, install the No. 1 traction battery cover.

   Refer to PROCEDURE - Step 1

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  18

See step  2

Result

Result: 

OK 

INSTALL HV BATTERY. Refer to  INSTALLATION [12/2023 - ]  

Result: 

NG 

REPAIR OR REPLACE MALFUNCTIONING PARTS 

1. Identify the leak locations(s) and replace the affected part(s).

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  16

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  16

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  16

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  16

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  16