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Home >> Toyota >> 2013 >> RAV4 EV >> Repair and Diagnosis >> External Pages >> Different car >> Section 13 (HYBRID CONTROL SYSTEM (DIAGNOSTIC CODES (BMS_f001 - CHG_f075)) (ELECTRIC)) >> Hybrid Control System >> DTC CHG_f019: Overcurrent Condition [09/2013 - ] >> Procedure

DTC CHG_f019: Overcurrent Condition [09/2013 - ]: Procedure

WARNING: This page is about a different car, the 2014 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. CHECK HARNESS AND CONNECTOR (DC/DC CONVERTER - ELECTRIC VEHICLE CHARGER) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY376567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors f5 and f6 from the DC/DC converter.
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      f5-1 (CHG+) - f6-1 (CHG-) Power switch off 1 kΩ or higher
      f5-1 (CHG+) - Body ground and other terminals Power switch off 1 kΩ or higher
      f6-1 (CHG-) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a No. 4 Motor Compartment Wire
      (to DC/DC Converter Assembly)

    NG → See step   6 

    OK: Go to next step 

  2. CHECK DC/DC CONVERTER ASSEMBLY 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY365470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors f5 and f6 from the DC/DC converter.
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      f5-1 (CHG+) - f6-1 (CHG-) Power switch off 1 kΩ or higher
      f5-1 (CHG+) - Body ground and other terminals Power switch off 1 kΩ or higher
      f6-1 (CHG-) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Component without harness connected
      (DC/DC Converter Assembly)

    NG → See step   3 

    OK → See step   19 

  3. INSPECT DC/DC CONVERTER ASSEMBLY 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY382852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors f5 and f6 from the DC/DC converter.
      GTY379613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect connector i1 from the DC/DC converter.
      GTY376738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect connector z11 from the DC/DC converter.
      GTY361002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect connector z0 from the DC/DC converter.
    8. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      f5-1 (CHG+) - f6-1 (CHG-) Power switch off 1 kΩ or higher
      f5-1 (CHG+) - Body ground and other terminals Power switch off 1 kΩ or higher
      f6-1 (CHG-) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Component without harness connected
      (DC/DC Converter Assembly)
      *b Air Conditioning Harness
      (to DC/DC Converter Assembly)
      *c Electric Heater Sub-assembly
      (to DC/DC Converter Assembly)
      *d Battery Coolant Heater
      (to DC/DC Converter Assembly)

    NG → See step   15 

    OK: Go to next step 

  4. CHECK HARNESS AND CONNECTOR (HIGH VOLTAGE LINE EXCEPT POWERTRAIN SYSTEM) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY377533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connector i1 from the DC/DC converter.
      GTY376409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect connector z11 from the DC/DC converter.
      GTY363382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect connector z0 from the DC/DC converter.
    7. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Compressor assembly with bracket circuit)

      Tester Connection Switch Condition Specified Condition
      i1-1 (PB) - i1-2 (PE) Power switch off 1 kΩ or higher
      i1-1 (PB) - Body ground and other terminals Power switch off 1 kΩ or higher
      i1-2 (PE) - Body ground and other terminals Power switch off 1 kΩ or higher

      Standard Resistance (Electric heater sub-assembly circuit)

      Tester Connection Switch Condition Specified Condition
      z11-2 (+) - z11-1 (-) Power switch off 1 kΩ or higher
      z11-2 (+) - Body ground and other terminals Power switch off 1 kΩ or higher
      z11-1 (-) - Body ground and other terminals Power switch off 1 kΩ or higher

      Standard Resistance (Battery coolant heater circuit)

      Tester Connection Switch Condition Specified Condition
      z0-1 (+) - z0-2 (-) Power switch off 1 kΩ or higher
      z0-1 (+) - Body ground and other terminals Power switch off 1 kΩ or higher
      z0-2 (-) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to DC/DC Converter Assembly)
      *b Front view of wire harness connector
      (to DC/DC Converter Assembly)
      *c Front view of wire harness connector
      (to DC/DC Converter Assembly)
      RESULT

      Result Proceed to
      Short in compressor assembly with bracket circuit A
      Short in electric heater sub-assembly circuit B
      Short in battery coolant heater circuit C

    B → See step   17 

    C → See step   20 

    A: Go to next step 

  5. CHECK AIR CONDITIONING HARNESS 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY377533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connector i1 from the DC/DC converter.
      GTY374039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect connector i2 from the compressor assembly with bracket.
    6. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      i1-1 (PB) - i1-2 (PE) Power switch off 1 kΩ or higher
      i1-1 (PB) - Body ground and other terminals Power switch off 1 kΩ or higher
      i1-2 (PE) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to DC/DC Converter Assembly)
      *b Front view of wire harness connector
      (to Compressor Assembly with Bracket)

    NG → REPLACE AIR CONDITIONING HARNESS 

    OK → See step   16 

  6. CHECK HARNESS AND CONNECTOR (ELECTRIC VEHICLE BATTERY - ELECTRIC VEHICLE TRACTION MOTOR) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY360874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors p2 and r2 from the electric vehicle battery.
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      p2-1 (+) - r2-1 (-) Power switch off 1 kΩ or higher
      p2-1 (+) - Body ground and other terminals Power switch off 1 kΩ or higher
      r2-1 (-) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a No. 8 Floor Wire
      (to Electric Vehicle Battery Assembly)

    NG → See step   14 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (ELECTRIC VEHICLE BATTERY - ELECTRIC VEHICLE CHARGER) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY433428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors U6 and U7 from the electric vehicle battery.
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      U6-1 (CHG+) - U7-1 (CHG-) Power switch off 1 kΩ or higher
      U6-1 (CHG+) - Body ground and other terminals Power switch off 1 kΩ or higher
      U7-1 (CHG-) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a No. 5 Motor Compartment Wire
      (to Electric Vehicle Battery Assembly)

    NG → See step   8 

    OK → See step   21 

  8. CHECK NO. 2 MOTOR COMPARTMENT WIRE 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY364123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connector T1 from the electric vehicle charger.
      GTY375739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the No. 2 motor compartment wire.
    6. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      T1-4 (DC+) - T1-1 (DC-) Power switch off 1 kΩ or higher
      T2-1 - T3-1 Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Electric Vehicle Charger Assembly)
      *b No. 2 Motor Compartment Wire
      (to Electric Vehicle Charger Assembly)

    NG → REPLACE NO. 2 MOTOR COMPARTMENT WIRE 

    OK: Go to next step 

  9. CHECK NO. 5 MOTOR COMPARTMENT WIRE (ELECTRIC VEHICLE CHARGER - ELECTRIC VEHICLE BATTERY) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY425712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors U2 and U4 from the electric vehicle charger.
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      U2-1 - U4-1 Power switch off 1 kΩ or higher
      U2-1 - Body ground and other terminals Power switch off 1 kΩ or higher
      U4-1 - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a No. 5 Motor Compartment Wire
      (to Electric Vehicle Charger Assembly)

    NG → REPLACE NO. 5 MOTOR COMPARTMENT WIRE 

    OK: Go to next step 

  10. CHECK NO. 4 MOTOR COMPARTMENT WIRE (ELECTRIC VEHICLE CHARGER - DC/DC CONVERTER) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY383530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors f1 and f3 from the electric vehicle charger.
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      f1-1 - f3-1 Power switch off 1 kΩ or higher
      f1-1 - Body ground and other terminals Power switch off 1 kΩ or higher
      f3-1 - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a No. 4 Motor Compartment Wire
      (to Electric Vehicle Charger Assembly)

    NG → REPLACE NO. 4 MOTOR COMPARTMENT WIRE 

    OK: Go to next step 

  11. CHECK NO. 5 MOTOR COMPARTMENT WIRE (ELECTRIC VEHICLE CHARGER - EV CHARGER WITH CABLE INLET) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY449393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connector U1 from the electric vehicle charger.
      GTY440932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect connector Uh1 from the No. 4 floor wire.
    6. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      U1-1 (DCHB) - U1-3 (DCHG) Power switch off 1 kΩ or higher
      U1-1 (DCHB) - Body ground and other terminals Power switch off 1 kΩ or higher
      U1-3 (DCHG) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Electric Vehicle Charger Assembly)
      *b Front view of wire harness connector
      (to No. 4 Floor Wire)

    NG → REPLACE NO. 5 MOTOR COMPARTMENT WIRE 

    OK: Go to next step 

  12. CHECK NO. 4 FLOOR WIRE 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY435847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connector Uh1 from the No. 5 motor compartment wire.
      GTY435922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect connector jh1 from the EV charger with cable inlet.
    6. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      Uh1-2 - Uh1-1 Power switch off 1 kΩ or higher
      Uh1-2 - Body ground and other terminals Power switch off 1 kΩ or higher
      Uh1-1 - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to No. 5 Motor Compartment Wire)
      *b Front view of wire harness connector
      (to EV Charger with Cable Inlet Sub-assembly)

    NG → See step   24 

    OK: Go to next step 

  13. CHECK EV CHARGER WITH CABLE INLET SUB-ASSEMBLY 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY441074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connector jh1 from the No. 4 floor wire.
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      jh1-2 - jh1-1 Power switch off 1 kΩ or higher
      jh1-2 - Body ground and other terminals Power switch off 1 kΩ or higher
      jh1-1 - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to No. 4 Floor Wire)

    NG → See step   25 

    OK → See step   22 

  14. CHECK NO. 8 FLOOR WIRE (ELECTRIC VEHICLE TRACTION MOTOR - ELECTRIC VEHICLE BATTERY) 
    WARNING:
    • Unexpected high voltage may be present.
    • Wear insulated gloves and protective goggles.
    1. Turn the power switch off.
    2. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair Service Information because this may cause a malfunction.

    3. Check the voltage at the terminals in the inspection point in the electric vehicle battery assembly. Refer to PRECAUTION [09/2013 - ] .
      GTY384342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect connectors p1 and r1 from the electric vehicle traction motor.
      GTY381207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect connectors p2 and r2 from the electric vehicle battery.
    6. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      p1-1 (+) - r1-1 (-) Power switch off 1 kΩ or higher
      p1-1 (+) - Body ground and other terminals Power switch off 1 kΩ or higher
      r1-1 (-) - Body ground and other terminals Power switch off 1 kΩ or higher
      TEXT IN ILLUSTRATION

      *a No. 8 Floor Wire
      (to Electric Vehicle Traction Motor Assembly)
      *b No. 8 Floor Wire
      (to Electric Vehicle Battery Assembly)

    NG → See step   18 

    OK → See step   23 

  15. REPLACE DC/DC CONVERTER ASSEMBLY. Refer to  REMOVAL [09/2013 - ] 
  16. REPLACE COMPRESSOR ASSEMBLY WITH BRACKET. Refer to  REMOVAL [09/2013 - ] 
  17. REPLACE ELECTRIC HEATER SUB-ASSEMBLY. Refer to  REMOVAL [09/2013 - ] 
  18. REPLACE NO. 8 FLOOR WIRE. Refer to  REMOVAL [09/2013 - ] 
  19. REPLACE ELECTRIC VEHICLE BATTERY ASSEMBLY. Refer to  REMOVAL [09/2013 - ] 
  20. REPLACE BATTERY COOLANT HEATER. Refer to  REMOVAL [09/2013 - ] 
  21. REPLACE ELECTRIC VEHICLE BATTERY ASSEMBLY. Refer to  REMOVAL [09/2013 - ] 
  22. REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY. Refer to  REMOVAL [09/2013 - ] 
  23. REPLACE ELECTRIC VEHICLE TRACTION MOTOR ASSEMBLY. Refer to  REMOVAL [09/2013 - ] 
  24. REPLACE NO. 4 FLOOR WIRE. Refer to  REMOVAL [09/2013 - ] 
  25. REPLACE EV CHARGER WITH CABLE INLET SUB-ASSEMBLY. Refer to  REMOVAL [09/2013 - ] 
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