Recovery Inspection [12/2021 - ]: Procedure

1. Inspect for electrolyte leaks after removing the HV supply stack sub-assembly.

   OK

   No leak was found on the lower part of the battery outer case.

   WARNING:

   • Perform this procedure in an area where the HV battery will not be exposed to fire.
   • Do not touch the HV supply stack sub-assembly, unless absolutely necessary, as electrolyte may be leaking.
   NOTE:

   If there is an electrolyte leak, make sure to wear insulated gloves and goggles and clean it using a piece of cloth. Do not leave electrolyte-contaminated cloths unattended. Dispose of them according to law or local regulations.

   Result

   Result
   OK
   NG

Result: 

NG 

DISCHARGING (WHEN USING THE SALT WATER SOLUTION) 

Result: 

OK 

See step  2

1. Check the previously recorded DTCs which resulted in replacement of the HV supply stack sub-assembly.

   Result

   Result	Proceed to
   DTC record not available.	A
   The HV supply stack sub-assembly was replaced due to a reason other than the DTCs listed in the following table.	B
   The HV supply stack sub-assembly was replaced due to one of the DTCs listed in the following table.	C

   DTC No.
   P1A60-17
   P31AA-17
   P0C30-00
   P31B3-00
   P1C7D-49

Result: 

B 

See step  5

Result: 

C 

See step  6

Result: 

A 

See step  3

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

   Standard Voltage

   Tester Connection	Condition	Specified Condition
   A - C	Always	Below 146.2 V
   B - D

   WARNING:

   Make sure not to cross the probes of the electrical tester.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 HV Supply Stack Sub-assembly
   *2	No. 2 HV Supply Stack Sub-assembly

   Result

   Result
   OK
   NG

Result: 

NG 

See step  6

Result: 

OK 

See step  4

1. Using a megohmmeter set to 500 V, measure the insulation 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
   A - Insulation Inspection Area of the Bracket	Always	1 MΩ or higher
   B - Insulation Inspection Area of the Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Insulation Inspection Area of the Bracket

   Result

   Result
   OK
   NG

Result: 

NG 

See step  6

Result: 

OK 

See step  5

1. Check that the HV supply stack sub-assembly is not deformed or damaged.

   OK

   The HV supply stack sub-assembly is not deformed or damaged.

   Result

   Result
   OK
   NG

Result: 

OK 

RETURN HV SUPPLY STACK SUB-ASSEMBLY 

Result: 

NG 

See step  6

1. Check that the orange connectors connected to the battery ECU assembly are not deformed or damaged.

   OK

   The connectors are not deformed or damaged.

   HINT: 

   If any of the connectors are damaged, a Li-ion battery discharger will not be able to be connected to the HV supply stack sub-assembly. Soak the HV supply stack sub-assembly in a saltwater solution to discharge it.

   Result

   Result
   OK
   NG

Result: 

OK 

DISCHARGING (WHEN USING THE LI-ION BATTERY DISCHARGER) 

Result: 

NG 

DISCHARGING (WHEN USING THE SALT WATER SOLUTION)