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Home >> Toyota >> 2021 >> Mirai Limited >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Battery System - Diagnostic Codes (4 Of 8) >> Hybrid Battery System >> DTC P0E2D-00: Hybrid/EV Battery Energy Control Module Hybrid/EV Battery Monitor Performance [11/2020 - 12/2022] >> Procedure

DTC P0E2D-00: Hybrid/EV Battery Energy Control Module Hybrid/EV Battery Monitor Performance [11/2020 - 12/2022]: Procedure

  1. CHECK DTC OUTPUT (EV BATTERY) 

    Pre-procedure1

    • None.
    • Check for DTCs.

      Powertrain > EV 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
      P0E2D-00 and Hybrid battery system DTCs 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
      P301A-1C Hybrid Battery Stack 1 Cell Voltage Detection Voltage Out of Range

      *1: If area specific insulation resistance malfunction DTCs (P1C7C-49, P1C7D-49, P1C7E-49, P1C7F-49, P1EEC-49, P1EED-49, P1EEE-49 or P1EEF-49) are output, perform repairs according to each DTC.

    Post-procedure1

    • Turn the ignition switch off.

    Result: 

    B 

    GO TO DTC CHART (HYBRID BATTERY SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2020 - 12/2022] 

    Result: 

    A 

    See step  2

  2. CHECK FREEZE FRAME DATA 

    Pre-procedure1

    • None.
    • 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.

      Powertrain > EV Battery > DTC(P0E2D-00) > Freeze Frame Data 

      Tester Display
      Lost Communication with Hybrid/EV Battery Monitoring IC
      Hybrid/EV Battery Monitoring IC 1 Internal Malfunction (Determinable)
      Hybrid/EV Battery Monitoring IC 2 Internal Malfunction (Determinable)
      Hybrid/EV Battery Monitoring IC 3 Internal Malfunction (Determinable)
      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
      Hybrid/EV Battery Monitoring IC 2 Power Supply Malfunction
      Hybrid/EV Battery Monitoring IC 3 Power Supply Malfunction
      Hybrid/EV Battery Monitoring IC 4 Power Supply Malfunction
      Hybrid/EV Battery Monitoring IC 1 Cell Voltage Detection Malfunction
      Hybrid/EV Battery Monitoring IC 2 Cell Voltage Detection Malfunction
      Hybrid/EV Battery Monitoring IC 3 Cell Voltage Detection Malfunction
      Hybrid/EV Battery Monitoring IC 4 Cell Voltage Detection Malfunction

      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)" or "Hybrid/EV Battery Monitoring IC 2 Internal Malfunction (Determinable)" is ON. B
      Either freeze frame data item "Hybrid/EV Battery Monitoring IC 3 Internal Malfunction (Determinable)" or "Hybrid/EV Battery Monitoring IC 4 Internal Malfunction (Determinable)" is ON. C
      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. D
      The freeze frame data item "Lost Communication with Hybrid/EV Battery Monitoring IC" is ON. E
      Any of the freeze frame data items "Hybrid/EV Battery Monitoring IC 1 Cell Voltage Detection Malfunction" through "Hybrid/EV Battery Monitoring IC 4 Cell Voltage Detection Malfunction" is ON. F

      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.

    Post-procedure1

    • Turn the ignition switch off.

    Result: 

    A 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side) and BATTERY VOLTAGE SENSOR (for Lower Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    C 

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    E 

    See step  4

    Result: 

    F 

    See step  24

    Result: 

    D 

    See step  3

  3. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - BATTERY VOLTAGE SENSOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for upper side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Disconnect the y1 battery voltage sensor (for upper side) connector.
      WARNING:

      When disconnecting connector y1 of the battery voltage sensor (for upper side), first disconnect connectors z14 and z15 from the battery voltage sensor (for upper side).

      GTY972447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    • Disconnect the y2 battery ECU assembly connector.
      GTY972449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    • Remove the No. 1 EV battery protector (for lower side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Disconnect the y3 battery voltage sensor (for lower side) connector.
      WARNING:

      When disconnecting connector y3 of the battery voltage sensor (for lower side), first disconnect connectors z16 and z17 from the battery voltage sensor (for lower side).

      GTY972457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      y2-16 (GFB0) - y1-26 (GFB0) Always Below 1 Ω
      y2-36 (FB0) - y1-27 (FB0) Always Below 1 Ω
      y2-14 (GFB1) - y1-30 (GFB1) Always Below 1 Ω
      y2-34 (FB1) - y1-31 (FB1) Always Below 1 Ω
      GTY972505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (to Battery ECU Assembly)
      *b Component without harness connected
      (to Battery Voltage Sensor (for Upper Side))
    • Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      y2-10 (GFB2) - y3-26 (GFB2) Always Below 1 Ω
      y2-30 (FB2) - y3-27 (FB2) Always Below 1 Ω
      y2-8 (GFB3) - y3-30 (GFB3) Always Below 1 Ω
      y2-28 (FB3) - y3-31 (FB3) Always Below 1 Ω
      GTY972531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (to Battery ECU Assembly)
      *b Component without harness connected
      (to Battery Voltage Sensor (for Lower Side))

      Result

      Result Proceed to
      OK Either recorded freeze frame data item "Hybrid/EV Battery Monitoring IC 1 Power Supply Malfunction" or "Hybrid/EV Battery Monitoring IC 2 Power Supply Malfunction" is ON. A
      Either recorded freeze frame data item "Hybrid/EV Battery Monitoring IC 3 Power Supply Malfunction" or "Hybrid/EV Battery Monitoring IC 4 Power Supply Malfunction" is ON. B
      NG C

    Post-procedure1

    • Install the battery voltage sensor (for lower side).
      WARNING:

      When connecting connectors z16 and z17 of the battery voltage sensor (for lower side), first connect connector y3 to the battery voltage sensor (for lower side).

      GTY972457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Reconnect the y2 battery ECU assembly connector.
    • Install the battery voltage sensor (for upper side).
      WARNING:

      When connecting connectors z14 and z15 of the battery voltage sensor (for upper side), first connect connector y1 to the battery voltage sensor (for upper side).

      GTY972447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Result: 

    A 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side) and BATTERY ECU ASSEMBLY 

    for Battery voltage sensor:

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    for Battery ECU assembly:

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result: 

    B 

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side) and BATTERY ECU ASSEMBLY 

    for Battery voltage sensor:

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    for Battery ECU assembly:

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  4. CLEAR DTC (EV BATTERY) 

    Pre-procedure1

    • None.
    • Clear the DTCs and freeze frame data.

      Powertrain > EV Battery > Clear DTCs 

      Result

      Proceed to
      NEXT

    Post-procedure1

    • Turn the ignition switch off.

    Result: 

    NEXT 

    See step  5

  5. CHECK DTC OUTPUT (EV BATTERY) 

    Pre-procedure1

    • Turn the ignition switch to ON and wait for 1 minute or more.
    • Check if DTCs are output.

      Powertrain > EV Battery > Trouble Codes 

      Result

      Result Proceed to
      P0E2D-00 is not output A
      P0E2D-00 is output B

    Post-procedure1

    • Turn the ignition switch off.

    Result: 

    B 

    See step  19

    Result: 

    A 

    See step  6

  6. SIMULATION TEST 
    NOTE:

    Do not turn the ignition switch off while performing this inspection.

    Pre-procedure1

    • None.
    • With the vehicle stopped and the shift state in park (P), turn the ignition switch to ON and wait for at least 70 seconds.
    • Turn the ignition switch to ON (READY) and without depressing the accelerator pedal, and while depressing the brake pedal, change the shift state to drive (D) and wait for 1 minute. (Step A)
    • Drive the vehicle 0.5 m (1.6 ft.) forward and perform step A.
    • Drive the vehicle another 0.5 m (1.6 ft.) forward and perform step A. Repeat this procedure 5 times (minimum total driving distance: 2 m (6.6 ft.)).
    • Check if DTCs are output.

      Powertrain > EV > Trouble Codes 

      HINT: 

      Use the Data List item and/or freeze frame data item "Short Wave Highest Value" for reference.

      Result

      Result Proceed to
      P0AA6-49 is not output A
      P0AA6-49 is output B

    Post-procedure1

    • Turn the ignition switch off.

    Result: 

    B 

    GO TO DTC CHART (P0AA6-49). Refer to  DTC P0AA6-49: Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure; DTC P1C7C-49: Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure; DTC P1C7D-49: Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure; DTC P1C7E-49: Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure; DTC P1C7F-49: Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure; DTC P1EEC-49: Hybrid/EV Battery Voltage System Isolation (FC Air Compressor Area) Internal Electronic Failure; DTC P1EED-49: Hybrid/EV Battery Voltage System Isolation (FC Area) Internal Electronic Failure; DTC P1EEE-49: Hybrid/EV Battery Voltage System Isolation (Hydrogen Pump Area) Internal Electronic Failure; DTC P1EEF-49: Hybrid/EV Battery Voltage System Isolation (FC Coolant Pump Area) Internal Electronic Failure [11/2020 - 12/2022] 

    Result: 

    A 

    See step  7

  7. CHECK ODOMETER 
    1. Check and record the total distance traveled of the vehicle.

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  8

  8. CHECK INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the No. 2 battery pack wire and FC air compressor motor cable assembly from the inverter with converter assembly.

      HINT: 

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

      GTY811787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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 Result
      High voltage terminal - Body ground Ignition switch off 1 MΩ or higher MΩ

      HINT: 

      Perform this inspection with the No. 2 battery pack wire and FC air compressor motor cable assembly disconnected from the inverter with converter assembly.

      GTY819640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 High Voltage Terminal

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Reconnect the No. 2 battery pack wire and FC air compressor motor cable assembly to the inverter with converter assembly.

    Result: 

    NG 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    OK 

    See step  9

  9. CHECK FCV WITH MOTOR TRANSAXLE ASSEMBLY (NO. 2 BATTERY PACK WIRE) 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the No. 2 battery pack wire from the inverter with converter assembly.

      HINT: 

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

      GTY811785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Connect the cable to the negative (-) auxiliary battery terminal.

      HINT: 

      As the insulation resistance may vary when motor (MG2) rotates, perform this inspection while rotating the rear wheels.

    • Turn the ignition switch to ON.
      NOTE:

      Turning the ignition switch to ON with the service plug grip removed causes DTCs to be stored. Clear the DTCs after performing this inspection.

    • Move the shift lever to select shift state neutral (N) and lift the vehicle.
    • Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below while rotating the rear wheels 2 revolutions in the same direction simultaneously.
      NOTE:
      • Carefully perform this inspection as the motor (MG2) may generate current when the rear wheels are rotated by hand.
      • 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 Result
      O2-3 (R-U) - Body ground and shield ground Ignition switch ON 100 MΩ or higher MΩ
      O2-2 (R-V) - Body ground and shield ground Ignition switch ON 100 MΩ or higher MΩ
      O2-1 (R-W) - Body ground and shield ground Ignition switch ON 100 MΩ or higher MΩ
      GTY972467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a No. 2 Battery Pack Wire
      (Inverter with Converter Assembly Side)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Lower the vehicle and push the P position switch (parking switch).
    • Turn the ignition switch off.
    • Disconnect the cable from the negative (-) auxiliary battery terminal.
    • Reconnect the No. 2 battery pack wire to the inverter with converter assembly.

    Result: 

    NG 

    See step  15

    Result: 

    OK 

    See step  10

  10. CHECK FC AIR COMPRESSOR WITH MOTOR ASSEMBLY (FC AIR COMPRESSOR MOTOR CABLE ASSEMBLY) 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the FC air compressor motor cable assembly from the inverter with converter assembly.

      HINT: 

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

      GTY811782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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 Result
      o3-1 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      o3-2 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      o3-3 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      GTY972374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a FC Air Compressor Motor Cable Assembly
      (Inverter with Converter Assembly Side)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Reconnect the FC air compressor motor cable assembly to the inverter with converter assembly.

    Result: 

    NG 

    See step  17

    Result: 

    OK 

    See step  11

  11. CHECK FC COOLING WATER PUMP ASSEMBLY (FC COOLING WATER PUMP CABLE) 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the FC cooling water pump cable from the FC converter assembly.
      GTY1003128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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 Result
      b1-1 (W) - Body ground and shield ground Ignition switch off 10 MΩ or higher MΩ
      b1-2 (V) - Body ground and shield ground Ignition switch off 10 MΩ or higher MΩ
      b1-3 (U) - Body ground and shield ground Ignition switch off 10 MΩ or higher MΩ
      GTY1018584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a FC Cooling Water Pump Cable
      (FC Converter Assembly Side)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Reconnect the FC cooling water pump cable to the FC converter assembly.

    Result: 

    NG 

    See step  18

    Result: 

    OK 

    See step  12

  12. CHECK HYDROGEN RECIRCULATION PUMP ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the z30 hydrogen recirculation pump assembly connector.
      GTY1003124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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 Result
      z30-1 (U) - Body ground Ignition switch off 10 MΩ or higher MΩ
      z30-2 (V) - Body ground Ignition switch off 10 MΩ or higher MΩ
      z30-3 (W) - Body ground Ignition switch off 10 MΩ or higher MΩ
      GTY1004097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hydrogen Recirculation Pump Assembly Connector
      (to FC Converter Assembly)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Reconnect the z30 hydrogen recirculation pump assembly connector.

    Result: 

    NG 

    REPLACE HYDROGEN RECIRCULATION PUMP ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    OK 

    See step  13

  13. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Upper Side) CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for upper side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Check the connections of the z14 and z15 battery voltage sensor (for upper side) connectors.

      HINT: 

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [11/2020 - ]

      GTY812206Courtesy 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
      Either connector z14 or z15 was not connected securely The terminals are damaged or corroded C

    Post-procedure1

    • None.

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    See step  20

    Result: 

    A 

    See step  14

  14. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Lower Side) CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for lower side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Check the connections of the z16 and z17 battery voltage sensor (for lower side) connectors.

      HINT: 

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [11/2020 - ]

      GTY800992Courtesy 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
      Either connector z16 or z17 was not connected securely The terminals are damaged or corroded C

    Post-procedure1

    • None.

    Result: 

    A 

    See step  19

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    See step  21

  15. CHECK NO. 2 BATTERY PACK WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the No. 2 battery pack wire from the inverter with converter assembly.

      HINT: 

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

      GTY811785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Disconnect the motor cable from the No. 2 battery pack wire.

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

      GTY1002862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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 Result
      O2-3 (R-U) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      O2-2 (R-V) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      O2-1 (R-W) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      GTY972467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a No. 2 Battery Pack Wire
      (Inverter with Converter Assembly Side)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Reconnect the motor cable to the No. 2 battery pack wire.
    • Reconnect the No. 2 battery pack wire to the inverter with converter assembly.

    Result: 

    NG 

    REPLACE NO. 2 BATTERY PACK WIRE. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    OK 

    See step  16

  16. CHECK MOTOR CABLE 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the motor cable wire from the No. 2 battery pack wire.

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

      GTY1002862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Remove the motor cable from the FCV with motor transaxle assembly.
      GTY1002860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • 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 Result
      q2-1 - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      q2-2 - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      q2-3 - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      GTY1003306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a Motor Cable
      (No. 2 Battery Pack Wire Side)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Install the motor cable to the FCV with motor transaxle assembly.
    • Reconnect the motor cable to the No. 2 battery pack wire.

    Result: 

    OK 

    REPLACE FCV WITH MOTOR TRANSAXLE ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    NG 

    REPLACE MOTOR CABLE. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  17. CHECK FC AIR COMPRESSOR MOTOR CABLE ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the FC air compressor motor cable assembly from the inverter with converter assembly.

      HINT: 

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

      GTY811782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Remove the FC air compressor motor cable assembly from the FC air compressor with motor assembly.

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

      GTY1002980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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 Result
      o3-1 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      o3-2 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      o3-3 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher MΩ
      GTY972374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a FC Air Compressor Motor Cable Assembly
      (Inverter with Converter Assembly Side)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Install the FC air compressor motor cable assembly to the FC air compressor with motor assembly.
    • Reconnect the FC air compressor motor cable assembly to the inverter with converter assembly.

    Result: 

    OK 

    REPLACE FC AIR COMPRESSOR WITH MOTOR ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    NG 

    REPLACE FC AIR COMPRESSOR MOTOR CABLE ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  18. CHECK FC COOLING WATER PUMP CABLE 
    WARNING:

    Be sure to wear insulated gloves.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Disconnect the FC cooling water pump cable from the FC converter assembly.
      GTY1003128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Disconnect the FC cooling water pump cable from the FC cooling water pump assembly.
      GTY1002874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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 Result
      b1-1 (W) - Body ground and shield ground Ignition switch off 10 MΩ or higher MΩ
      b1-2 (V) - Body ground and shield ground Ignition switch off 10 MΩ or higher MΩ
      b1-3 (U) - Body ground and shield ground Ignition switch off 10 MΩ or higher MΩ
      GTY1018584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a FC Cooling Water Pump Cable
      (FC Converter Assembly Side)

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Reconnect the FC cooling water pump cable to the FC converter assembly.
    • Reconnect the FC cooling water pump cable to the FC cooling water pump assembly.

    Result: 

    OK 

    REPLACE FC COOLING WATER PUMP ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    NG 

    FC COOLING WATER PUMP CABLE. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  19. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - BATTERY VOLTAGE SENSOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for upper side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Disconnect the y1 battery voltage sensor (for upper side) connector.
      WARNING:

      When disconnecting connector y1 of the battery voltage sensor (for upper side), first disconnect connectors z14 and z15 from the battery voltage sensor (for upper side).

      GTY972447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    • Disconnect the y2 battery ECU assembly connector.
      GTY972449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    • Remove the No. 1 EV battery protector (for lower side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Disconnect the y3 battery voltage sensor (for lower side) connector.
      WARNING:

      When disconnecting connector y3 of the battery voltage sensor (for lower side), first disconnect connectors z16 and z17 from the battery voltage sensor (for lower side).

      GTY972457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

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

      Standard Resistance

      Tester Connection Condition Specified Condition Result
      y2-18 (DIN) - y1-25 (DIN0) Always Below 1 Ω Ω
      y2-38 (DIP) - y1-23 (DIP0) Always Below 1 Ω Ω
      y2-40 (CIN) - y1-22 (CIN0) Always Below 1 Ω Ω
      y2-20 (CIP) - y1-20 (CIP0) Always Below 1 Ω Ω
      y2-16 (GFB0) - y1-26 (GFB0) Always Below 1 Ω Ω
      y2-36 (FB0) - y1-27 (FB0) Always Below 1 Ω Ω
      y2-14 (GFB1) - y1-30 (GFB1) Always Below 1 Ω Ω
      y2-34 (FB1) - y1-31 (FB1) Always Below 1 Ω Ω
      GTY972524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (to Battery ECU Assembly)
      *b Component without harness connected
      (to Battery Voltage Sensor (for Upper Side))
    • Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition Result
      y2-1 (CON) - y3-37 (CON3) Always Below 1 Ω Ω
      y2-3 (COP) - y3-38 (COP3) Always Below 1 Ω Ω
      y2-23 (DON) - y3-39 (DON3) Always Below 1 Ω Ω
      y2-21 (DOP) - y3-40 (DOP3) Always Below 1 Ω Ω
      y2-10 (GFB2) - y3-26 (GFB2) Always Below 1 Ω Ω
      y2-30 (FB2) - y3-27 (FB2) Always Below 1 Ω Ω
      y2-8 (GFB3) - y3-30 (GFB3) Always Below 1 Ω Ω
      y2-28 (FB3) - y3-31 (FB3) Always Below 1 Ω Ω
      GTY972504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (to Battery ECU Assembly)
      *b Component without harness connected
      (to Battery Voltage Sensor (for Lower Side))
    • Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition Result
      y1-37 (CON1) - y3-22 (CIN2) Always Below 1 Ω Ω
      y1-38 (COP1) - y3-20 (CIP2) Always Below 1 Ω Ω
      y1-39 (DON1) - y3-25 (DIN2) Always Below 1 Ω Ω
      y1-40 (DOP1) - y3-23 (DIP2) Always Below 1 Ω Ω
      GTY972522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (to Battery Voltage Sensor (for Upper Side))
      *b Component without harness connected
      (to Battery Voltage Sensor (for Lower Side))

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Install the battery voltage sensor (for lower side).
      WARNING:

      When connecting connectors z16 and z17 of the battery voltage sensor (for lower side), first connect connector y3 to the battery voltage sensor (for lower side).

      GTY972457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Reconnect the y2 battery ECU assembly connector.
    • Install the battery voltage sensor (for upper side).
      WARNING:

      When connecting connectors z14 and z15 of the battery voltage sensor (for upper side), first connect connector y1 to the battery voltage sensor (for upper side).

      GTY972447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Result: 

    OK 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side), BATTERY VOLTAGE SENSOR (for Lower Side) and BATTERY ECU ASSEMBLY 

    for Battery voltage sensor:

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    for Battery ECU assembly:

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  20. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  22

  21. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  23

  22. REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  23. REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  24. CHECK ODOMETER 
    1. Check and record the total distance traveled of the vehicle.

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  25. CHECK FREEZE FRAME DATA 

    Pre-procedure1

    • None.
    • Read the value of freeze frame data items "Hybrid/EV Battery Cell 1 Voltage" through "Hybrid/EV Battery Cell 84 Voltage" for DTC P0E2D-00 and make a note if the value of any is 1.6 V or less.

      HINT: 

      Use this for reference when measuring the EV battery cell voltage.

      Powertrain > EV Battery > DTC(P0E2D-00) > Freeze Frame Data 

      Tester Display
      Hybrid/EV Battery Cell 1 Voltage
      Hybrid/EV Battery Cell 2 Voltage
      Hybrid/EV Battery Cell 3 Voltage
      Hybrid/EV Battery Cell 4 Voltage
      Hybrid/EV Battery Cell 5 Voltage
      Hybrid/EV Battery Cell 6 Voltage
      Hybrid/EV Battery Cell 7 Voltage
      Hybrid/EV Battery Cell 8 Voltage
      Hybrid/EV Battery Cell 9 Voltage
      Hybrid/EV Battery Cell 10 Voltage
      Hybrid/EV Battery Cell 11 Voltage
      Hybrid/EV Battery Cell 12 Voltage
      Hybrid/EV Battery Cell 13 Voltage
      Hybrid/EV Battery Cell 14 Voltage
      Hybrid/EV Battery Cell 15 Voltage
      Hybrid/EV Battery Cell 16 Voltage
      Hybrid/EV Battery Cell 17 Voltage
      Hybrid/EV Battery Cell 18 Voltage
      Hybrid/EV Battery Cell 19 Voltage
      Hybrid/EV Battery Cell 20 Voltage
      Hybrid/EV Battery Cell 21 Voltage
      Hybrid/EV Battery Cell 22 Voltage
      Hybrid/EV Battery Cell 23 Voltage
      Hybrid/EV Battery Cell 24 Voltage
      Hybrid/EV Battery Cell 25 Voltage
      Hybrid/EV Battery Cell 26 Voltage
      Hybrid/EV Battery Cell 27 Voltage
      Hybrid/EV Battery Cell 28 Voltage
      Hybrid/EV Battery Cell 29 Voltage
      Hybrid/EV Battery Cell 30 Voltage
      Hybrid/EV Battery Cell 31 Voltage
      Hybrid/EV Battery Cell 32 Voltage
      Hybrid/EV Battery Cell 33 Voltage
      Hybrid/EV Battery Cell 34 Voltage
      Hybrid/EV Battery Cell 35 Voltage
      Hybrid/EV Battery Cell 36 Voltage
      Hybrid/EV Battery Cell 37 Voltage
      Hybrid/EV Battery Cell 38 Voltage
      Hybrid/EV Battery Cell 39 Voltage
      Hybrid/EV Battery Cell 40 Voltage
      Hybrid/EV Battery Cell 41 Voltage
      Hybrid/EV Battery Cell 42 Voltage
      Hybrid/EV Battery Cell 43 Voltage
      Hybrid/EV Battery Cell 44 Voltage
      Hybrid/EV Battery Cell 45 Voltage
      Hybrid/EV Battery Cell 46 Voltage
      Hybrid/EV Battery Cell 47 Voltage
      Hybrid/EV Battery Cell 48 Voltage
      Hybrid/EV Battery Cell 49 Voltage
      Hybrid/EV Battery Cell 50 Voltage
      Hybrid/EV Battery Cell 51 Voltage
      Hybrid/EV Battery Cell 52 Voltage
      Hybrid/EV Battery Cell 53 Voltage
      Hybrid/EV Battery Cell 54 Voltage
      Hybrid/EV Battery Cell 55 Voltage
      Hybrid/EV Battery Cell 56 Voltage
      Hybrid/EV Battery Cell 57 Voltage
      Hybrid/EV Battery Cell 58 Voltage
      Hybrid/EV Battery Cell 59 Voltage
      Hybrid/EV Battery Cell 60 Voltage
      Hybrid/EV Battery Cell 61 Voltage
      Hybrid/EV Battery Cell 62 Voltage
      Hybrid/EV Battery Cell 63 Voltage
      Hybrid/EV Battery Cell 64 Voltage
      Hybrid/EV Battery Cell 65 Voltage
      Hybrid/EV Battery Cell 66 Voltage
      Hybrid/EV Battery Cell 67 Voltage
      Hybrid/EV Battery Cell 68 Voltage
      Hybrid/EV Battery Cell 69 Voltage
      Hybrid/EV Battery Cell 70 Voltage
      Hybrid/EV Battery Cell 71 Voltage
      Hybrid/EV Battery Cell 72 Voltage
      Hybrid/EV Battery Cell 73 Voltage
      Hybrid/EV Battery Cell 74 Voltage
      Hybrid/EV Battery Cell 75 Voltage
      Hybrid/EV Battery Cell 76 Voltage
      Hybrid/EV Battery Cell 77 Voltage
      Hybrid/EV Battery Cell 78 Voltage
      Hybrid/EV Battery Cell 79 Voltage
      Hybrid/EV Battery Cell 80 Voltage
      Hybrid/EV Battery Cell 81 Voltage
      Hybrid/EV Battery Cell 82 Voltage
      Hybrid/EV Battery Cell 83 Voltage
      Hybrid/EV Battery Cell 84 Voltage

      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 42 Voltage" is 1.6 V or less. A
      The value of any of the freeze frame data items "Hybrid/EV Battery Cell 43 Voltage" through "Hybrid/EV Battery Cell 84 Voltage" is 1.6 V or less. B
      Other than above Either freeze frame data item recorded "Hybrid/EV Battery Monitoring IC 1 Cell Voltage Detection Malfunction" or "Hybrid/EV Battery Monitoring IC 2 Cell Voltage Detection Malfunction" is ON. C
      Either freeze frame data item recorded "Hybrid/EV Battery Monitoring IC 3 Cell Voltage Detection Malfunction" or "Hybrid/EV Battery Monitoring IC 4 Cell Voltage Detection Malfunction" is ON. D

    Post-procedure1

    • Turn the ignition switch off.

    Result: 

    B 

    See step  37

    Result: 

    C 

    See step  48

    Result: 

    D 

    See step  51

    Result: 

    A 

    See step  26

  26. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Upper Side) CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for upper side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Check the connections of the z14 and z15 battery voltage sensor (for upper side) connectors.

      HINT: 

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [11/2020 - ]

      GTY812205Courtesy 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
      Either connector z14 or z15 was not connected securely The terminals are damaged or corroded C

    Post-procedure1

    • None.

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    See step  31

    Result: 

    A 

    See step  27

  27. CHECK NO. 1 EV SUPPLY STACK SUB-ASSEMBLY (EV BATTERY CELL VOLTAGE) 
    WARNING:
    • Be sure to wear insulated gloves and protective goggles.
    • Disconnect only the connector corresponding to the EV battery cell to be checked. Do not disconnect the other connectors.
    NOTE:

    Make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the voltage of each EV battery cell.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for upper side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • The value of any of the freeze frame data items "Hybrid/EV Battery Cell 1 Voltage" through "Hybrid/EV Battery Cell 22 Voltage" is 1.6 V or less.
      1. Disconnect the z14 battery voltage sensor (for upper side) connector.
        GTY821121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

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

        HINT: 

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

        Standard Voltage

        Tester Connection EV Battery Cell Condition
        z14-10 (GA0) - z14-24 (VA1) 1 Always
        z14-24 (VA1) - z14-9 (VA2) 2 Always
        z14-9 (VA2) - z14-23 (VA3) 3 Always
        z14-23 (VA3) - z14-8 (VA4) 4 Always
        z14-8 (VA4) - z14-7 (VA5) 5 Always
        z14-7 (VA5) - z14-22 (VA6) 6 Always
        z14-22 (VA6) - z14-6 (VA7) 7 Always
        z14-6 (VA7) - z14-21 (VA8) 8 Always
        z14-21 (VA8) - z14-20 (VA9) 9 Always
        z14-20 (VA9) - z14-19 (VA10) 10 Always
        z14-19 (VA10) - z14-18 (VA11) 11 Always
        z14-18 (VA11) - z14-17 (VA12) 12 Always
        z14-17 (VA12) - z14-16 (VA13) 13 Always
        z14-16 (VA13) - z14-15 (VA14) 14 Always
        z14-15 (VA14) - z14-14 (VA15) 15 Always
        z14-14 (VA15) - z14-5 (VA16) 16 Always
        z14-5 (VA16) - z14-13 (VA17) 17 Always
        z14-13 (VA17) - z14-4 (VA18) 18 Always
        z14-4 (VA18) - z14-3 (VA19) 19 Always
        z14-3 (VA19) - z14-12 (VA20) 20 Always
        z14-12 (VA20) - z14-2 (VA21) 21 Always
        z14-2 (VA21) - z14-11 (VA22) 22 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.

        GTY817656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Rear view of wire harness connector
        (to Battery Voltage Sensor (for Upper Side))
      3. Reconnect the z14 battery voltage sensor (for upper side) connector.
    • The value of any of the freeze frame data items "Hybrid/EV Battery Cell 23 Voltage" through "Hybrid/EV Battery Cell 42 Voltage" is 1.6 V or less.
      1. Disconnect the z15 battery voltage sensor (for upper side) connector.
        GTY783966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

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

        HINT: 

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

        Standard Voltage

        Tester Connection EV Battery Cell Condition
        z15-23 (GA1) - z15-8 (VA23) 23 Always
        z15-8 (VA23) - z15-7 (VA24) 24 Always
        z15-7 (VA24) - z15-22 (VA25) 25 Always
        z15-22 (VA25) - z15-6 (VA26) 26 Always
        z15-6 (VA26) - z15-21 (VA27) 27 Always
        z15-21 (VA27) - z15-20 (VA28) 28 Always
        z15-20 (VA28) - z15-19 (VA29) 29 Always
        z15-19 (VA29) - z15-18 (VA30) 30 Always
        z15-18 (VA30) - z15-17 (VA31) 31 Always
        z15-17 (VA31) - z15-16 (VA32) 32 Always
        z15-16 (VA32) - z15-15 (VA33) 33 Always
        z15-15 (VA33) - z15-14 (VA34) 34 Always
        z15-14 (VA34) - z15-5 (VA35) 35 Always
        z15-5 (VA35) - z15-13 (VA36) 36 Always
        z15-13 (VA36) - z15-4 (VA37) 37 Always
        z15-4 (VA37) - z15-3 (VA38) 38 Always
        z15-3 (VA38) - z15-12 (VA39) 39 Always
        z15-12 (VA39) - z15-2 (VA40) 40 Always
        z15-2 (VA40) - z15-11 (VA41) 41 Always
        z15-11 (VA41) - z15-1 (VA42) 42 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.

        GTY823033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Rear view of wire harness connector
        (to Battery Voltage Sensor (for Upper Side))
      3. Reconnect the z15 battery voltage sensor (for upper side) connector.

      Result

      Result Proceed to
      The voltage between the terminals is below 1.2 V. A
      The voltage between the terminals is 1.2 to 1.6 V. B
      The voltage between the terminals is higher than 1.6 V. C

    Post-procedure1

    • None.

    Result: 

    B 

    See step  32

    Result: 

    C 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    A 

    See step  28

  28. CHECK BATTERY VOLTAGE SENSOR (for Upper Side) (VA1 - VA42) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:

    Make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the battery voltage sensor (for upper side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

      WARNING:

      When disconnecting connector y1 of the battery voltage sensor (for upper side), first disconnect connectors z14 and z15 from the battery voltage sensor (for upper side).

      GTY972447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

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

      HINT: 

      Only inspect the terminals of the battery ECU assembly which correspond to the EV battery cells which measured 1.6 V or less in the previous step.

      GTY775950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Battery Voltage Sensor (for Upper Side))      		 - -

      Standard Resistance

      Tester Connection
      (Tester Probe Polarity)      		 EV Battery Cell Condition Specified Condition
      z14-10 (GA0) (-) - z14-24 (VA1) (+) 1 Always 50 kΩ or higher
      z14-24 (VA1) (-) - z14-9 (VA2) (+) 2 Always 50 kΩ or higher
      z14-9 (VA2) (-) - z14-23 (VA3) (+) 3 Always 50 kΩ or higher
      z14-23 (VA3) (-) - z14-8 (VA4) (+) 4 Always 50 kΩ or higher
      z14-8 (VA4) (-) - z14-7 (VA5) (+) 5 Always 50 kΩ or higher
      z14-7 (VA5) (-) - z14-22 (VA6) (+) 6 Always 50 kΩ or higher
      z14-22 (VA6) (-) - z14-6 (VA7) (+) 7 Always 50 kΩ or higher
      z14-6 (VA7) (-) - z14-21 (VA8) (+) 8 Always 50 kΩ or higher
      z14-21 (VA8) (-) - z14-20 (VA9) (+) 9 Always 50 kΩ or higher
      z14-20 (VA9) (-) - z14-19 (VA10) (+) 10 Always 50 kΩ or higher
      z14-19 (VA10) (-) - z14-18 (VA11) (+) 11 Always 50 kΩ or higher
      z14-18 (VA11) (-) - z14-17 (VA12) (+) 12 Always 50 kΩ or higher
      z14-17 (VA12) (-) - z14-16 (VA13) (+) 13 Always 50 kΩ or higher
      z14-16 (VA13) (-) - z14-15 (VA14) (+) 14 Always 50 kΩ or higher
      z14-15 (VA14) (-) - z14-14 (VA15) (+) 15 Always 50 kΩ or higher
      z14-14 (VA15) (-) - z14-5 (VA16) (+) 16 Always 50 kΩ or higher
      z14-5 (VA16) (-) - z14-13 (VA17) (+) 17 Always 50 kΩ or higher
      z14-13 (VA17) (-) - z14-4 (VA18) (+) 18 Always 50 kΩ or higher
      z14-4 (VA18) (-) - z14-3 (VA19) (+) 19 Always 50 kΩ or higher
      z14-3 (VA19) (-) - z14-12 (VA20) (+) 20 Always 50 kΩ or higher
      z14-12 (VA20) (-) - z14-2 (VA21) (+) 21 Always 50 kΩ or higher
      z14-2 (VA21) (-) - z14-11 (VA22) (+) 22 Always 50 kΩ or higher
      z15-23 (GA1) (-) - z15-8 (VA23) (+) 23 Always 50 kΩ or higher
      z15-8 (VA23) (-) - z15-7 (VA24) (+) 24 Always 50 kΩ or higher
      z15-7 (VA24) (-) - z15-22 (VA25) (+) 25 Always 50 kΩ or higher
      z15-22 (VA25) (-) - z15-6 (VA26) (+) 26 Always 50 kΩ or higher
      z15-6 (VA26) (-) - z15-21 (VA27) (+) 27 Always 50 kΩ or higher
      z15-21 (VA27) (-) - z15-20 (VA28) (+) 28 Always 50 kΩ or higher
      z15-20 (VA28) (-) - z15-19 (VA29) (+) 29 Always 50 kΩ or higher
      z15-19 (VA29) (-) - z15-18 (VA30) (+) 30 Always 50 kΩ or higher
      z15-18 (VA30) (-) - z15-17 (VA31) (+) 31 Always 50 kΩ or higher
      z15-17 (VA31) (-) - z15-16 (VA32) (+) 32 Always 50 kΩ or higher
      z15-16 (VA32) (-) - z15-15 (VA33) (+) 33 Always 50 kΩ or higher
      z15-15 (VA33) (-) - z15-14 (VA34) (+) 34 Always 50 kΩ or higher
      z15-14 (VA34) (-) - z15-5 (VA35) (+) 35 Always 50 kΩ or higher
      z15-5 (VA35) (-) - z15-13 (VA36) (+) 36 Always 50 kΩ or higher
      z15-13 (VA36) (-) - z15-4 (VA37) (+) 37 Always 50 kΩ or higher
      z15-4 (VA37) (-) - z15-3 (VA38) (+) 38 Always 50 kΩ or higher
      z15-3 (VA38) (-) - z15-12 (VA39) (+) 39 Always 50 kΩ or higher
      z15-12 (VA39) (-) - z15-2 (VA40) (+) 40 Always 50 kΩ or higher
      z15-2 (VA40) (-) - z15-11 (VA41) (+) 41 Always 50 kΩ or higher
      z15-11 (VA41) (-) - z15-1 (VA42) (+) 42 Always 50 kΩ or higher
      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 higher. A
      Other than above B

    Post-procedure1

    • Install the battery voltage sensor (for upper side).
      WARNING:

      When connecting connectors z14 and z15 of the battery voltage sensor (for upper side), first connect connector y1 to the battery voltage sensor (for upper side).

      GTY972447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Result: 

    B 

    See step  32

    Result: 

    A 

    See step  29

  29. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  30

  30. REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  31. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  34

  32. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    B 

    See step  35

    Result: 

    A 

    See step  33

  33. REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  34. REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  35. REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    See step  36

  36. REPLACE EV BATTERY TERMINAL BLOCK 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  37. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Lower Side) CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for lower side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Check the connections of the z16 and z17 battery voltage sensor (for lower side) connectors.

      HINT: 

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [11/2020 - ]

      GTY800991Courtesy 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
      Either connector z16 or z17 was not connected securely The terminals are damaged or corroded C

    Post-procedure1

    • None.

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    See step  42

    Result: 

    A 

    See step  38

  38. CHECK NO. 2 EV SUPPLY STACK SUB-ASSEMBLY (EV BATTERY CELL VOLTAGE) 
    WARNING:
    • Be sure to wear insulated gloves and protective goggles.
    • Disconnect only the connector corresponding to the EV battery cell to be checked. Do not disconnect the other connectors.
    NOTE:

    Make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the voltage of each EV battery cell.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for lower side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • The value of any of the freeze frame data items "Hybrid/EV Battery Cell 43 Voltage" through "Hybrid/EV Battery Cell 64 Voltage" is 1.6 V or less.
      1. Disconnect the z16 battery voltage sensor (for lower side) connector.
        GTY816980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

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

        HINT: 

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

        Standard Voltage

        Tester Connection EV Battery Cell Condition
        z16-10 (GA2) - z16-24 (VA43) 43 Always
        z16-24 (VA43) - z16-9 (VA44) 44 Always
        z16-9 (VA44) - z16-23 (VA45) 45 Always
        z16-23 (VA45) - z16-8 (VA46) 46 Always
        z16-8 (VA46) - z16-7 (VA47) 47 Always
        z16-7 (VA47) - z16-22 (VA48) 48 Always
        z16-22 (VA48) - z16-6 (VA49) 49 Always
        z16-6 (VA49) - z16-21 (VA50) 50 Always
        z16-21 (VA50) - z16-20 (VA51) 51 Always
        z16-20 (VA51) - z16-19 (VA52) 52 Always
        z16-19 (VA52) - z16-18 (VA53) 53 Always
        z16-18 (VA53) - z16-17 (VA54) 54 Always
        z16-17 (VA54) - z16-16 (VA55) 55 Always
        z16-16 (VA55) - z16-15 (VA56) 56 Always
        z16-15 (VA56) - z16-14 (VA57) 57 Always
        z16-14 (VA57) - z16-5 (VA58) 58 Always
        z16-5 (VA58) - z16-13 (VA59) 59 Always
        z16-13 (VA59) - z16-4 (VA60) 60 Always
        z16-4 (VA60) - z16-3 (VA61) 61 Always
        z16-3 (VA61) - z16-12 (VA62) 62 Always
        z16-12 (VA62) - z16-2 (VA63) 63 Always
        z16-2 (VA63) - z16-11 (VA64) 64 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.

        GTY817659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Rear view of wire harness connector
        (to Battery Voltage Sensor (for Lower Side))
      3. Reconnect the z16 battery voltage sensor (for lower side) connector.
    • The value of any of the freeze frame data items "Hybrid/EV Battery Cell 65 Voltage" through "Hybrid/EV Battery Cell 84 Voltage" is 1.6 V or less.
      1. Disconnect the z17 battery voltage sensor (for lower side) connector.
        GTY776782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

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

        HINT: 

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

        Standard Voltage

        Tester Connection EV Battery Cell Condition
        z17-23 (GA3) - z17-8 (VA65) 65 Always
        z17-8 (VA65) - z17-7 (VA66) 66 Always
        z17-7 (VA66) - z17-22 (VA67) 67 Always
        z17-22 (VA67) - z17-6 (VA68) 68 Always
        z17-6 (VA68) - z17-21 (VA69) 69 Always
        z17-21 (VA69) - z17-20 (VA70) 70 Always
        z17-20 (VA70) - z17-19 (VA71) 71 Always
        z17-19 (VA71) - z17-18 (VA72) 72 Always
        z17-18 (VA72) - z17-17 (VA73) 73 Always
        z17-17 (VA73) - z17-16 (VA74) 74 Always
        z17-16 (VA74) - z17-15 (VA75) 75 Always
        z17-15 (VA75) - z17-14 (VA76) 76 Always
        z17-14 (VA76) - z17-5 (VA77) 77 Always
        z17-5 (VA77) - z17-13 (VA78) 78 Always
        z17-13 (VA78) - z17-4 (VA79) 79 Always
        z17-4 (VA79) - z17-3 (VA80) 80 Always
        z17-3 (VA80) - z17-12 (VA81) 81 Always
        z17-12 (VA81) - z17-2 (VA82) 82 Always
        z17-2 (VA82) - z17-11 (VA83) 83 Always
        z17-11 (VA83) - z17-1 (VA84) 84 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.

        GTY823054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Rear view of wire harness connector
        (to Battery Voltage Sensor (for Lower Side))
      3. Reconnect the z17 battery voltage sensor (for lower side) connector.

      Result

      Result Proceed to
      The voltage between the terminals is below 1.2 V. A
      The voltage between the terminals is 1.2 to 1.6 V. B
      The voltage between the terminals is higher than 1.6 V. C

    Post-procedure1

    • None.

    Result: 

    B 

    See step  43

    Result: 

    C 

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    A 

    See step  39

  39. CHECK BATTERY VOLTAGE SENSOR (for Lower Side) (VA43 - VA84) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:

    Make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the battery voltage sensor (for lower side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

      WARNING:

      When disconnecting connector y3 of the battery voltage sensor (for lower side), first disconnect connectors z16 and z17 from the battery voltage sensor (for lower side).

      GTY972457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

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

      HINT: 

      Only inspect the terminals of the battery ECU assembly which correspond to the EV battery cells which measured 1.6 V or less in the previous step.

      GTY827462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Battery Voltage Sensor (for Lower Side))      		 - -

      Standard Resistance

      Tester Connection
      (Tester Probe Polarity)      		 EV Battery Cell Condition Specified Condition
      z16-10 (GA2) (-) - z16-24 (VA43) (+) 43 Always 50 kΩ or higher
      z16-24 (VA43) (-) - z16-9 (VA44) (+) 44 Always 50 kΩ or higher
      z16-9 (VA44) (-) - z16-23 (VA45) (+) 45 Always 50 kΩ or higher
      z16-23 (VA45) (-) - z16-8 (VA46) (+) 46 Always 50 kΩ or higher
      z16-8 (VA46) (-) - z16-7 (VA47) (+) 47 Always 50 kΩ or higher
      z16-7 (VA47) (-) - z16-22 (VA48) (+) 48 Always 50 kΩ or higher
      z16-22 (VA48) (-) - z16-6 (VA49) (+) 49 Always 50 kΩ or higher
      z16-6 (VA49) (-) - z16-21 (VA50) (+) 50 Always 50 kΩ or higher
      z16-21 (VA50) (-) - z16-20 (VA51) (+) 51 Always 50 kΩ or higher
      z16-20 (VA51) (-) - z16-19 (VA52) (+) 52 Always 50 kΩ or higher
      z16-19 (VA52) (-) - z16-18 (VA53) (+) 53 Always 50 kΩ or higher
      z16-18 (VA53) (-) - z16-17 (VA54) (+) 54 Always 50 kΩ or higher
      z16-17 (VA54) (-) - z16-16 (VA55) (+) 55 Always 50 kΩ or higher
      z16-16 (VA55) (-) - z16-15 (VA56) (+) 56 Always 50 kΩ or higher
      z16-15 (VA56) (-) - z16-14 (VA57) (+) 57 Always 50 kΩ or higher
      z16-14 (VA57) (-) - z16-5 (VA58) (+) 58 Always 50 kΩ or higher
      z16-5 (VA58) (-) - z16-13 (VA59) (+) 59 Always 50 kΩ or higher
      z16-13 (VA59) (-) - z16-4 (VA60) (+) 60 Always 50 kΩ or higher
      z16-4 (VA60) (-) - z16-3 (VA61) (+) 61 Always 50 kΩ or higher
      z16-3 (VA61) (-) - z16-12 (VA62) (+) 62 Always 50 kΩ or higher
      z16-12 (VA62) (-) - z16-2 (VA63) (+) 63 Always 50 kΩ or higher
      z16-2 (VA63) (-) - z16-11 (VA64) (+) 64 Always 50 kΩ or higher
      z17-23 (GA3) (-) - z17-8 (VA65) (+) 65 Always 50 kΩ or higher
      z17-8 (VA65) (-) - z17-7 (VA66) (+) 66 Always 50 kΩ or higher
      z17-7 (VA66) (-) - z17-22 (VA67) (+) 67 Always 50 kΩ or higher
      z17-22 (VA67) (-) - z17-6 (VA68) (+) 68 Always 50 kΩ or higher
      z17-6 (VA68) (-) - z17-21 (VA69) (+) 69 Always 50 kΩ or higher
      z17-21 (VA69) (-) - z17-20 (VA70) (+) 70 Always 50 kΩ or higher
      z17-20 (VA70) (-) - z17-19 (VA71) (+) 71 Always 50 kΩ or higher
      z17-19 (VA71) (-) - z17-18 (VA72) (+) 72 Always 50 kΩ or higher
      z17-18 (VA72) (-) - z17-17 (VA73) (+) 73 Always 50 kΩ or higher
      z17-17 (VA73) (-) - z17-16 (VA74) (+) 74 Always 50 kΩ or higher
      z17-16 (VA74) (-) - z17-15 (VA75) (+) 75 Always 50 kΩ or higher
      z17-15 (VA75) (-) - z17-14 (VA76) (+) 76 Always 50 kΩ or higher
      z17-14 (VA76) (-) - z17-5 (VA77) (+) 77 Always 50 kΩ or higher
      z17-5 (VA77) (-) - z17-13 (VA78) (+) 78 Always 50 kΩ or higher
      z17-13 (VA78) (-) - z17-4 (VA79) (+) 79 Always 50 kΩ or higher
      z17-4 (VA79) (-) - z17-3 (VA80) (+) 80 Always 50 kΩ or higher
      z17-3 (VA80) (-) - z17-12 (VA81) (+) 81 Always 50 kΩ or higher
      z17-12 (VA81) (-) - z17-2 (VA82) (+) 82 Always 50 kΩ or higher
      z17-2 (VA82) (-) - z17-11 (VA83) (+) 83 Always 50 kΩ or higher
      z17-11 (VA83) (-) - z17-1 (VA84) (+) 84 Always 50 kΩ or higher
      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 higher. A
      Other than above B

    Post-procedure1

    • Install the battery voltage sensor (for lower side).
      WARNING:

      When connecting connectors z16 and z17 of the battery voltage sensor (for lower side), first connect connector y3 to the battery voltage sensor (for lower side).

      GTY972457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Result: 

    B 

    See step  43

    Result: 

    A 

    See step  40

  40. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  41

  41. REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  42. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  45

  43. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    B 

    See step  46

    Result: 

    A 

    See step  44

  44. REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  45. REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  46. REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    See step  47

  47. REPLACE EV BATTERY TERMINAL BLOCK 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  48. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Upper Side) CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for upper side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Check the connections of the z14 and z15 battery voltage sensor (for upper side) connectors.

      HINT: 

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [11/2020 - ]

      GTY812205Courtesy 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
      The connector z14 or z15 terminals are abnormal The terminals are damaged or corroded C
      The battery voltage sensor (for upper side) terminals are abnormal The terminals are damaged or corroded D

    Post-procedure1

    • None.

    Result: 

    A 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    D 

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    C 

    See step  49

  49. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  50

  50. REPLACE NO. 1 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

  51. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Lower Side) CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    Pre-procedure1

    • Check that the service plug grip and FC converter power outlet cable are not installed.
      NOTE:

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

    • Remove the No. 1 EV battery protector (for lower side).

      HINT: 

      Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    • Check the connections of the z16 and z17 battery voltage sensor (for lower side) connectors.

      HINT: 

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [11/2020 - ]

      GTY800991Courtesy 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
      The connector z16 or z17 terminals are abnormal The terminals are damaged or corroded C
      The battery voltage sensor (for lower side) terminals are abnormal The terminals are damaged or corroded D

    Post-procedure1

    • None.

    Result: 

    A 

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    D 

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side). Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    C 

    See step  52

  52. CHECK TOTAL DISTANCE DRIVEN 
    1. Check the recorded total distance traveled of the vehicle.

      Result

      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when EV battery terminal block replaced = less than 200000 km (124280 mile)*1
      Other than above B

      HINT: 

      *1: If the EV battery terminal block has been replaced, use the total distance driven since it was replaced.

    Result: 

    A 

    REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

    Result: 

    B 

    See step  53

  53. REPLACE NO. 2 EV SUPPLY STACK SUB-ASSEMBLY 

    HINT: 

    Refer to REMOVAL [11/2020 - 11/2021] , or refer to REMOVAL [11/2021 - 12/2022]

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV BATTERY TERMINAL BLOCK. Refer to  REMOVAL [11/2020 - 11/2021]  , or refer to  REMOVAL [11/2021 - 12/2022] 

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