P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–1 HYBRID BATTERY SYSTEM PRECAUTION 1. Lever A083545E01 PRECAUTIONS FOR INSPECTING HYBRID BATTERY SYSTEM (a) Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip (see page IN-5). After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, do not turn the power switch ON (READY) unless instructed by the repair manual. (b) After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the highvoltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. (c) Since liquid leakage may occur, wear protective goggles when checking inside the HV battery. (d) Wear insulated gloves, turn the power switch OFF, and disconnect the negative terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system. (e) Turn the power switch OFF before performing a resistance check. (f) Turn the power switch OFF before disconnecting or reconnecting any connector. (g) To install the service plug grip, the lever must be flipped and locked downward. Once it is locked in place, it turns the interlock switch ON. Make sure to lock it securely because if you leave it unlocked, the system will output a DTC related to the interlock switch system. Lock Lever A089219E03 HB HB–2 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 2. System Name See Page Power Window Control System IN-32 3. HB NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. NOTICE FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first attempt. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–3 HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3. NEXT 4 CHECK AND RECORD DTC AND FREEZE FRAME DATA* (a) Refer to the the DTC CHECK / CLEAR (see page HB17). HINT: If a DTC related to the CAN communication system malfunction is output, first troubleshoot and repair the CAN communication system (see page CA-6). NEXT 5 CLEAR DTC* (a) Refer to the the DTC CHECK / CLEAR (see page HB17). NEXT 6 PROBLEM SYMPTOM CONFIRMATION (a) When a malfunction does not occur, go to A. (b) When a malfunction occurs, go to B. B A Go to step 8 HB HB–4 7 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM SYMPTOM SIMULATION NEXT 8 CHECK DTC* (a) Refer to the the DTC CHECK / CLEAR (see page HB17). NEXT 9 DTC CHART (a) Refer to the the DIAGNOSTIC TROUBLE CODE CHART (see page HB-23). NEXT 10 CIRCUIT INSPECTION NEXT 11 IDENTIFICATION OF PROBLEM NEXT HB 12 ADJUSTMENT AND/OR REPAIR NEXT 13 NEXT END CONFIRMATION TEST P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–5 DEFINITION OF TERMS 1. DEFINITION OF TERMS Term Definition Duration The minimum time that the battery ECU must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met Frequency of operation The number of times that the battery ECU checks for malfunction per driving cycle "Once per driving cycle" means that the battery ECU detects malfunction only one time during a single driving cycle "Continuous" means that the battery ECU detects malfunction every time when enabling condition is met MIL operation MIL illumination timing after a defect is detected "Immediate" means that the battery ECU illuminates the MIL the instant the battery ECU determines that there is malfunction "2 driving cycles" means that the battery ECU illuminates the MIL if the same malfunction is detected again in the 2nd driving cycle Monitor description Description of what the battery ECU monitors and how it detects malfunction (monitoring purpose and its details) Related DTCs A group of DTCs that is classified by a system and a troubleshooting procedure Required sensor/components The sensors and components that are used by the battery ECU to detect malfunction Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded Typical enabling condition Preconditions that allow the battery ECU to detect malfunction With all preconditions satisfied, the battery ECU sets the DTC when the monitored value(s) exceeds the malfunction threshold(s) Typical malfunction thresholds Beyond this value, the battery ECU will conclude that there is malfunction and set a DTC HB HB–6 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM PARTS LOCATION HV BATTERY ASSEMBLY ENGINE ROOM RELAY BLOCK - BATT FAN FUSE - HEV FUSE MULTI-INFORMATION DISPLAY COMBINATION METER ECU GATEWAY ECU HB HYBRID VEHICLE CONTROL ECU ECM DLC3 A/C AMPLIFIER C115885E01 HB–7 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM BATTERY BLOWER VENTILATOR INNER DUCT NO. 1 BATTERY BLOWER RELAY NO. 2 QUARTER VENT DUCT INNER QUARTER VENT DUCT HV BATTERY ASSEMBLY NO. 2 QUARTER VENT DUCT BATTERY BLOWER MOTOR CONTROLLER NO. 2 FRAME WIRE (BUSBAR MODULE) NO. 2 MAIN BATTERY CABLE INTAKE AIR TEMPERATURE SENSOR BATTERY TEMPERATURE SENSOR 1 BATTERY MODULE BATTERY CURRENT SENSOR HB MAIN BATTERY CABLE JUNCTION BLOCK ASSEMBLY (BUSBAR MODULE) BATTERY TEMPERATURE SENSOR 2 JUNCTION BLOCK ASSEMBLY (BUSBAR MODULE) BATTERY ECU BATTERY PLUG SERVICE PLUG GRIP (INCLUDES HIGH VOLTAGE FUSE) BATTERY TEMPERATURE SENSOR 3 C115886E01 HB–8 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM SYSTEM DIAGRAM Battery ECU HEV AM A IGCT IGCT HV Battery Assembly VBB14 VBB13 VBB11 Hybrid Vehicle Control ECU VBB10 MREL Service Plug Grip IG2 AM2 IGN IG2 Power Source Control ECU VBB8 VBB1 AM2 HB High Voltage VBB9 IG2D GBB0 P/I B FCTL1 BATT FAN MAIN No. 1 Battery Blower CANH CAN Communication Auxiliary Battery CANL A133089E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–9 Battery Temperature Sensor 1 TB1 GB1 Battery Temperature Sensor 2 Battery Blower VM TB2 GB2 Battery Temperature Sensor 3 TB3 +B VM GB3 SI SI GND GND Intake Air Temperature Sensor Battery Blower Motor Controller TC1 GC1 HB C115883E01 HB–10 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM VIB IB GIB Hybrid Vehicle Control ECU System Main B No. 3 (-) CON3 Battery Current Sensor System Main No. 1 CON1 System Main Resistor System Main HB A No. 2 (+) CON2 C115884E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–11 Communication System Diagram Hybrid Vehicle Control ECU ECM Battery ECU A/C Amplifier Gateway ECU : CAN : BEAN A081780E01 HB HB–12 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM SYSTEM DESCRIPTION 1. HB OUTLINE The principal role of the hybrid battery system is to monitor the condition of the HV battery assembly through the use of the battery ECU and transmit this information to the hybrid vehicle control ECU. Furthermore, this system controls the battery blower motor controller in order to maintain a proper temperature in the HV battery assembly. The battery ECU uses the CAN (Controller Area Network) to maintain communication with the following devices: the hybrid vehicle control ECU, ECM, and A/C amplifier.* HINT: *: Because it the battery ECU connected to the BEAN (Body Electronics Area Network), data is transmitted via the gateway ECU. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM System Diagram HB–13 : CAN : BEAN Battery ECU Battery Current Sensor Battery Blower Motor Controller CPU Hybrid Vehicle Control ECU HV Battery Assembly ECM - Temperature Sensor Voltage Detection Circuit Gateway ECU - Voltage Fault Current Detection Circuit A/C Amplifier HB C115881E01 2. CONTROL DESCRIPTION (a) HV battery assembly management and fail-safe function. (1) When the vehicle is accelerated, the battery assembly is discharged. When the vehicle is decelerated, the battery assembly is charged by converting brake energy. The battery ECU calculates SOC (state of charge) of the HV battery based on voltage, current, and temperature, and then sends the results to the hybrid vehicle control ECU. As a result, charge and discharge control is performed in the hybrid vehicle control ECU depending on the SOC. HB–14 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (2) If a malfunction occurs, the battery ECU performs a fail-safe function and protects the HV battery assembly in accordance with the extent of the malfunction. (b) Battery blower motor control. (1) To control an increase in the temperature of the HV battery assembly while the vehicle is being driven, the battery ECU determines and controls the operating mode of the battery blower in accordance with the temperature of the HV battery assembly. (c) MIL illumination control. (1) If the battery ECU detects a malfunction that affects the exhaust gas emissions, it will transmit an MIL illumination request to the hybrid vehicle control ECU. (The battery ECU does not directly illuminate the MIL.) HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–15 CHECK FOR INTERMITTENT PROBLEMS 1. CHECK FOR INTERMITTENT PROBLEMS (a) Perform a simulation test (see page IN-36). (1) In the simulation test, reproduce the driving condition when the trouble occurred according to the customer's comments and freeze frame data recorded with DTCs. (b) Check the connector(s) and terminal(s) (see page IN-45). (c) Wiggle the harness and connector(s) (see page IN45). HB HB–16 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TERMINALS OF ECU 1. CHECK BATTERY ECU Vehicle Rear B11 Vehicle Front B13 B12 A090442E01 (a) Measure the voltage of the battery ECU connector. HINT: Each ECU terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminal No.)" for the terminals to be inspected. The standard voltage between the terminals is shown under "Specified Condition". Use the illustration above as a reference for the ECU terminals. HB Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AM (B11-1) - GND (B1112) G - W-B Auxiliary battery (for measuring battery voltage and for battery ECU memory) Always 9 to 14 V IGCT (B11-2) - GND (B1112) L - W-B Control signal Power switch ON (READY) 9 to 14 V VM (B11-9) - GND (B1112) V - W-B Battery blower motor monitoring signal Battery blower motor mode 1 actuation (at low speed) 10 to 14 V VM (B11-9) - GND (B1112) V - W-B Battery blower motor monitoring signal Battery blower motor mode 6 actuation (at high speed) 2 to 6 V HB–17 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition FCTL1 (B11-10) - GND (B11-12) BR - W-B No. 1 battery blower relay Battery blower motor actuation Below 1 V IG2 (B11-13) - GND (B1112) O - W-B IG signal Power switch ON (IG) 9 to 14 V CANH (B11-18) - GND (B11-12) B - W-B HIGH-level CAN bus line Power switch ON (IG) Pulse generation (See waveform 1) CANL (B11-19) - GND (B11-12) W - W-B LOW-level CAN bus line Power switch ON (IG) Pulse generation (See waveform 2) SI (B11-24) - GND (B1112) Y - W-B Battery blower motor actuation signal Battery blower motor modes 1 to 6 actuation Pulse generation (See waveform 3) TB1 (B13-1) - GB1 (B132) W-W HV battery temperature sensor 1 HV battery temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V TB2 (B13-3) - GB2 (B134) B-B HV battery temperature sensor 2 HV battery temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V TB3 (B13-5) - GB3 (B136) L-L HV battery temperature sensor 3 HV battery temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V TC1 (B13-9) - GC1 (B1310) G-G Intake air temperature sensor Intake air temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V VIB (B13-15) - GIB (B1314) - Power source of battery current sensor (a specific voltage) Power switch ON (IG) 4.5 to 5.5 V IB (B13-16) - GIB (B13-14) - Battery current sensor Power switch ON (READY) 0.5 to 4.5 V GND (B11-12) - Body ground W-B - Body ground Ground Always (resistance check) Below 6 Ω (b) Using an oscilloscope, check the waveform 1. Waveform 1 (HIGH-level CAN bus line) Item Content Symbols (Terminal No.) CANH (B11-18) - GND (B11-12) Tool Setting 1 V/Div., 2 µsec./Div. Condition Power switch ON (IG) GND HINT: The waveform varies depending on the contents of the communication. A093177E01 (c) Using an oscilloscope, check the waveform 2. Waveform 2 (LOW-level CAN bus line) GND A093178E01 Item Content Symbols (Terminal No.) CANL (B11-19) - GND (B11-12) Tool Setting 1 V/Div., 2 µsec./Div. Condition Power switch ON (IG) HINT: The waveform varies depending on the contents of the communication. HB HB–18 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (d) Using an oscilloscope, check the waveform 3. Waveform 3 (Battery blower motor actuation signal) A GND B Item Content Symbols (Terminal No.) SI (B11-24) - GND (B11-12) Tool Setting 1 V/Div., 50 µsec./Div. Condition During vehicle stop HINT: Amplitude A and B in the diagram vary by mode. A093179E01 A B 1 44.4 µsec. 155.6 µsec. 2 44.4 µsec. 155.6 µsec. 3 51.6 µsec. 148.4 µsec. 4 59.0 µsec. 141.0 µsec. 5 59.0 µsec. 141.0 µsec. 6 146.4 µsec. 53.6 µsec. DIAGNOSIS SYSTEM Combination Meter 1. Master Warning Light Multi-information Display HB Mode DESCRIPTION • The battery ECU has a self-diagnosis system. If the computer, HV battery system or the components are not working properly, the ECU carries out a diagnosis to detect the malfunction, and illuminates the master warning light in the combination meter together with the HV system warning indicator on the multiinformation display. HINT: The master warning light illuminates when the HV battery system fails and it blinks when in inspection mode. HV System Warning A131410E01 • When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you need to connect the OBD II scan tool (complying with ISO 15031-4) or the intelligent tester to the vehicle, and read various data output from the vehicle's ECUs. FI00534E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM • OBD II regulations require that the vehicle's on-board computer illuminate the MIL in the instrument panel when the computer detects a malfunction in: 1) the emission control systems/components, or 2) the powertrain control components (which affect vehicle emissions), or 3) the computers. In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the battery ECU memory (see page HB-23). If the malfunction does not recur in 3 consecutive trips, the MIL will turn off automatically. However the DTCs remain recorded in the battery ECU memory. • To check the DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) with the CAN vehicle interface module (CAN VIM). Or, connect the OBD II scan tool to the DLC3. The intelligent tester or OBD II scan tool also enables you to erase DTCs and check the freeze frame data and various forms of the HV battery system data (for operating instructions, refer to their respective instruction manuals). The DTCs include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set by a manufacturer within the prescribed limits (see page HB-23). • Freeze frame data: The freeze frame data records the driving condition when a malfunction is detected. When troubleshooting, it can help determine if the vehicle was moving forward, braking, stationary, or moving in reverse. Intelligent Tester DLC3 CAN VIM C118371E01 2. DLC3 CG SG CANH SIL CHECK DLC3 The battery ECU uses the ISO 15765-4. The terminal arrangement of the DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format. 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL Symbols (Terminal No.) BAT HB–19 A082779E81 Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF 200 Ω or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF 200 Ω or higher HB HB–20 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 3. 4. HB HINT: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, other switches or doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester or the OBD II scan tool to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates UNABLE TO CONNECT TO VEHICLE has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester or scan tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester or scan tool is connected to another vehicle, the problem is probably in the tester or scan tool itself, so consult the Service Department listed in its instruction manual. INSPECT AUXILIARY BATTERY (a) Measure the voltage of the auxiliary battery. Standard voltage: 11 to 14 V (b) Inspect the auxiliary battery, fuses, fusible links, wiring harness, connectors and ground. CHECK MIL (a) The MIL illuminates when the power switch is turned ON (IG) and the "READY" light is OFF. If the MIL is not illuminated, troubleshoot the MIL circuit (see page ES-428). FI00534E01 (b) When the "READY" light turns illuminated, the MIL should turn off. If the MIL remains on, the diagnosis system has detected a malfunction or abnormality in the system. A087700E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–21 DTC CHECK / CLEAR 1. CHECK DTC (HV BATTERY) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Confirm the details of the DTCs (see page HB-23). Intelligent Tester DLC3 CAN VIM C118371E01 2. HV_ECU A093189E01 CHECK FREEZE FRAME DATA (a) If a DTC is present, select that DTC in order to display its freeze frame data. (b) Read freeze frame data recorded when the DTC was set. 3. CHECK DTC (SYSTEMS OTHER THAN HV BATTERY) HINT: The battery ECU maintains mutual communication with the computers, including the ECM, hybrid vehicle control ECU and others. Therefore, if the battery ECU outputs a warning, it is necessary to check and record the DTCs of all the systems. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / CODES (All). (d) If DTCs output, check the relevant system. HINT: If DTCs for the CAN communication system are present in addition to other DTCs, first troubleshoot and repair any malfunctions in the CAN communication (see page CA-6). 4. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Check that the shift position is in the P position. (d) Clear DTCs and freeze frame data. (1) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DTC INFO / CLEAR CODES. (2) Press YES. HB HB–22 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM FREEZE FRAME DATA 1. FREEZE FRAME DATA HINT: The freeze frame data records the operating conditions of the HV battery system and components when the DTC was set. It is used for estimating or simulating the condition of the vehicle when a malfunction occurred. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Select a DTC in order to display its freeze frame data. (e) Check the freeze frame data of the DTC that has been detected. Freeze frame data HB Intelligent Tester Display Measurement Item/Range Suspected Vehicle Status When Malfunction Occurs BATTERY SOC State of charge (SOC) of HV battery Min.: 0%, Max: 100% - DELTA SOC SOC variance/ Min.: 0%, Max.: 100% Difference between maximum and minimum values of SOC at every battery block IB BATTERY Current value of battery pack/ Min.: -327.68 A, Max.: 327.67 A Charging/discharging condition of HV battery • Discharging amperage indicated by a positive value • Charging amperage indicated by a negative value BATT INSIDE AIR Temperature of intake ambient air to battery pack/ Min.: -327.68°C, Max.: 327.67°C - VMF FAN VOLTAGE Battery blower motor voltage/ Min.: 0 V, Max.: 25.4 V Actuation condition of battery blower motor AUX. BATT V Auxiliary battery voltage/ Min.: 0 V, Max.: 25.4 V Condition of auxiliary battery WIN Charge wattage of HV battery/ Min.: -64 kW, Max.: 0 kW Charge control wattage which is sent from battery ECU to hybrid vehicle control ECU WOUT Discharge wattage of HV battery/ Min.: 0 kW, Max.: 63.5 kW Discharge control wattage which is sent from battery ECU to hybrid vehicle control ECU COOLING FAN SPD Battery blower motor drive mode/ Min.: 0, Max.: 6 Stopped: 0 Low to high speed actuation: 1 to 6 ECU CTRL MODE ECU control mode/ Min.: 0, Max.: 4 Operating condition of HV battery SBLW RQST Battery blower motor stop control request (standby blower) - BATT TEMP 1 to 3 Temperature of HV battery/ Min.: -327.68°C, Max.: 327.67°C - V1 to V14 BATT BLOCK Battery block voltage/ Min.: -327.68 V, Max.: 327.67 V Voltage variance among battery blocks P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–23 FAIL-SAFE CHART 1. FAIL-SAFE CHART DTC No. Detection Item Driving Condition P0560 System Voltage Turns on READY light and drives normally P0A1F Battery Energy Control Module Turns on READY light and drives in fail-safe mode P0A7F Hybrid Battery Pack Deterioration Turns on READY light and drives normally P0A80 Replace Hybrid Battery Pack Turns on READY light and drives normally P0A81 Hybrid Battery Pack Cooling Fan 1 Turns on READY light and drives normally P0A82 Hybrid Battery Pack Cooling Fan 1 Performance or Stuck OFF Turns on READY light and drives normally P0A84 Hybrid Battery Pack Cooling Fan 1 Control Circuit Low Turns on READY light and drives normally P0A85 Hybrid Battery Pack Cooling Fan 1 Control Circuit High Turns on READY light and drives normally P0A95 High Voltage Fuse Turns on READY light and drives in fail-safe mode (while the engine is running) Turns off READY light and stops the HV control system (while the engine stops) P0A9C Hybrid Battery Temperature Sensor "A" Range/Performance Turns on READY light and drives normally P0A9D Hybrid Battery Temperature Sensor "A" Circuit Low Turns on READY light and drives normally P0A9E Hybrid Battery Temperature Sensor "A" Circuit High Turns on READY light and drives normally P0AAC Hybrid Battery Pack Air Temperature Sensor "A" Circuit Turns on READY light and drives normally P0ABF Hybrid Battery Pack Current Sensor Circuit Turns on READY light and drives normally P0AC0 Hybrid Battery Pack Current Sensor Circuit Range/Performance Turns on READY light and drives normally P0AC1 Hybrid Battery Pack Current Sensor Circuit Low Turns on READY light and drives normally P0AC2 Hybrid Battery Pack Current Sensor Circuit High Turns on READY light and drives normally P0AFA Hybrid Battery System Voltage Turns on READY light and drives normally P3011 Battery Block 1 Becomes Weak Turns on READY light and drives in fail-safe mode P3012 Battery Block 2 Becomes Weak Turns on READY light and drives in fail-safe mode P3013 Battery Block 3 Becomes Weak Turns on READY light and drives in fail-safe mode P3014 Battery Block 4 Becomes Weak Turns on READY light and drives in fail-safe mode P3015 Battery Block 5 Becomes Weak Turns on READY light and drives in fail-safe mode P3016 Battery Block 6 Becomes Weak Turns on READY light and drives in fail-safe mode P3017 Battery Block 7 Becomes Weak Turns on READY light and drives in fail-safe mode P3018 Battery Block 8 Becomes Weak Turns on READY light and drives in fail-safe mode P3019 Battery Block 9 Becomes Weak Turns on READY light and drives in fail-safe mode P3020 Battery Block 10 Becomes Weak Turns on READY light and drives in fail-safe mode P3021 Battery Block 11 Becomes Weak Turns on READY light and drives in fail-safe mode HB HB–24 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. Detection Item Driving Condition P3022 Battery Block 12 Becomes Weak Turns on READY light and drives in fail-safe mode P3023 Battery Block 13 Becomes Weak Turns on READY light and drives in fail-safe mode P3024 Battery Block 14 Becomes Weak Turns on READY light and drives in fail-safe mode U0100 Lost Communication with ECM/PCM "A" Turns on READY light and drives normally U0293 Lost Communication with HV ECU Turns on READY light and drives normally P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–25 DATA LIST / ACTIVE TEST 1. READ DATA LIST NOTICE: • The DATA LIST values may vary significantly if there are slight differences in measurement, differences in the environment in which the measurements are obtained, or the aging of the vehicle. Thus, definite standards or judgment values are unavailable. There may be a malfunction even if a measured value is within the reference range. • In the event of intricate symptoms, collect sample data from another vehicle of the same model operating under identical conditions, in order to reach an overall judgment by comparing all the items of the DATA LIST. HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST as the first step of troubleshooting is one method to shorten diagnostic time. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DATA LIST. (d) Check the results by referring to the following table. Intelligent Tester Display Measurement Item/Range (Display) Reference Range Diagnostic Note MIL status MIL status/ ON or OFF MIL ON: ON Constant ON: Repair in accordance with detected DTCs DRIVING MILEAGE Accumulated driving mileage after the malfunction occurrence/ Min.: 0 km, Max.: 65,535 km - - BATTERY SOC Battery state of charge/ Min.: 0%, Max: 100% Always: 0 to 100% - DELTA SOC Difference between maximum and minimum values of SOC/ Min.: 0%, Max.: 100% READY light ON, engine stopped and no electrical load: 0 to 60% - IB BATTERY Current value of battery pack/ Min.: -327.68 A, Max.: 327.67 A • Soon after a full-load acceleration with the engine stopped: Maximum 140 A (room temperature) When shifting into N position, 1 second has elapsed after engine started with P position, engine stopped, head light ON, A/C fan high, and READY light ON: Maximum 30 A - • BATT INSIDE AIR Temperature of intake ambient air to battery pack/ Min.: -327.68°C, Max.: 327.67°C Undisturbed for 1 day: Same as ambient air temperature - VMF FAN VOLTAGE Battery blower motor monitoring voltage/ Min.: -25.6 V, Max.: 25.4 V Fan mode 1 with READY light ON and P position: 9.5 to 11.5 V - HB HB–26 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Intelligent Tester Display Measurement Item/Range (Display) Reference Range Diagnostic Note AUX. BATT V Auxiliary battery voltage/ Min.: 0 V, Max.: 25.4 V Equivalent to auxiliary battery voltage - WIN Charge control wattage which is sent from battery ECU to hybrid vehicle control ECU/ Min.: -64 kW, Max.: 0 kW -25 kW or more - WOUT Discharge control wattage which is sent from battery ECU to hybrid vehicle control ECU/ Min.: 0 kW, Max.: 63.5 kW 21 kW or less - COOLING FAN SPD Battery blower motor actuation mode/ Min.: 0, Max.: 6 Stopped: 0 Low to high speed actuation: 1 to 6 - ECU CTRL MODE ECU control mode/ Min.: 0, Max.: 4 - - SBLW RQST Battery blower motor stop control request (standby blower) ON/OFF - BATT TEMP 1 to 3 Temperature of HV battery/ Min.: -327.68°C, Max.: 327.67°C Undisturbed for 1 day: Same as ambient air temperature - NUM OF BATT The number of battery blocks/ Min.: 0, Max.: 255 Always: 14 - BAT BLOCK MIN V Battery block minimum voltage/ Min.: -327.68 V, Max.: 327.67 V SOC 50 to 60%: 12 V or more - MIN BAT BLOCK # Battery block number with minimum voltage One of numbers 0 to 13 - BAT BLOCK MAX V Battery block maximum voltage/ Min.: -327.68 V, Max.: 327.67 V SOC 55 to 60%: 23 V or less - MAX BAT BLOCK # Battery block number with maximum voltage One of numbers 0 to 13 - V1 to V14 BATT BLOCK Battery block voltage/ Min.: -327.68 V, Max.: 327.67 V SOC 60%: 12 to 20 V - 1 to 14 INTNL RESIST Internal resistance of each battery block/ Min.: 0 Ω, Max.: 0.255 Ω Always: 0.01 to 0.1 Ω - REGULATION Compliance regulation OBD2 (CARB) - #CODES The number of emission related powertrain DTCs/ Min.: 0, Max.: 127 - - DTC The number of stored DTCs/ Min.: 0, Max.: 255 - - 2. PERFORM ACTIVE TEST NOTICE: Beware that if the connector to the intelligent tester becomes disconnected or a communication error occurs during the ACTIVE TEST, the vehicle could become inoperative (READY light OFF). HINT: Performing an ACTIVE TEST using the intelligent tester enables components including the relay, VSV, and actuator, to be operated without removing any parts. Performing an ACTIVE TEST as the first step of troubleshooting is one method to shorten diagnostic time. It is possible to display items in the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–27 (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. Intelligent Tester Display Purpose Test Details Test Condition COOLING FAN SPD To check the operation and the speed of the battery blower motor Stops the battery blower motor in mode 0 or operates it in modes 1 to 6 Disabled when a DTC is detected HB HB–28 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • *1: "Comes on" means that the MIL is illuminated. "-" means that the MIL is not illuminated. • *2: "Comes on" means that the master warning light is illuminated. • *3: Warning shown on the multi-information display. HB DTC No. Detection Item Trouble Area MIL P0560 System Voltage - Wire harness or connector - HEV fuse - Battery ECU Comes on P0A1F Battery Energy Control Module Battery ECU P0A7F Hybrid Battery Pack Deterioration P0A80 Master Warning Light Warning Memory See page Comes on HV system DTC Stored HB-27 Comes on Comes on HV system DTC Stored HB-31 - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-33 Replace Hybrid Battery Pack - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-35 P0A81 Hybrid Battery Pack Cooling Fan 1 - Quarter vent duct (blower motor controller) - Battery ECU - Comes on HV system DTC Stored HB-37 P0A82 Hybrid Battery Pack Cooling Fan 1 Performance or Stuck OFF - Quarter vent duct - No. 2 quarter vent duct - No. 2 quarter vent duct inner - Ventilator inner duct - Battery blower - Battery ECU - Comes on HV system DTC Stored HB-39 P0A84 Hybrid Battery Pack Cooling Fan 1 Control Circuit Low - Wire harness or connector - BATT FAN fuse - No. 1 battery blower relay - Battery blower - Quarter vent duct (blower motor controller) - Battery ECU - Comes on HV system DTC Stored HB-41 P0A85 Hybrid Battery Pack Cooling Fan 1 Control Circuit High - Wire harness or connector - BATT FAN fuse - No. 1 battery blower relay - Battery blower - Quarter vent duct (blower motor controller) - Battery ECU - Comes on HV system DTC Stored HB-41 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. Detection Item Trouble Area MIL P0A95 High Voltage Fuse - High voltage fuse - Service plug grip - Battery plug - Battery ECU - P0A9C Hybrid Battery Temperature Sensor "A" - HV battery assembly (battery temperature sensor) - Battery ECU P0A9D Hybrid Battery Temperature Sensor "A" Circuit Low P0A9E Master Warning Light HB–29 Warning Memory See page Comes on HV system DTC Stored HB-52 Comes on Comes on HV system DTC Stored HB-55 - HV battery assembly (battery temperature sensor) - Battery ECU Comes on Comes on HV system DTC Stored HB-55 Hybrid Battery Temperature Sensor "A" Circuit High - HV battery assembly (battery temperature sensor) - Battery ECU Comes on Comes on HV system DTC Stored HB-55 P0AAC Hybrid Battery Pack Air Temperature Sensor "A" Circuit - HV battery assembly (intake air temperature sensor) - Battery ECU Comes on Comes on HV system DTC Stored HB-59 P0ABF Hybrid Battery Pack Current Sensor Circuit - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 P0AC0 Hybrid Battery Pack Current Sensor Circuit Range/ Performance - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 P0AC1 Hybrid Battery Pack Current Sensor Circuit Low - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 P0AC2 Hybrid Battery Pack Current Sensor Circuit High - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 HB HB–30 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. Detection Item Trouble Area MIL P0AFA Hybrid Battery System Voltage Low - Junction block assembly (busbar module) - No. 2 frame wire (busbar and wire harness) Battery ECU Comes on P3011 Battery Block 1 Becomes Weak - HV battery assembly - Battery ECU P3012 Battery Block 2 Becomes Weak P3013 Master Warning Light Warning Memory See page Comes on HV system DTC Stored HB-67 Comes on Comes on HV system DTC Stored HB-72 - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 Battery Block 3 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3014 Battery Block 4 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3015 Battery Block 5 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3016 Battery Block 6 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3017 Battery Block 7 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3018 Battery Block 8 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3019 Battery Block 9 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3020 Battery Block 10 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3021 Battery Block 11 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3022 Battery Block 12 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3023 Battery Block 13 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3024 Battery Block 14 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 U0100 Lost Communication with ECM/PCM "A" CAN communication system Comes on Comes on HV system DTC Stored HB-75 U0293 Lost Communication with HV ECU CAN communication system Comes on Comes on HV system DTC Stored HB-75 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0560 HB–31 System Voltage DESCRIPTION Battery power is constantly supplied to the AM terminal of the battery ECU for the purpose of maintaining the DTCs and freeze frame data in memory. This voltage is supplied as a backup even if the power switch is turned OFF. DTC No. DTC Detection Condition Trouble Area P0560 Open in auxiliary battery power supply system while battery power is supplied to terminal IGCT (1 trip detection logic) • • • Wire harness or connector HEV fuse Battery ECU MONITOR DESCRIPTION If 1 or more seconds have elapsed with a voltage of 1 V or less at the AM terminal at the battery ECU, the battery ECU will determine that malfunction has occurred in the back-up power supply system, illuminate the MIL, and set a DTC. MONITOR STRATEGY Related DTCs P0560: Battery ECU/Range check Required sensors/components Main: Back-up power source circuit Sub: Battery ECU Frequency of operation Continuous Duration 1 second MIL operation Immediate after next power switch ON (IG) Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HB TYPICAL MALFUNCTION THRESHOLDS Stand-by RAM back-up voltage 1 V or less COMPONENT OPERATING RANGE Auxiliary battery voltage 9 to 14 V HB–32 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU HEV From Auxiliary Battery AM C118374E01 INSPECTION PROCEDURE 1 CHECK FUSE (HEV) (a) Remove the HEV fuse from the engine room relay block. (b) Measure the resistance of the HEV fuse. Standard resistance: Below 1 Ω (c) Reinstall the HEV fuse. Engine Room Relay Block NG HB HEV Fuse C118372E01 OK Go to step 3 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 2 HB–33 CHECK WIRE HARNESS (BATTERY ECU - AUXILIARY BATTERY) (a) (b) (c) (d) (e) Positive Terminal Disconnect the negative auxiliary battery terminal. Disconnect the positive auxiliary battery terminal. Remove the HEV fuse from the engine room relay block. Disconnect the B11 battery ECU connector. Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B11-1 (AM) - HEV fuse terminal 2 Below 1 Ω HEV fuse terminal 1 - Positive auxiliary battery terminal Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (f) Reconnect the battery ECU connector. (g) Reinstall the HEV fuse. (h) Reconnect the positive auxiliary battery terminal. (i) Reconnect the negative auxiliary battery terminal. Engine Room Relay Block NG HEV Fuse REPAIR OR REPLACE HARNESS AND CONNECTOR B11 Battery ECU HB AM A131604E01 OK CHECK AND REPAIR CONNECTOR CONNECTION HB–34 3 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM CHECK WIRE HARNESS (BATTERY ECU - HEV FUSE) (a) Disconnect the B11 battery ECU connector. (b) Remove the HEV fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connector. Standard resistance B11 Battery ECU AM Engine Room Relay Block Tester Connection Specified Condition B11-1 (AM) or HEV fuse terminal 2 Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reconnect the battery ECU connector. (e) Reinstall the HEV fuse. NG HEV Fuse A131605E01 HB OK REPLACE FUSE (HEV) AFTER REPAIRING OR REPLACING HARNESS AND CONNECTOR, REPLACE FUSE (HEV) P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A1F HB–35 Battery Energy Control Module DESCRIPTION For the purpose of calculating the SOC (state of charge) of the HV battery and ensuring safety in the event of a malfunction in the HV battery assembly, the battery ECU provides the following control functions: • SOC calculation The battery ECU calculates the SOC by estimating the charging and discharging amperage and monitoring other values. • Cooling fan control The battery ECU controls the battery blower in order to protect the HV battery assembly from heat that is generated during charging and discharging. By maintaining a stable temperature, it promotes the effective operation of the HV battery assembly. • HV battery assembly malfunction monitoring If the battery ECU detects a malfunction, it protects the HV battery assembly by limiting or stopping the charging or discharging of the HV battery in accordance with the temperature or voltage of the HV battery assembly. DTC No. DTC Detection Condition Trouble Area P0A1F Battery ECU internal error (1 trip detection logic) Battery ECU MONITOR DESCRIPTION If the battery ECU detects an internal malfunction in the ECU itself, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F: Battery ECU/Rationality Required sensors/components Battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate or 1 driving cycle or 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Battery ECU Abnormal COMPONENT OPERATING RANGE Battery ECU DTC P0A1F is not detected HB HB–36 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECTION PROCEDURE 1 REPLACE BATTERY ECU NEXT COMPLETED HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A7F HB–37 Hybrid Battery Pack Deterioration DESCRIPTION Upper SOC control limit Control region Example of change in SOC SOC Time Lower SOC control limit Central SOC level C115845E01 The battery ECU calculates the SOC (state of charge) of the HV battery by estimating the amperage that flows into the HV battery and monitoring other values. The battery ECU sends the calculated SOC to the hybrid vehicle control ECU. The hybrid vehicle control ECU charges and discharges the HV battery depending on driving patterns based on the information sent by the battery ECU. DTC No. DTC Detection Condition Trouble Area P0A7F When either condition below is met: • Resistance of HV battery assembly is higher than standard (1 trip detection logic) • When the capacity difference between battery modules exceeds the specified value (2 trip detection logic) • • HV battery assembly Battery ECU MONITOR DESCRIPTION The battery ECU calculates the resistance of the HV battery through amperage and voltage, and uses this resistance to determine the extent of deterioration of the HV battery. If the battery ECU detects that the resistance of the HV battery has exceeded the standard, it determines that malfunction has occurred. In addition, the battery ECU monitors the SOC, and if the difference between the maximum and minimum SOC values exceeds the standard, it determines that malfunction has occurred. When either of the malfunction detection conditions is met, the battery ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7F: HV battery/Rationality Required sensors/components Main: Battery voltage sensor inside battery ECU, battery current sensor Sub: Battery temperature sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate or 2 driving cycles Sequence of operation None HB HB–38 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Either of the following condition (1) or (2) (1) Internal resistance Exceeds the standard level (2) The difference between the maximum SOC and the minimum SOC Exceeds the standard level COMPONENT OPERATING RANGE TOYOTA's intellectual property - INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES NO HB REPLACE HV SUPPLY BATTERY ASSEMBLY REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A80 HB–39 Replace Hybrid Battery Pack DESCRIPTION The HV battery assembly consists of nickel hydride batteries. Nickel hydride batteries do not require external charging. The SOC (state of charge) of the HV battery is maintained at a constant voltage level by the hybrid vehicle control ECU while the vehicle is being driven. In the HV battery assembly, 28 modules are connected in series, and each module has six 1.2 V cells that are connected in series. Thus, the HV battery assembly contains a total of 168 cells which produce 201.6 V. The battery ECU, which monitors two modules as a single battery block, detects the battery block voltage at a total of 14 locations. Battery Block Battery Module GBB0 VBB2 VBB13 VBB3 VBB1 VBB14 Battery ECU C115846E01 DTC No. DTC Detection Condition Trouble Area P0A80 Voltage difference between battery blocks is higher than standard (2 trip detection logic) • • HV battery assembly Battery ECU MONITOR DESCRIPTION The battery ECU, which monitors the voltage of the battery blocks, determines that malfunction has occurred if a voltage difference between the battery blocks exceeds the standard. When the malfunction detection condition is satisfied, the battery ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A80: HV battery/Rationality Required sensors/components Main: Battery voltage sensor inside battery ECU Sub: Battery current sensor, battery temperature sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HB HB–40 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TYPICAL MALFUNCTION THRESHOLDS Battery voltage difference Exceeds the standard level COMPONENT OPERATING RANGE TOYOTA's intellectual property - INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES NO REPLACE HV SUPPLY BATTERY ASSEMBLY HB REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A81 HB–41 Hybrid Battery Pack Cooling Fan 1 DESCRIPTION Refer to DTC P0A84 (see page HB-41). DTC No. DTC Detection Condition Trouble Area P0A81 Voltage at motor is out of predetermined range in proportion to target control voltage (1 trip detection logic) • • Quarter vent duct (blower motor controller) Battery ECU WIRING DIAGRAM Refer to DTC P0A84 (see page HB-42). INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0A81 A P0A81 and P0A1F B P0A81 and P0A84 C B REPLACE BATTERY ECU C GO TO DTC P0A84 CHART A 2 REPLACE QUARTER VENT DUCT (BATTERY BLOWER MOTOR CONTROLLER) (a) (b) (c) (d) Replace the quarter vent duct (blower motor controller). Connect the intelligent tester to the DLC3. Turn the power switch ON (IG) and the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / CLEAR CODES. (e) Perform a simulation test. NEXT 3 READ DTC OUTPUT (DTC P0A81 IS OUTPUT AGAIN) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. HB HB–42 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (d) Read DTCs. Result: DTC P0A81 is output again YES NO SYSTEM IS OK HB REPLACE BATTERY ECU HB–43 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A82 Hybrid Battery Pack Cooling Fan 1 Performance or Stuck OFF DESCRIPTION The cooling air flows into the inlet on the right of the rear seat and travels through an intake duct to the battery blower on the right surface of the luggage compartment. Furthermore, the cooling air travels through an intake duct (which connects the battery blower to the upper right surface of the HV battery assembly) and flows to the HV battery assembly. The cooling air flows from the top to the bottom between the HV battery modules. After it has cooled the modules, it is discharged from the bottom right surface of the HV battery assembly. The exhaust air travels through an exhaust duct on the right surface of the luggage compartment and is discharged into the cabin as well as outside of the vehicle. The battery ECU uses battery temperature sensors in order to detect the temperature of the HV battery assembly. Based on the results of this detection, the battery ECU controls the battery blower. (Thus, the battery blower starts when the HV battery temperature rises to a predetermined level.) Ventilator Inner Duct No. 2 Quarter Vent Duct Inner Battery Blower HV Battery Assembly No. 2 Quarter Vent Duct Quarter Vent Duct Top Flow of cooling air inside HV battery case HB Intake : Cooling Air Flow Bottom Battery Module Exhaust A093182E01 DTC No. DTC Detection Condition Trouble Area P0A82 Difference between estimated battery temperature based on blower fan cooling performance and actual temperature is excessive (2 trip detection logic) • • • • • • Quarter vent duct No. 2 quarter vent duct No. 2 quarter vent duct inner Ventilator inner duct Battery blower Battery ECU HB–44 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK DUCT AND BLOWER (a) Check the ducts and the blower listed below for disconnection and damage. Also, check that they are not clogged up with foreign substances. (1) Quarter vent duct (2) No. 2 quarter vent duct (3) No. 2 quarter vent duct inner (4) Ventilator inner duct (5) Battery blower NG OK HB REPLACE BATTERY ECU REMOVE FOREIGN SUBSTANCES OR REPLACE AFFECTED PARTS HB–45 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A84 Hybrid Battery Pack Cooling Fan 1 Control Circuit Low DTC P0A85 Hybrid Battery Pack Cooling Fan 1 Control Circuit High DESCRIPTION The blower motor controller regulates the voltage of the battery blower. The blower motor controller has fins made of aluminum. The exhaust air from the HV battery assembly that flows through the quarter vent duct cools the blower motor controller, which is installed in the quarter vent duct. The current flows from the FCTL1 terminal of the battery ECU to the relay coil of the No. 1 battery blower relay and as the contact point of the relay closes, the power is supplied to the battery blower. When a fan actuation signal is transmitted from the battery ECU, the blower motor controller adjusts voltage (VM) which is applied to the battery blower in order to get the requested fan speed. The adjusted voltage is also transmitted to the VM terminal of the battery ECU in the form of a monitoring signal. The blower motor controller corrects the voltage at the blower motor by monitoring voltage at the +B terminal of the battery blower. Battery ECU No. 1 Battery Blower FCTL1 Battery Blower VM BATT FAN +B MAIN Auxiliary Battery VM GND SI HB SI Duty Signal Battery Blower Motor Controller A133090E01 DTC No. DTC Detection Condition Trouble Area P0A84 Battery blower voltage is lower than malfunction threshold at constant vehicle speed • • • • • • P0A85 Battery blower voltage is higher than malfunction threshold at constant vehicle speed • • • • • • Wire harness or connector BATT FAN fuse No. 1 battery blower relay Battery blower Quarter vent duct (battery blower motor controller) Battery ECU Wire harness or connector BATT FAN fuse No. 1 battery blower relay Battery blower Quarter vent duct (battery blower motor controller) Battery ECU HB–46 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU No. 1 Battery Blower FCTL1 Battery Blower VM BATT FAN +B Battery Blower Motor Controller VM SI SI GND From Auxiliary Battery A133091E01 INSPECTION PROCEDURE 1 CHECK FUSE (BATT FAN) (a) Remove the BATT FAN fuse from the engine room relay block. (b) Measure the resistance of the BATT FAN fuse. Standard resistance: Below 1 Ω (c) Reinstall the BATT FAN fuse. Engine Room Relay Block HB BATT FAN Fuse NG C129041E01 OK Go to step 14 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 2 INSPECT NO. 1 BATTERY BLOWER RELAY 1 5 (a) Remove the No. 1 battery blower relay. (b) Measure the resistance of the terminals of the relay. Standard resistance 2 3 5 1 HB–47 2 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) 3 B060778E30 (c) Reinstall the No. 1 battery blower relay. NG REPLACE NO. 1 BATTERY BLOWER RELAY OK 3 INSPECT BATTERY BLOWER 2 (+) B9 (a) Disconnect the B9 battery blower connector. (b) Connect the positive terminal of the battery to terminal 2 of the battery blower connector, and the negative battery terminal to terminal 1 of the connector. (c) Check that the blower fan rotates when voltage is applied. OK: Blower fan rotates 1 (-) A090450E03 NG REPLACE BATTERY BLOWER OK 4 HB CHECK BATTERY BLOWER MOTOR CONTROLLER (a) Check the battery blower motor controller (see page HB159). NG OK REPLACE QUARTER VENT DUCT (BATTERY BLOWER MOTOR CONTROLLER) HB–48 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 5 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATT FAN FUSE) (a) Remove the B14 No. 1 battery blower relay. (b) Remove the BATT FAN fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Engine Room Relay Block BATT FAN Fuse Tester Connection Specified Condition B14-1 and 3 - BATT FAN fuse terminal 2 Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reinstall the BATT FAN fuse. NG A131431E01 HB OK REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 6 HB–49 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY BLOWER) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B9 battery blower connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Tester Connection Specified Condition B14-5 - B9-2 Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reconnect the battery blower connector. Wire Harness Side Battery Blower NG B9 1 2 REPAIR OR REPLACE HARNESS AND CONNECTOR A131597E01 OK 7 CHECK WIRE HARNESS (BATTERY BLOWER - BATTERY BLOWER MOTOR CONTROLLER) (a) Disconnect the B9 battery blower connector. (b) Disconnect the B10 battery blower motor controller connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Battery Blower B9 1 2 Tester Connection Specified Condition B9-2 - B10-3 (+B) Below 1 Ω (d) Reconnect the battery blower connector. (e) Reconnect the battery blower motor controller connector. NG B10 1 2 3 4 Battery Blower Motor Controller +B A131598E01 REPAIR OR REPLACE HARNESS AND CONNECTOR HB HB–50 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM OK 8 CHECK WIRE HARNESS (BATTERY BLOWER - BATTERY ECU) (a) Disconnect the B9 battery blower connector. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Battery Blower B9 1 2 Tester Connection Specified Condition B9-1 - B11-9 (VM) Below 1 Ω B9-1 or B11-9 (VM) - Body ground 10 kΩ or higher (d) Reconnect the battery blower connector. (e) Reconnect the battery ECU connector. NG B11 REPAIR OR REPLACE HARNESS AND CONNECTOR Battery ECU VM A131599E01 OK 9 HB CHECK WIRE HARNESS (BATTERY BLOWER - BATTERY BLOWER MOTOR CONTROLLER) (a) Disconnect the B9 battery blower connector. (b) Disconnect the B10 battery blower motor controller connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side B9 1 2 Battery Blower Tester Connection Specified Condition B9-1 - B10-4 (VM) Below 1 Ω B9-1 or B10-4 (VM) - Body ground 10 kΩ or higher (d) Reconnect the battery blower connector. (e) Reconnect the battery blower motor controller connector. NG B10 1 2 3 4 Battery Blower Motor Controller VM A131598E02 REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–51 OK 10 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY ECU) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 5 B14 1 2 Tester Connection Specified Condition B14-2 - B11-10 (FCTL1) Below 1 Ω B14-2 or B11-10 (FCTL1) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reconnect the battery ECU connector. B11 Battery ECU NG REPAIR OR REPLACE HARNESS AND CONNECTOR FCTL1 A131600E01 OK 11 CHECK WIRE HARNESS (BATTERY BLOWER MOTOR CONTROLLER - BATTERY ECU) Wire Harness Side B10 1 2 3 4 Battery Blower Motor Controller SI (a) Disconnect the B10 battery blower motor controller connector. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B10-2 (SI) - B11-24 (SI) Below 1 Ω B10-2 (SI) or B11-24 (SI) - Body ground 10 kΩ or higher (d) Reconnect the battery blower motor controller connector. (e) Reconnect the battery ECU connector. B11 NG Battery ECU SI A131601E01 REPAIR OR REPLACE HARNESS AND CONNECTOR HB HB–52 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM OK 12 CHECK WIRE HARNESS (BATTERY BLOWER MOTOR CONTROLLER - BODY GROUND) Wire Harness Side Battery Blower Motor Controller B10 GND (a) Disconnect the B10 battery blower motor controller connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition B10-1 (GND) - Body ground Below 1 Ω (c) Reconnect the battery blower motor controller connector. A090454E13 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 13 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY) (a) Remove the B14 No. 1 battery blower relay. (b) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side 3 B14 5 1 2 No. 1 Battery Blower Relay A129366E01 HB Tester Connection Specified Condition B14-1 - B14-3 Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (c) Reinstall the No. 1 battery blower relay. NG OK REPLACE BATTERY ECU REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 14 HB–53 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATT FAN FUSE) (a) Remove the B14 No. 1 battery blower relay. (b) Remove the BATT FAN fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connector. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Engine Room Relay Block BATT FAN Fuse Tester Connection Specified Condition B14-3 or BATT FAN fuse terminal 2 Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reinstall the BATT FAN fuse. NG REPAIR OR REPLACE HARNESS AND CONNECTOR AND REPLACE FUSE (BATT FAN) A131431E01 OK HB HB–54 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 15 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY BLOWER) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B9 battery blower connector. (c) Disconnect the B10 battery blower motor controller connector. (d) Measure the resistance of the wire harness side connector. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Wire Harness Side 1 2 Battery Blower Motor Controller B10 1 2 3 4 +B A131602E01 HB OK Specified Condition B14-5, B9-2 or B10-3 (+B) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (e) Reinstall the No. 1 battery blower relay. (f) Reconnect the battery blower connector. (g) Reconnect the battery blower motor controller connector. Battery Blower B9 Tester Connection NG REPAIR OR REPLACE HARNESS AND CONNECTOR AND REPLACE FUSE (BATT FAN) P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 16 HB–55 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY ECU) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 5 B14 1 2 Tester Connection Specified Condition B14-1, B14-3 or B11-10 (FCTL1) Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reconnect the battery ECU connector. B11 NG Battery ECU REPAIR OR REPLACE HARNESS AND CONNECTOR AND REPLACE FUSE (BATT FAN) FCTL1 A131600E01 OK 17 CHECK BATTERY BLOWER MOTOR CONTROLLER (a) Check the battery blower motor controller (see page HB159). NG OK REPLACE BATTERY ECU REPLACE QUARTER VENT DUCT (BATTERY BLOWER MOTOR CONTROLLER) HB HB–56 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A95 High Voltage Fuse DESCRIPTION DTC No. DTC Detection Condition Trouble Area P0A95 Voltage between VBB9 and VBB10 terminals is below standard in spite of interlock switch being engaged (1 trip detection logic) • • • • High voltage fuse Service plug grip Battery plug Battery ECU WIRING DIAGRAM (+) HV Battery Assembly Battery ECU Service Plug Grip VBB10 High Voltage VBB9 (-) HB C118375E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–57 Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 INSPECT SERVICE PLUG GRIP CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Measure the resistance of the service plug grip. Standard resistance: Below 1 Ω A081749E01 NG Go to step 4 OK 3 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-88). (b) Remove the battery plug (see page HB-112). (c) Measure the resistance of the battery plug. Standard resistance A B D C A093184E01 OK REPLACE BATTERY ECU Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (d) Reinstall the battery plug (see page HB-112). (e) Reinstall the HV battery assembly (see page HB-88). NG REPLACE BATTERY PLUG HB HB–58 4 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECT HIGH VOLTAGE FUSE CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the high voltage fuse (see page HB-153). HINT: The high voltage fuse is enclosed in the service plug grip. (b) Measure the resistance of the high voltage fuse. Standard resistance: Below 1 Ω (c) Reinstall the high voltage fuse. A057824E01 OK REPLACE SERVICE PLUG GRIP HB NG REPLACE HIGH VOLTAGE FUSE P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–59 DTC P0A9C Hybrid Battery Temperature Sensor "A" DTC P0A9D Hybrid Battery Temperature Sensor "A" Circuit Low DTC P0A9E Hybrid Battery Temperature Sensor "A" Circuit High DESCRIPTION Reference: Sensor Characteristic Diagram Resistance kΩ 250 200 150 100 50 0 Battery Temperature °C (°F) HB C118369E01 3 battery temperature sensors are located on the bottom of the HV battery assembly. The resistance of the thermistor, which is enclosed in each battery temperature sensor, changes in accordance with the changes in the temperature of the HV battery assembly. The lower the battery temperature, the higher the resistance of the thermistor. Conversely, the higher the temperature, the lower the resistance. The battery ECU uses the battery temperature sensors to detect the temperature of the HV battery assembly. Based on the results of this detection, the battery ECU controls the battery blower. (Thus, the blower fan starts when the HV battery temperature rises to a predetermined level.) DTC No. DTC Detection Condition Trouble Area P0A9C Battery temperature sensor malfunction • P0A9D Low resistance in battery temperature sensor • • • P0A9E High resistance in battery temperature sensor • • HV battery assembly (HV battery temperature sensor) Battery ECU HV battery assembly (HV battery temperature sensor) Battery ECU HV battery assembly (HV battery temperature sensor) Battery ECU HB–60 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HINT: After confirming DTC P0A9C, P0A9D and P0A9E, enter the following menus on the intelligent tester: DIAGNOSIS / OBD/MOBD / HV BATTERY / DATA LIST. Then, confirm the temperature of the HV battery by checking "BATT TEMP 1 to 3". Temperature Displayed Malfunction -45°C (-49°F) or less Open or +B short circuit 95°C (203°F) or more GND short circuit MONITOR DESCRIPTION If the temperature indicated by the battery temperature sensors is lower than the standard level (open), or is higher than the standard level (short), the battery ECU interprets this as a sensor malfunction. If the battery ECU detects that HV battery temperature is out of a normal range or its value is abnormal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Case 1: Battery temperature sensor malfunction Related DTCs P0A9C Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 2: Battery temperature sensor low resistance HB Related DTCs P0A9D Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 3: Battery temperature high resistance Related DTCs P0A9E Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Case 1: Battery temperature sensor malfunction Temperature deviation among batteries (Maximum temperature - minimum temperature) Exceeds standard level P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–61 Case 2: Battery temperature sensor low resistance Resistance of battery temperature sensor 1.108 kΩ or less Case 3: Battery temperature high resistance Resistance of battery temperature sensor 247.7 kΩ or more COMPONENT OPERATING RANGE Battery temperature sensor 9 to 11 kΩ (at 25°C (77°F)) WIRING DIAGRAM Battery ECU 5V Battery Temperature Sensor 1 TB1 GB1 5V Battery Temperature Sensor 2 TB2 GB2 5V Battery Temperature Sensor 3 TB3 GB3 C118376E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. HB HB–62 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK CONNECTION OF BATTERY TEMPERATURE SENSOR CONNECTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Check the connection condition of the B13 battery ECU connector. OK: Connector has been connected securely and there is no poor connection. HINT: Since the battery temperature sensor is not available by itself, if replacement is required, replace the entire HV battery assembly. B13 GB3 TB3 GB2 TB2 GB1 TB1 Battery ECU A093174E01 NG OK HB REPLACE HV SUPPLY BATTERY ASSEMBLY CONNECT SECURELY P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0AAC HB–63 Hybrid Battery Pack Air Temperature Sensor "A" Circuit DESCRIPTION The intake air temperature sensor is provided on the HV battery assembly. Its resistance value varies with the changes in the intake air temperature. The characteristics of the intake air temperature sensor are the same as the battery temperature sensors (see page HB-55). The battery ECU uses the signals from the intake air temperature sensor for adjusting the air flow speed of the battery blower. DTC No. DTC Detection Condition Trouble Area P0AAC Temperature detected by intake air temperature sensor is lower than standard (open) or higher than standard (short) (1 trip detection logic) • • HV battery assembly (intake air temperature sensor) Battery ECU HINT: After confirming DTC P0AAC, enter the following menus on the intelligent tester: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DATA LIST. Then, confirm the temperature of the intake ambient air to the battery pack by checking "BATT INSIDE AIR". Temperature Displayed Malfunction -45°C (-49°F) or less Open or +B short circuit 95°C (203°F) or more GND short circuit MONITOR DESCRIPTION If the temperature indicated by the intake air temperature sensor is lower than the standard level (open), or is higher than the standard level (short), the battery ECU determines that a malfunction has occurred. If the battery ECU detects an abnormal intake air temperature, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0AAC: Intake cooling air temperature sensor/Range check Required sensors/components Intake air temperature sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Resistance of intake air temperature sensor 1.108 kΩ or less or 247.7 kΩ or more COMPONENT OPERATING RANGE Intake air temperature sensor 9 to 11 kΩ (at 25°C (77°F)) HB HB–64 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU Battery Intake Air Temperature Sensor 5V TC1 GC1 C118378E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 HB READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK CONNECTION OF INTAKE AIR TEMPERATURE SENSOR CONNECTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Check the connection condition of the B13 battery ECU connector. OK: Connector has been connected securely and there is no poor connection. HINT: Since the intake air temperature sensor is not available it self, if replacement is required, replace the entire HV battery assembly. B13 GC1 TC1 Battery ECU HB–65 A093174E05 NG CONNECT SECURELY OK REPLACE HV SUPPLY BATTERY ASSEMBLY HB HB–66 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0ABF Hybrid Battery Pack Current Sensor Circuit DTC P0AC0 Hybrid Battery Pack Current Sensor Circuit Range/Performance DTC P0AC1 Hybrid Battery Pack Current Sensor Circuit Low DTC P0AC2 Hybrid Battery Pack Current Sensor Circuit High DESCRIPTION The battery current sensor, which is mounted on the negative cable side of the HV battery assembly, detects the amperage that flows into the HV battery. The battery current sensor inputs a voltage (which varies between 0 to 5 V in proportion to the amperage) into the IB terminal of the battery ECU. An output voltage of the battery current sensor below 2.5 V indicates that the HV battery assembly is being charged, and above 2.5 V indicates that the HV battery assembly is being discharged. The battery ECU determines the charging and discharging amperage of the HV battery assembly based on the signals that are input to its IB terminal, and calculates the SOC (state of charge) of the HV battery through the estimation of the amperage. Battery Current Sensor Output Voltage (V) Battery ECU 4.5 HB VIB IB GIB HV Battery 2.5 0.5 Discharging Amperage -200 Charging Amperage 0 Charging 200 Discharging HV Battery Amperage (A) Battery Current Sensor A093186E01 DTC No. DTC Detection Condition Trouble Area P0ABF Power source of battery current sensor • • • P0AC0 Battery current sensor malfunction • • • HV battery assembly (wire harness or connector) Battery current sensor Battery ECU HV battery assembly (wire harness or connector) Battery current sensor Battery ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. DTC Detection Condition Trouble Area P0AC1 Low voltage in battery current sensor • • • P0AC2 High voltage in battery current sensor • • • HB–67 HV battery assembly (wire harness or connector) Battery current sensor Battery ECU HV battery assembly (wire harness or connector) Battery current sensor Battery ECU MONITOR DESCRIPTION If the battery ECU detects malfunction in the battery current sensor, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Case 1: Power source of battery current sensor Related DTCs P0ABF Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 2: Battery current sensor malfunction Related DTCs P0AC0 Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation 2 driving cycles Sequence of Operation None Case 3: Battery current sensor low voltage Related DTCs P0AC1 Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 4: Battery current sensor high voltage Related DTCs P0AC2 Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None HB HB–68 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Case 1: Power source of battery current sensor Power-supply voltage for current sensor Exceeds standard level Case 2: Battery current sensor malfunction Sensor current Exceeds standard level Case 3: Battery current sensor low voltage Sensor voltage Exceeds standard level Case 4: Battery current sensor high voltage Sensor voltage Exceeds standard level COMPONENT OPERATING RANGE Battery current sensor DTC P0ABF, P0AC0, P0AC1 and P0AC2 are not detected WIRING DIAGRAM Battery Current Sensor Battery ECU IB IB VIB VIB GIB GIB HB C118377E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–69 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK WIRE HARNESS (BATTERY ECU - BATTERY CURRENT SENSOR) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the B13 battery ECU connector. (d) Disconnect the battery current sensor connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage of the battery ECU connector. Standard voltage B13 Battery ECU IB Tester Connection GIB VIB Wire Harness Side 1 VIB 2 GIB Battery Current Sensor 3 IB A131603E01 Specified Condition B13-16 (IB) - Body ground Below 1 V B13-14 (GIB) - Body ground Below 1 V B13-15 (VIB) - Body ground Below 1 V (g) Turn the power switch OFF. (h) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B13-16 (IB) - 3 (battery current sensor) Below 1 Ω B13-14 (GIB) - 2 (battery current sensor) Below 1 Ω B13-15 (VIB) - 1 (battery current sensor) Below 1 Ω HB HB–70 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Tester Connection Specified Condition B13-16 (IB) or 3 (battery current sensor) - Body ground 10 kΩ or higher B13-14 (GIB) or 2 (battery current sensor) - Body ground 10 kΩ or higher B13-15 (VIB) or 1 (battery current sensor) - Body ground 10 kΩ or higher (i) Reconnect the battery current sensor connector. (j) Reconnect the battery ECU connector. (k) Reinstall the service plug grip (see page HB-153). HINT: Since the wire harness is not available by itself, if replacement is required, replace the entire HV battery assembly. NG REPAIR HARNESS AND CONNECTOR, OR REPLACE HV SUPPLY BATTERY ASSEMBLY OK 3 REPLACE BATTERY CURRENT SENSOR (a) (b) (c) (d) HB Replace the battery current sensor (see page HB-141). Connect the intelligent tester to the DLC3. Turn the power switch ON (IG) and the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Perform a simulation test. HINT: Some of the steps involve the detection of 2 trips. Therefore, after performing a simulation test, turn the power switch OFF, and perform the simulation test again. NEXT 4 READ DTC OUTPUT (DTC P0ABF, P0AC0, P0AC1 AND P0AC2 IS NOT OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0ABF, P0AC0, P0AC1 and P0AC2 is not output again NO YES SYSTEM IS OK REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0AFA HB–71 Hybrid Battery System Voltage Low DESCRIPTION Refer to DTC P0A80 (see page HB-35). DTC No. DTC Detection Condition Trouble Area P0AFA Either of the following conditions occurs (1 trip detection logic) • Voltage at each battery block is below 2 V • Voltage of all the battery blocks is -24 to 2 V • • • Junction block assembly (busbar module) No. 2 frame wire (busbar and wire harness) Battery ECU MONITOR DESCRIPTION The battery ECU monitors a voltage of the battery blocks to detect an open malfunction in internal battery voltage sensor circuits of the battery ECU and the wire harness between each battery block and battery ECU. If a voltage at one of the battery blocks is below a standard level or of all the battery blocks is within a specified range, the battery ECU judges that there is an open in the internal sensor circuit(s) or wire harness. The battery ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0AFA: Battery voltage sensor/Range check Required sensors/components The wire harness from each battery block to the battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is satisfied: (a) or (b) (a) Voltage at single battery block Below 2 V (b) Voltage of all battery blocks -24 to 2 V COMPONENT OPERATING RANGE Battery ECU No open malfunction HB HB–72 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU VBB14 VBB13 VBB12 VBB11 VBB10 VBB9 HV Battery VBB8 Busbar Module VBB7 VBB6 VBB5 VBB4 VBB3 VBB2 VBB1 GBB0 HB C118379E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–73 Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 READ VALUE OF INTELLIGENT TESTER (BATTERY BLOCK VOL-V01 TO V14) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DATA LIST. (d) Read "V1 to V14 BATTERY BLOCK" on the tester. Standard voltage: 2 V or more OK Go to step 5 NG 3 CHECK JUNCTION BLOCK ASSEMBLY (BUSBAR MODULE) CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the battery assembly (see page HB-88). (b) Remove the battery cover (see page HB-88). (c) Check that the nuts of the junction block are tightened to the specified torque. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NG TIGHTEN NUTS TO SPECIFIED TORQUE A081782E01 OK 4 CHECK NO. 2 FRAME WIRE (BUSBAR MODULE) CAUTION: Wear insulated gloves and goggles before performing the following operation. HB HB–74 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (a) Check that the nuts of the No. 2 frame wire are tightened to the specified torque. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NG TIGHTEN NUTS TO SPECIFIED TORQUE A081783E01 OK 5 CHECK CONNECTION OF NO. 2 FRAME WIRE CONNECTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Check the connection condition of the B12 battery ECU connector. OK: Connector has been connected securely and there is no poor connection. B12 NG CONNECT SECURELY Battery ECU A093174E02 OK HB 6 INSPECT NO. 2 FRAME WIRE (BUSBAR MODULE) #1 #3 #2 #5 #4 #7 #9 #6 #11 #13 #14 #15 #8 #10 #12 B12 Battery ECU CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the No. 2 frame wire (see page HB-108). (b) Measure the resistance of each connector and the metal portions of the No. 2 frame wire. Standard resistance Tester Connection Specified Condition B12-22 (GBB0) - #1 Below 1 Ω B12-11 (VBB1) - #2 Below 1 Ω B12-21 (VBB2) - #3 Below 1 Ω B12-10 (VBB3) - #4 Below 1 Ω B12-20 (VBB4) - #5 Below 1 Ω B12-9 (VBB5) - #6 Below 1 Ω B12-19 (VBB6) - #7 Below 1 Ω B12-8 (VBB7) - #8 Below 1 Ω B12-18 (VBB8) - #9 Below 1 Ω B12-7 (VBB9) - #10 Below 1 Ω B12-17 (VBB10) - #11 Below 1 Ω A090457E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Tester Connection Specified Condition B12-6 (VBB11) - #12 Below 1 Ω B12-16 (VBB12) - #13 Below 1 Ω B12-5 (VBB13) - #14 Below 1 Ω B12-15 (VBB14) - #15 Below 1 Ω HB–75 (c) Reinstall the No. 2 frame wire. NG REPLACE NO. 2 FRAME WIRE OK REPLACE BATTERY ECU HB HB–76 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P3011 Battery Block 1 Becomes Weak DTC P3012 Battery Block 2 Becomes Weak DTC P3013 Battery Block 3 Becomes Weak DTC P3014 Battery Block 4 Becomes Weak DTC P3015 Battery Block 5 Becomes Weak DTC P3016 Battery Block 6 Becomes Weak DTC P3017 Battery Block 7 Becomes Weak DTC P3018 Battery Block 8 Becomes Weak DTC P3019 Battery Block 9 Becomes Weak DTC P3020 Battery Block 10 Becomes Weak DTC P3021 Battery Block 11 Becomes Weak DTC P3022 Battery Block 12 Becomes Weak DTC P3023 Battery Block 13 Becomes Weak DTC P3024 Battery Block 14 Becomes Weak DESCRIPTION Refer to DTC P0A80 (see page HB-35). DTC No. DTC Detection Condition Trouble Area P3011 P3012 P3013 P3014 P3015 P3016 P3017 P3018 P3019 P3020 P3021 P3022 P3023 P3024 Presence of a malfunctioning block is determined based on the voltages from the battery blocks (1 trip detection logic) • • HV battery assembly Battery ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–77 MONITOR DESCRIPTION If there is an abnormal internal resistance or electromotive voltage in the battery blocks, the battery ECU determines that a malfunction has occurred. When the malfunction detection condition is satisfied, the battery ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P3011 to P3024: HV battery/Rationality Required sensors/components HV battery Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS HV battery Abnormal COMPONENT OPERATING RANGE HV battery DTCs P3011 to P3024 are not detected WIRING DIAGRAM Refer to DTC P0AFA (see page HB-68). INSPECTION PROCEDURE 1 HB READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK BATTERY BLOCK VOLTAGE (a) Depress the brake pedal and turn the power switch ON (IG). (b) Depress the brake pedal and accelerator pedal to charge with the HV battery. HB–78 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (c) Read the battery block voltage in the DATA LIST. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DATA LIST. Read the values of "V1 BATT BLOCK" to "V14 BATT BLOCK". (d) Compare the voltages as listed below. • V1 BATT BLOCK and V2 BATT BLOCK • V3 BATT BLOCK and V4 BATT BLOCK • V5 BATT BLOCK and V6 BATT BLOCK • V7 BATT BLOCK and V8 BATT BLOCK • V9 BATT BLOCK and V10 BATT BLOCK • V11 BATT BLOCK and V12 BATT BLOCK • V13 BATT BLOCK and V14 BATT BLOCK Result: All of the battery voltage differences are 0.3 V or more. YES NO REPLACE HV SUPPLY BATTERY ASSEMBLY HB REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC U0100 Lost Communication with ECM/PCM "A" DTC U0293 Lost Communication with HV ECU HB–79 DESCRIPTION The battery ECU receives signals from the hybrid vehicle control ECU, ECM, and gateway ECU via CAN (Controller Area Network) communication. DTC No. DTC Detection Condition Trouble Area U0100 CAN communication malfunction (no signal reception) with ECM CAN communication system U0293 CAN communication malfunction (no signal reception) with hybrid vehicle control ECU CAN communication system MONITOR DESCRIPTION If the battery ECU detects malfunction in the CAN communication with the ECM or hybrid vehicle control ECU, it illuminates the MIL and sets a DTC. MONITOR STRATEGY U0100: Related DTCs U0100: Communication between ECM and battery ECU/Non-received check Required sensors/components Main: ECM Sub: CAN bus line Frequency of operation Continuous Duration 0.68 seconds or more MIL operation Immediate or 1 driving cycle Sequence of operation None U0293: Related DTCs U0293: Communication between hybrid vehicle control and battery ECU/Non-received check Required sensors/components Main: Hybrid vehicle control ECU Sub: CAN bus line Frequency of operation Continuous Duration 0.68 seconds or more MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Receiving data No reception COMPONENT OPERATING RANGE ECM DTC U0100 is not detected Hybrid vehicle control ECU DTC U0293 is not detected HB HB–80 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECTION PROCEDURE 1 READ DTC OUTPUT (CODES ALL) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (ALL). (d) Read and record DTCs. HINT: When DTCs other than CAN communication malfunction DTCs are output simultaneously, first correct the CAN communication problem, and then perform troubleshooting for other DTCs. NEXT GO TO CAN COMMUNICATION SYSTEM HB P112 HYBRID BATTERY CONTROL – HV BATTERY HB–81 DECK TRIM SIDE PANEL RH LUGGAGE HOLD BELT STRIKER REAR NO. 4 FLOOR BOARD REAR SIDE SEAT BACK FRAME RH DECK FLOOR BOX LH HB DECK TRIM SIDE PANEL LH REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER A124454E01 HB–82 P112 HYBRID BATTERY CONTROL – HV BATTERY NO. 2 QUARTER VENT DUCT INNER NO. 1 BATTERY BLOWER RELAY 28 (286, 21) BATTERY BRACKET REINFORCEMENT 28 (286, 21) 28 (286, 21) 28 (286, 21) CONNECTOR 4.0 (41, 35 in.*lbf) BATTERY CARRIER BRACKET HB 28 (286, 21) QUARTER VENT DUCT 28 (286, 21) N*m (kgf*cm, ft.*lbf) : Specified torque A124455E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–83 7.5 (76, 66 in.*lbf) NO. 6 BATTERY CARRIER PANEL JUNCTION TERMINAL 7.5 (76, 66 in.*lbf) 19 (194, 14) HV BATTERY ASSEMBLY 19 (194, 14) WIRE HARNESS 19 (194, 14) 5.6 (57, 50 in.*lbf) FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124456E01 HB HB–84 P112 HYBRID BATTERY CONTROL – HV BATTERY NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) MAIN BATTERY CABLE 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) TERMINAL COVER NO. 1 WIRE HARNESS PROTECTOR COVER TERMINAL COVER 5.6 (57, 50 in.*lbf) 5.6 (57, 50 in.*lbf) HB 5.4 (55, 48 in.*lbf) NO. 3 WIRE HARNESS PROTECTOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque NO. 2 MAIN BATTERY CABLE 5.4 (55, 48 in.*lbf) NO. 3 BATTERY CARRIER CUSHION Non-reusable part A124457E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–85 BATTERY CLAMP PAD NO. 4 WIRE HARNESS PROTECTOR COVER NO. 2 WIRE HARNESS PROTECTOR COVER NO. 1 WIRE HARNESS PROTECTOR COVER 5.4 (55, 48 in.*lbf) JUNCTION BLOCK 5.4 (55, 48 in.*lbf) 5.4 (55, 48 in.*lbf) JUNCTION BLOCK 5.4 (55, 48 in.*lbf) 1.4 (14, 12 in.*lbf) BATTERY CURRENT SENSOR SERVICE PLUG N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124458E01 HB HB–86 P112 HYBRID BATTERY CONTROL – HV BATTERY 3.4 (35, 30 in.*lbf) SYSTEM MAIN RESISTOR 3.4 (35, 30 in.*lbf) SYSTEM MAIN RELAY NO. 2 SYSTEM MAIN RELAY 3.4 (35, 30 in.*lbf) 3.4 (35, 30 in.*lbf) NO. 3 SYSTEM MAIN RELAY BATTERY ECU 3.3 (34, 29 in.*lbf) 3.4 (35, 30 in.*lbf) HB 5.5 (56, 49 in.*lbf) UPPER BATTERY CARRIER N*m (kgf*cm, ft.*lbf) : Specified torque A124459E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–87 BATTERY ROOM VENTILATION HOSE NO. 2 BATTERY SPACER HB x 26 5.4 (55, 48 in.*lbf) NO. 2 FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124460E01 HB–88 P112 HYBRID BATTERY CONTROL – HV BATTERY REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (a) Detach the 4 clips shown in the illustration, then remove the deck trim cover. HB Clip A083536E03 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–89 8. REMOVE TONNEAU COVER (a) Remove the tonneau cover from the vehicle. 9. REMOVE REAR SEAT CUSHION ASSEMBLY (a) Undo the 2 joints shown in the illustration, then remove the rear seat cushion. A083594E01 : Joint A083593E03 10. REMOVE REAR NO. 1 FLOOR BOARD (a) Remove the 2 bolts and luggage hold belt strikers. (b) Remove the 5 clips shown in the illustration and the rear floor board. : Clip A083543E03 11. REMOVE REAR SIDE SEAT BACK FRAME LH (a) Remove the bolt from the rear side seat back frame LH. (b) Undo the 3 joints, then remove the rear side seat back frame LH. : Joint A083540E04 12. REMOVE REAR SIDE SEAT BACK FRAME RH (a) Remove the bolt from the rear side seat back frame RH. (b) Undo the 4 joints, then remove the rear side seat back frame RH. : Joint A083539E03 HB HB–90 P112 HYBRID BATTERY CONTROL – HV BATTERY 13. REMOVE REAR NO. 4 FLOOR BOARD (a) While lifting up the rear floor board as shown in the illustration, undo the 2 joints and remove the rear floor board. : Joint A083542E03 14. REMOVE DECK FLOOR BOX LH (a) Remove the clip and deck floor box LH. 15. REMOVE DECK TRIM SIDE PANEL LH (a) Remove the bolt and luggage hold belt striker. Clip A083541E01 (b) Remove the 2 bolts from the deck trim side panel LH. (c) Remove the clip from the deck trim side panel LH. (d) Undo the 8 clips, then pull out a part of the weather strip and remove the deck trim side panel LH. (e) Disconnect the lighting connector. 16. REMOVE DECK TRIM SIDE PANEL RH (a) Remove the bolt and luggage hold belt striker. HB Clip A083537E03 (b) Remove the 2 bolts from the deck trim side panel RH. (c) Remove the clip from the deck trim side panel RH. (d) Undo the 7 clips, then pull out a part of the weather strip and remove the deck trim side panel RH. : Clip A083538E05 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–91 17. REMOVE BATTERY CARRIER BRACKET (a) Remove the 7 bolts and battery carrier bracket. A083527E01 No. 1 Battery Blower Relay 18. REMOVE NO. 2 QUARTER VENT DUCT INNER (a) Disconnect the clamp and No. 1 battery blower relay. (b) Remove the 2 clips. (c) Slide the vent duct to the battery side, then remove it. A083530E02 19. REMOVE BATTERY BRACKET REINFORCEMENT (a) Remove the 7 bolts and battery bracket reinforcement. A083528E01 20. REMOVE QUARTER VENT DUCT (a) Disconnect the connector. (b) Remove the clamp, then disconnect the wire harness. (c) Remove the bolt, clip and quarter vent duct. Bolt : Clamp Clip A083604E03 21. REMOVE NO. 6 BATTERY CARRIER PANEL (a) Remove the 3 bolts, 2 nuts and battery carrier panel. A083532E01 HB HB–92 P112 HYBRID BATTERY CONTROL – HV BATTERY 22. REMOVE JUNCTION TERMINAL CAUTION: Wear insulating gloves. A083531E01 23. REMOVE FRAME WIRE CAUTION: • Wear insulating gloves. • Insulate the removed terminals with insulating tape. (a) Remove the 2 nuts, then disconnect the frame wire from the No. 2 and No. 3 system main relay. A083533E03 24. REMOVE HV BATTERY ASSEMBLY (a) Remove the earth bolt and 4 bolts shown in the illustration. Earth Bolt A083534E02 HB System Main Relay Connector Battery ECU Connector Interlock Connector : Clamp A083535E06 (b) Disconnect the system main relay connector. CAUTION: Wear insulating gloves. (c) Disconnect the interlock connector. CAUTION: Wear insulating gloves. (d) Remove the clamp, then disconnect the battery ECU connector. CAUTION: Wear insulating gloves. (e) Disconnect the battery room ventilation hose from the floor panel. CAUTION: Wear insulating gloves. (f) Remove the HV battery. CAUTION: Wear insulating gloves. A083548E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–93 DISASSEMBLY 1. REMOVE BATTERY COVER (a) Remove the protector shown in the illustration. (b) Remove the 6 bolts, 2 nuts, clip, battery cover and battery carrier catch bracket. A083610E01 Clip Battery Cover No. 1 Battery Carrier Catch Bracket A083611E01 2. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-102) 3. REMOVE NO. 3 WIRE HARNESS PROTECTOR COVER (See page HB-102) 4. REMOVE NO. 3 BATTERY CARRIER CUSHION (See page HB-103) 5. REMOVE MAIN BATTERY CABLE (See page HB-103) 6. REMOVE NO. 2 MAIN BATTERY CABLE (See page HB-103) 7. REMOVE BATTERY CURRENT SENSOR (See page HB-142) 8. REMOVE NO. 2 WIRE HARNESS PROTECTOR COVER (See page HB-116) 9. REMOVE NO. 4 WIRE HARNESS PROTECTOR COVER (See page HB-116) 10. REMOVE BATTERY CLAMP PAD (See page HB-112) 11. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-113) 12. REMOVE BATTERY PLUG (See page HB-113) 13. REMOVE JUNCTION BLOCK (See page HB-117) 14. REMOVE NO. 2 SYSTEM MAIN RELAY (See page HB123) 15. REMOVE NO. 3 SYSTEM MAIN RELAY (See page HB124) 16. REMOVE SYSTEM MAIN RESISTOR (See page HB136) HB HB–94 P112 HYBRID BATTERY CONTROL – HV BATTERY 17. REMOVE NO. 1 SYSTEM MAIN RELAY (See page HB124) 18. REMOVE BATTERY ECU (See page HB-149) 19. REMOVE UPPER BATTERY CARRIER CAUTION: Wear insulating gloves. (a) Remove the 3 nuts and upper battery carrier. 20. REMOVE NO. 2 BATTERY SPACER CAUTION: Wear insulating gloves. 21. REMOVE NO. 2 FRAME WIRE (See page HB-109) A077549E01 22. REMOVE BATTERY ROOM VENTILATION HOSE CAUTION: Wear insulating gloves. A077535E01 REASSEMBLY HB 1. INSTALL BATTERY ROOM VENTILATION HOSE CAUTION: Wear insulating gloves and protective glasses. 2. INSTALL NO. 2 FRAME WIRE (See page HB-109) 3. INSTALL NO. 2 BATTERY SPACER CAUTION: Wear insulating gloves and protective glasses. 4. INSTALL UPPER BATTERY CARRIER CAUTION: Wear insulating gloves and protective glasses. (a) Install the upper battery carrier with the 3 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 5. INSTALL BATTERY ECU (See page HB-149) 6. INSTALL NO. 1 SYSTEM MAIN RELAY (See page HB127) 7. INSTALL SYSTEM MAIN RESISTOR (See page HB136) 8. INSTALL NO. 3 SYSTEM MAIN RELAY (See page HB127) 9. INSTALL NO. 2 SYSTEM MAIN RELAY (See page HB127) A077535E01 A077549E01 10. INSPECT CONTACT CONDITION (See page HB-128) P112 HYBRID BATTERY CONTROL – HV BATTERY HB–95 11. INSTALL JUNCTION BLOCK (See page HB-117) 12. INSTALL BATTERY PLUG (See page HB-114) 13. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-114) 14. INSTALL BATTERY CLAMP PAD (See page HB-114) 15. INSTALL NO. 4 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 16. INSTALL NO. 2 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 17. INSTALL BATTERY CURRENT SENSOR (See page HB-143) 18. INSTALL NO. 2 MAIN BATTERY CABLE (See page HB-104) 19. INSTALL MAIN BATTERY CABLE (See page HB-104) 20. INSTALL NO. 3 BATTERY CARRIER CUSHION (See page HB-105) 21. INSTALL NO. 3 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 22. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. HB 23. INSTALL BATTERY COVER CAUTION: Wear insulating gloves. (a) Temporarily fasten the battery carrier catch bracket to the battery room ventilation hose. (b) Install the battery cover with the 6 bolts, 2 nuts and clip. Battery Cover Clip No. 1 Battery Carrier Catch Bracket A083611E01 Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Install the protector on the battery cover. HB–96 P112 HYBRID BATTERY CONTROL – HV BATTERY INSTALLATION Earth Bolt 1. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery with the earth bolt and 4 bolts. Torque: 19 N*m (194 kgf*cm, 14 in.*lbf) A083534E02 System Main Relay Connector (b) Connect the system main relay connector. CAUTION: Wear insulating gloves. (c) Connect the interlock connector. CAUTION: Wear insulating gloves. (d) Connect the battery ECU connector. CAUTION: Wear insulating gloves. Battery ECU Connector Interlock Connector : Clamp A083535E06 (e) Connect the battery room ventilation hose to the floor panel. A083548E01 HB 2. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Install the frame wire on the No. 2 and No. 3 system main relay with 2 new nuts. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (b) Connect the 2 clamps, then install the frame wire to the upper battery carrier. 3. INSTALL JUNCTION TERMINAL CAUTION: Wear insulating gloves. A083533E03 A083531E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–97 4. INSTALL NO. 6 BATTERY CARRIER PANEL (a) Install the battery carrier panel with the bolt and 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 5. INSTALL QUARTER VENT DUCT NOTICE: Ensure that the duct is installed securely. (a) Install the quarter vent duct with the bolt and clip. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (b) Connect the connector. (c) Install the clamp. 6. INSTALL BATTERY BRACKET REINFORCEMENT (a) Install the battery bracket reinforcement with the 7 bolts. Torque: 28 N*m (286 kgf*cm, 21 in.*lbf) 7. INSTALL NO. 2 QUARTER VENT DUCT INNER (a) Insert the quarter vent duct inner until it touches the backside of the HV battery. (b) Slide the fitting surface of the quarter vent duct inner downward, then attach it to the battery blower assembly. NOTICE: Ensure that the duct is installed securely. (c) Install the 2 clips on the vent duct. (d) Install the battery blower relay. 8. INSTALL BATTERY CARRIER BRACKET (a) Install the battery carrier bracket with the 7 bolts. Torque: 28 N*m (286 kgf*cm, 21 in.*lbf) A083532E01 Bolt : Clamp Clip A083604E04 A083528E01 No. 1 Battery Blower Relay A083530E02 A083527E01 HB HB–98 P112 HYBRID BATTERY CONTROL – HV BATTERY 9. INSTALL DECK TRIM SIDE PANEL RH (a) Install the deck trim side panel with the 7 clips and 2 bolts, and then install the part of the weather strip. (b) Install the luggage hold belt striker with the bolt. 10. INSTALL DECK TRIM SIDE PANEL LH (a) Connect the lighting connector. : Clip A083538E05 (b) Install the deck trim side panel with the 8 clips and 2 bolts, and then install the part of the weather strip. (c) Install the luggage hold belt striker with the bolt. Clip A083537E03 HB 11. INSTALL DECK FLOOR BOX LH (a) Install the deck floor box with the clip. Clip A083541E01 12. INSTALL REAR NO. 4 FLOOR BOARD : Joint A083542E04 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–99 13. INSTALL REAR SIDE SEAT BACK FRAME RH (a) Install the seat back frame with the bolt. : Joint A083539E03 14. INSTALL REAR SIDE SEAT BACK FRAME LH (a) Install the seat back frame with the bolt. : Joint A083540E04 15. INSTALL REAR NO. 1 FLOOR BOARD (a) Install the floor board. (b) Install the 2 luggage strikers with the 2 bolts. : Clip A083543E03 16. INSTALL REAR SEAT CUSHION ASSEMBLY : Joint A083593E03 17. INSTALL TONNEAU COVER A083594E01 HB HB–100 P112 HYBRID BATTERY CONTROL – HV BATTERY 18. INSTALL REAR DECK TRIM COVER 19. INSTALL SERVICE PLUG GRIP (See page HB-154) 20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 21. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) Clip A083536E03 22. INSTALL REAR DECK FLOOR BOX (See page CH-8) 23. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 24. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–101 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE MAIN BATTERY CABLE HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO.1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) MAIN BATTERY CABLE 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) NO. 1 WIRE HARNESS PROTECTOR COVER TERMINAL COVER TERMINAL COVER 5.6 (57, 50 in.*lbf) HB 5.6 (57, 50 in.*lbf) 5.4 (55, 48 in.*lbf) NO. 2 MAIN BATTERY CABLE NO. 3 WIRE HARNESS PROTECTOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 5.4 (55, 48 in.*lbf) NO. 3 BATTERY CARRIER CUSHION A131339E01 HB–102 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. HB No. 1 Wire Harness Protector Cover 10. REMOVE NO. 3 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. No. 3 Wire Harness Protector Cover A083582E02 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE HB–103 11. REMOVE NO. 3 BATTERY CARRIER CUSHION CAUTION: Wear insulating gloves. (a) Peel off the bonded parts, then remove the battery carrier cushion. Bonded Parts A077542E01 12. REMOVE MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Remove the terminal cover shown in the illustration. Terminal Cover A125183E01 (b) Remove the nut, then disconnect the aluminum shield wire. (c) Remove the nut, then disconnect the main battery cable from the No. 3 system main relay. (d) Remove the nut, then disconnect the main battery cable from the No. 2 frame wire. (e) Remove the main battery cable from the HV battery. Aluminum Shield Wire HB Main Battery Cable A083551E01 13. REMOVE NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Remove the terminal cover shown in the illustration. Terminal Cover A083580E01 HB–104 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE (b) Remove the nut, then disconnect the system main relay terminal and No. 2 main battery cable from the No. 2 system main relay. (c) Remove the nut, then disconnect the No. 2 main battery cable from the frame wire. (d) Remove the No. 2 main battery cable from the HV battery. No. 2 Main Battery Cable System Main Relay Terminal A083566E02 INSTALLATION No. 2 Main Battery Cable 1. System Main Relay Terminal A083566E02 INSTALL NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Temporarily install the No. 2 main battery cable to the HV battery. (b) Install the No. 2 main battery cable to the No. 2 frame wire with a new nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (c) Temporarily install the main battery cable and system main relay terminal, in that order, to the No. 2 system main relay, then tighten the new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (d) Install the terminal cover shown in the illustration. HB Terminal Cover A083580E01 2. Aluminum Shield Wire Main Battery Cable A083551E01 INSTALL MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Temporarily install the main battery cable to the HV battery. (b) Install the main battery cable to the No. 2 frame wire with a new nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (c) Install the main battery cable to the No. 3 system main relay with a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (d) Install the aluminum shield wire with a new nut. Torque: 3.3 N*m (34 kgf*cm, 29 in.*lbf) P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE HB–105 (e) Install the terminal cover shown in the illustration. Terminal Cover A083579E01 3. INSTALL NO. 3 BATTERY CARRIER CUSHION CAUTION: Wear insulating gloves. (a) Degrease and clean the installation surface of the battery carrier cushion. (b) Install a new battery carrier cushion. 4. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 5. INSTALL NO. 3 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 6. INSTALL BATTERY COVER (See page HB-95) 7. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 8. INSTALL SERVICE PLUG GRIP (See page HB-114) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) Bonded Parts A077542E01 No. 1 Wire Harness Protector Cover No. 3 Wire Harness Protector Cover A083582E02 10. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 11. INSTALL REAR DECK FLOOR BOX (See page CH-8) 12. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 13. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–106 P112 HYBRID BATTERY CONTROL – FRAME WIRE FRAME WIRE HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) MAIN BATTERY CABLE 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) NO. 1 WIRE HARNESS PROTECTOR COVER HB TERMINAL COVER TERMINAL COVER 5.6 (57, 50 in.*lbf) 5.6 (57, 50 in.*lbf) 5.4 (55, 48 in.*lbf) NO. 2 MAIN BATTERY CABLE NO. 3 WIRE HARNESS PROTECTOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 5.4 (55, 48 in.*lbf) NO. 3 BATTERY CARRIER CUSHION A131339E02 P112 HYBRID BATTERY CONTROL – FRAME WIRE HB–107 NO. 2 FRAME WIRE 5.4 (55, 48 in.*lbf) HB x 26 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131340E01 HB–108 P112 HYBRID BATTERY CONTROL – FRAME WIRE REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-102) HB 10. REMOVE NO. 3 WIRE HARNESS PROTECTOR COVER (See page HB-102) 11. REMOVE NO. 3 BATTERY CARRIER CUSHION (See page HB-103) 12. REMOVE MAIN BATTERY CABLE (See page HB-103) 13. REMOVE NO. 2 MAIN BATTERY CABLE (See page HB-103) P112 HYBRID BATTERY CONTROL – FRAME WIRE HB–109 14. REMOVE NO. 2 FRAME WIRE CAUTION: Wear insulating gloves. (a) Disconnect the temperature sensor connector from the battery ECU. (b) Remove the clamp, then disconnect the No. 2 frame wire connector from the battery ECU. Clamp A077536E01 (c) Remove the 26 nuts and No. 2 frame wire. A089187E01 INSTALLATION 1. INSTALL NO. 2 FRAME WIRE CAUTION: Wear insulating gloves. (a) Install the No. 2 frame wire with new 26 nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A089187E01 (b) Connect the No. 2 frame wire connector to the battery ECU, then connect the clamp. (c) Connect the temperature sensor connector to the battery ECU. Clamp 2. INSTALL NO. 2 MAIN BATTERY CABLE (See page HB-104) 3. INSTALL MAIN BATTERY CABLE (See page HB-104) 4. INSTALL NO. 3 BATTERY CARRIER CUSHION (See page HB-105) 5. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-105) 6. INSTALL NO. 3 WIRE HARNESS PROTECTOR COVER (See page HB-105) 7. INSTALL BATTERY COVER (See page HB-95) 8. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 9. INSTALL SERVICE PLUG GRIP (See page HB-154) A077536E02 HB HB–110 P112 HYBRID BATTERY CONTROL – FRAME WIRE 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 11. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 12. INSTALL REAR DECK FLOOR BOX (See page CH-8) 13. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–111 P112 HYBRID BATTERY CONTROL – BATTERY PLUG BATTERY PLUG HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) 5.4 (55, 48 in.*lbf) NO. 4 WIRE HARNESS PROTECTOR COVER BATTERY CLAMP PAD NO. 1 WIRE HARNESS PROTECTOR COVER SERVICE PLUG GRIP 5.4 (55, 48 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131341E01 HB HB–112 P112 HYBRID BATTERY CONTROL – BATTERY PLUG REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE BATTERY CLAMP PAD CAUTION: Wear insulating gloves. (a) Peel off the bonded parts, then remove the battery clamp pad (the battery carrier cushion). HB Bonded Parts A077541E01 P112 HYBRID BATTERY CONTROL – BATTERY PLUG HB–113 10. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (a) Open the wire harness protector cover. (b) Remove the 2 nuts, then disconnect the service plug. (c) Remove the wire harness protector cover. No. 4 Wire Harness Protector Cover A077550E02 Connector Clamp 11. REMOVE BATTERY PLUG (a) Disconnect the connector clamp. (b) Remove the 2 bolts, then disconnect the service plug from the upper battery carrier. A077543E01 (c) Open the wire harness protector cover as shown in the illustration. Then remove the service plug from the junction block. HB Junction Block Wire Harness Protector Cover A077544E03 INSPECTION 1. A092566E01 INSPECT BATTERY PLUG (a) Check the resistance. (1) Measure the resistance between the terminals. Standard resistance: 10 kΩ or higher If the result is not as specified, replace the battery plug. HB–114 P112 HYBRID BATTERY CONTROL – BATTERY PLUG (2) Install the service plug grip to the socket. (3) Measure the resistance between the terminals. Standard resistance: Below 1 Ω If the result is not as specified, replace the battery plug. Service Plug Grip Socket A092575E01 INSTALLATION 1. INSTALL BATTERY PLUG (a) Temporarily fasten the service plug. (b) Install the service plug to the upper battery carrier with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (c) Assemble the connector clamp. 2. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER (a) Temporarily fasten the wire harness protector cover to the service plug. (b) Install the wiring harness protector cover through the service plug with 2 new nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL BATTERY CLAMP PAD CAUTION: Wear insulating gloves. (a) Install a new clamp pad (the battery carrier cushion). 4. INSTALL BATTERY COVER (See page HB-95) 5. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 6. INSTALL SERVICE PLUG GRIP (See page HB-154) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 8. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 9. INSTALL REAR DECK FLOOR BOX (See page CH-8) Connector Clamp A077543E01 HB Bonded Parts A077541E01 10. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB–115 P112 HYBRID BATTERY CONTROL – JUNCTION BLOCK JUNCTION BLOCK HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) HB NO. 2 WIRE HARNESS PROTECTOR COVER 5.4 (55, 48 in.*lbf) x 26 NO. 4 WRE HARNESS PROTECTOR COVER JUNCTION BLOCK 5.4 (55, 48 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131342E01 HB–116 P112 HYBRID BATTERY CONTROL – JUNCTION BLOCK REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE NO. 2 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. HB No. 4 Wire Harness Protector Cover No. 2 Wire Harness Protector Cover A083565E02 10. REMOVE NO. 4 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. P112 HYBRID BATTERY CONTROL – JUNCTION BLOCK HB–117 11. REMOVE JUNCTION BLOCK CAUTION: Wear insulating gloves. (a) Remove the 26 nuts and junction block. A083549E01 INSTALLATION 1. INSTALL JUNCTION BLOCK CAUTION: Wear insulating gloves. (a) Install the junction block assembly with 26 new nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 2. INSTALL NO. 2 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 3. INSTALL NO. 4 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 4. INSTALL BATTERY COVER (See page HB-95) 5. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 6. INSTALL SERVICE PLUG GRIP (See page HB-154) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 8. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 9. INSTALL REAR DECK FLOOR BOX (See page CH-8) A083549E01 No. 4 Wire Harness Protector Cover No. 2 Wire Harness Protector Cover A083565E02 10. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–118 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY SYSTEM MAIN RELAY HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E10 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–119 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E04 HB–120 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY REAR NO. 4 FLOOR BOARD 28 (286, 21) 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET DECK FLOOR BOX LH DECK TRIM SIDE PANEL LH HB REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER N*m (kgf*cm, ft.*lbf) : Specified torque A131403E01 HB–121 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY 7.5 (76, 66 in.*lbf) NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL 5.6 (57, 50 in.*lbf) 3.4 (35, 30 in.*lbf) NO. 1 SYSTEM MAIN RELAY SYSTEM MAIN RESISTOR WIRE HARNESS NO. 2 SYSTEM MAIN RELAY 3.4 (35, 30 in.*lbf) 3.4 (35, 30 in.*lbf) 3.4 (35, 30 in.*lbf) 5.6 (57, 50 in.*lbf) 3.4 (35, 30 in.*lbf) FRAME WIRE NO. 3 SYSTEM MAIN RELAY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131343E01 HB HB–122 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77 ). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH8) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) HB 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–123 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE JUNCTION TERMINAL (See page HB-92) 18. SEPARATE FRAME WIRE (See page HB-92) 19. REMOVE NO. 2 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Remove the 2 terminal covers. Terminal Covers A083581E01 (b) Remove the nut, then disconnect the system main battery relay terminal and main battery cable. Main Battery Cable System Main Battery Relay Terminal HB A077540E03 (c) Disconnect the connector. (d) Remove the 2 nuts and No. 2 system main relay. Connector A077539E01 HB–124 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY 20. REMOVE NO. 3 SYSTEM MAIN RELAY NOTICE: Wear insulating gloves. (a) Remove the nut, then disconnect the main battery cable. (b) Remove the 2 nuts, then disconnect the No. 3 system main relay. (c) Disconnect the connector and remove the No. 3 system main relay. Main Battery Cable Connector A077538E01 21. REMOVE NO. 1 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Disconnect the connector. (b) Remove the nut, then disconnect the ground terminal. (c) Disconnect the 2 clamps. (d) Remove the system main relay connector. (e) Remove the 2 bolts and No. 1 system main relay. Clamp Ground Terminal System Main Relay Connector No. 1 System Main Relay A092580E01 HB HB–125 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY INSPECTION 1. INSPECT NO. 1 SYSTEM MAIN RELAY NOTICE: Connectors B and C have the same shape. Identify each connector by the wire harness length (L) and the wire harness color on the terminal 2 side. Connector Wire Harness Length (L) Wire Harness Color B Short Yellow C Long Black Positive Terminal GND CONT2 2 1 L Connetor B Negative Terminal CONT1 L 2 1 CONT3 2 1 4 3 GND Terminal Connector C CONT2 CONT3 Connector A GND A131261E01 (a) Check the resistance. (1) Measure the resistance between the connectors. Standard resistance Tester Connection Specified Condition Positive terminal - Negative terminal 10 kΩ or higher A-2 (CONT2) - B-2 (CONT2) Below 1 Ω A-3 (CONT3) - C-2 (CONT3) Below 1 Ω B-1 (GND) - GND Below 1 Ω C-1 (GND) - GND Below 1 Ω If the results are not as specified, replace the No. 1 system main relay. HB HB–126 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY (2) Apply battery voltage between the GND terminal and CONT1 terminal of the connector A, then measure the resistance between the positive and negative terminals. Standard resistance: Below 1 Ω If the results are not as specified, replace the No. 1 system main relay. (b) Inspect the resistance. (1) Measure the resistance between the GND terminal and CONT1 terminal of the connector A. Standard resistance: 70 to 160 kΩ If the the results are not as specified, replace the No. 1 system main relay. Negative Terminal Positive Terminal 2. INSPECT NO. 2 SYSTEM MAIN RELAY (a) Install the 2 installed nuts to the negative and positive terminals. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (b) Check the resistance. (1) Measure the resistance between the positive and negative terminals. Standard resistance: 10 kΩ or higher If the result is not as specified, replace the No. 2 system main relay. (2) Apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals. Standard resistance: Below 1 Ω If the result is not as specified, replace the No. 2 system main relay. (c) Inspect the resistance. (1) Measure the resistance between the connector terminals. Standard resistance: 20 to 50 kΩ If the result is not as specified, replace the No. 2 system main relay. 3. INSPECT NO. 3 SYSTEM MAIN RELAY (a) Install the 2 installed nuts to the negative and positive terminals. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (b) Check the resistance. (1) Measure the resistance between the positive and negative terminals. Standard resistance: 10 kΩ or higher If the result is not as specified, replace the No. 3 system main relay. A077579E01 HB Negative Terminal Positive Terminal A077579E01 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–127 (2) Apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals. Standard resistance: Below 1 Ω If the result is not as specified, replace the No. 3 system main relay. (c) Inspect the resistance. (1) Measure the resistance between the connector terminals. Standard resistance: 20 to 50 kΩ If the result is not as specified, replace the No. 3 system main relay. HB HB–128 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY INSTALLATION 1. INSTALL NO. 1 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Install the No. 1 system main relay with the 2 bolts. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (b) Connect the system main relay connector. Ground Terminal Clamp System Main Relay Connector No. 1 System Main Relay A092580E01 (c) Connect the 2 clamps, then install the system main relay sub wiring harness to the upper battery carrier. (d) Install the ground terminal with the nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (e) Install the connector. Main Battery Cable HB 2. INSTALL NO. 3 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Connect the connector, then temporarily install the No. 3 system main relay. (b) Install the No. 3 system main relay with 2 new nuts. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (c) Install the main battery cable with the nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 3. INSTALL NO. 2 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Install the No. 2 system main relay with the 2 nuts. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (b) Connect the connector. Connector A077538E01 Connector A077539E01 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–129 (c) Temporarily install the system main relay terminal and No. 2 main battery cable terminal, in that order, and tighten a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (d) Install the 2 terminal covers. Main Battery Cable 4. System Main Battery Relay Terminal INSPECT CONTACT CONDITION CAUTION: Wear insulating gloves. (a) Check that all the wire harnesses are correctly and securely connected on the upper battery carrier. A077540E03 System Main Resistor No. 1 System Main Relay Aluminum Shield Wire Clamp No. 2 Main Battery Cable Main Battery Cable A093049E01 NOTICE: Make sure that the connectors and clamps are connected exactly the same as the illustration above. If any of them is different, correct it immediately. 5. INSTALL FRAME WIRE (See page HB-96) 6. INSTALL JUNCTION TERMINAL (See page HB-96) 7. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 8. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 9. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 10. INSTALL DECK FLOOR BOX LH (See page HB-98) 11. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) 12. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) HB HB–130 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY 13. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 14. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 15. INSTALL TONNEAU COVER (See page HB-99) 16. INSTALL REAR DECK TRIM COVER (See page HB99) 17. INSTALL SERVICE PLUG GRIP (See page HB-154) 18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 19. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 20. INSTALL REAR DECK FLOOR BOX (See page CH-8) 21. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 22. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–130 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER RELAY BATTERY BLOWER RELAY 3 5 1 2 ON-VEHICLE INSPECTION 1. 5 2 1 3 B060778E14 INSPECT BATTERY BLOWER RELAY (a) Measure the battery blower relay resistance. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. HB P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR HB–131 SYSTEM MAIN RESISTOR HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E11 HB–132 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E05 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR HB–133 REAR NO. 4 FLOOR BOARD 28 (286, 21) 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET DECK FLOOR BOX LH DECK TRIM SIDE PANEL LH HB REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER N*m (kgf*cm, ft.*lbf) : Specified torque A131403E02 HB–134 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR 7.5 (76, 66 in.*lbf) NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL 3.4 (35, 30 in.*lbf) HB SYSTEM MAIN RESISTOR 5.6 (57, 50 in.*lbf) FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131344E01 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR HB–135 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) HB HB–136 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE JUNCTION TERMINAL (See page HB-92) 18. DISCONNECT FRAME WIRE CAUTION: • Wear insulating gloves. • Insulate the removed terminals with insulating tape. (a) Remove the nut, then disconnect the frame wire from the No. 2 system main relay. No. 2 System Main Relay A088629E01 System Main Resistor 19. REMOVE SYSTEM MAIN RESISTOR CAUTION: Wear insulating gloves. (a) Disconnect the connector from the No. 1 system main relay. (b) Remove the bolt and system main resistor. No. 1 System Main Relay A083568E01 INSPECTION 1. HB INSPECT SYSTEM MAIN RESISTOR (a) Measure the resistance between the terminals. Standard resistance: 18 to 22 Ω If the result is not as specified, replace the system main resistor. A077581E01 System Main Resistor No. 1 System Main Relay A083568E01 INSTALLATION 1. INSTALL SYSTEM MAIN RESISTOR CAUTION: Wear insulating gloves. (a) Install the system main resistor with the bolt. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (b) Install the connector to the No. 1 system main relay. 2. INSPECT CONTACT CONDITION (See page HB-128) P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR No. 2 System Main Relay HB–137 3. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Temporarily install the system main resistor terminal and frame wire, in that order, and tighten a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 4. INSTALL JUNCTION TERMINAL (See page HB-96) 5. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 6. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 7. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 8. INSTALL DECK FLOOR BOX LH (See page HB-98) 9. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) A088629E01 10. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) 11. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 12. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 13. INSTALL TONNEAU COVER (See page HB-99) 14. INSTALL REAR DECK TRIM COVER (See page HB100) 15. INSTALL SERVICE PLUG GRIP (See page HB-154) 16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 17. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 18. INSTALL REAR DECK FLOOR BOX (See page CH-8) 19. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 20. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–138 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR BATTERY CURRENT SENSOR HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E12 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR HB–139 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E06 HB–140 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET 28 (286, 21) 28 (286, 21) 7.5 (76, 66 in.*lbf) REAR NO. 4 FLOOR BOARD NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) TERMINAL COVER DECK FLOOR BOX LH 5.6 (55, 71 in.*lbf) HB MAIN BATTERY CABLE DECK TRIM SIDE PANEL LH BATTERY CURRENT SENSOR CONNECTOR 1.4 (14, 12 in.*lbf) BATTERY CURRENT SENSOR REAR SIDE SEAT BACK FRAME LH N*m (kgf*cm, ft.*lbf) : Specified torque LUGGAGE HOLD BELT STRIKER Non-reusable part A131405E01 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR HB–141 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) HB HB–142 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE BATTERY CURRENT SENSOR CAUTION: Wear insulating gloves. (a) Remove the terminal cover. Terminal Cover A083579E01 (b) Remove the nut, then disconnect the main battery cable. A083638E01 (c) Disconnect the connector. (d) Remove the 2 screws and battery current sensor. HB Connector A083564E01 INSPECTION 1. INSPECT BATTERY CURRENT SENSOR (a) Inspect the resistance. (1) Measure the resistance between terminals 1 (VIB) and 2 (GIB). Standard resistance Tester Connection IB GIB VIB A077580E01 Resistance Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ If the the results are not as specified, replace the battery current sensor. P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR HB–143 (2) Measure the resistance between terminals 1 (VIB) and 3 (IB). Standard resistance Tester Connection Resistance Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 3.5 to 4.5 kΩ Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 5 to 7 kΩ If the results are not as specified, replace the battery current sensor. (3) Measure the resistance between terminals 2 (GIB) and 3 (IB). Standard resistance: 0.2 kΩ or less NOTICE: Even if the probes are changed around, the resistance will not vary. If the result is not as specified, replace the battery current sensor. INSTALLATION 1. Connector INSTALL BATTERY CURRENT SENSOR CAUTION: Wear insulating gloves. (a) Install the battery current sensor with the 2 screws. Torque: 1.4 N*m (14 kgf*cm, 12 in.*lbf) (b) Connect the connector. A083564E01 (c) Install the main battery cable with a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) A083638E01 (d) Install the terminal cover. 2. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 3. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 4. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 5. INSTALL DECK FLOOR BOX LH (See page HB-98) 6. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) Terminal Cover A083579E02 HB HB–144 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR 7. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) 8. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 10. INSTALL TONNEAU COVER (See page HB-99) 11. INSTALL REAR DECK TRIM COVER (See page HB100) 12. INSTALL SERVICE PLUG GRIP (See page HB-154) 13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 14. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 15. INSTALL REAR DECK FLOOR BOX (See page CH-8) 16. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 17. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–145 P112 HYBRID BATTERY CONTROL – BATTERY ECU BATTERY ECU HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E13 HB–146 P112 HYBRID BATTERY CONTROL – BATTERY ECU TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E07 P112 HYBRID BATTERY CONTROL – BATTERY ECU HB–147 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET 28 (286, 21) 28 (286, 21) 7.5 (76, 66 in.*lbf) REAR NO. 4 FLOOR BOARD NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL DECK FLOOR BOX LH 3.3 (34, 30 in.*lbf) HB BATTERY ECU BATTERY ECU CONNECTOR REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER N*m (kgf*cm, ft.*lbf) : Specified torque DECK TRIM SIDE PANEL LH Non-reusable part A131345E01 HB–148 P112 HYBRID BATTERY CONTROL – BATTERY ECU REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) HB 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) P112 HYBRID BATTERY CONTROL – BATTERY ECU HB–149 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE JUNCTION TERMINAL (See page HB-92) System Main Relay Connector Battery ECU Battery ECU Connector A083606E02 18. REMOVE BATTERY ECU CAUTION: Wear insulating gloves. (a) Disconnect the system main relay connector. CAUTION: Insulate the disconnected connectors with insulating tape. (b) Disconnect the battery ECU connector. CAUTION: Insulate the disconnected connectors with insulating tape. (c) Disconnect the thermistor connector. CAUTION: Insulate the disconnected connectors with insulating tape. (d) Remove the clamp, then disconnect the No. 2 frame wire connector. CAUTION: Insulate the disconnected connectors with insulating tape. (e) Remove the nut, then disconnect the aluminum shield wire of the main battery cable. Thermistor Connector No. 2 Frame Wire Connector HB Clamp Aluminum Shield Wire A083605E01 (f) Remove the 2 screws and battery ECU. HB–150 P112 HYBRID BATTERY CONTROL – BATTERY ECU INSTALLATION 1. INSTALL BATTERY ECU CAUTION: Wear insulating gloves. (a) Install the battery ECU with the 2 screws. Torque: 3.3 N*m (34 kgf*cm, 29 in.*lbf) Thermistor Connector No. 2 Frame Wire Connector Clamp Aluminum Shield Wire A083605E01 (b) Install the aluminum shield wire of the main battery cable together with the battery ECU with a new nut. Torque: 3.3 N*m (34 kgf*cm, 29 in.*lbf) (c) Connect the clamp and No. 2 frame wire connector. (d) Connect the thermistor connector. System Main Relay Connector Battery ECU Battery ECU Connector HB (e) Connect the system main relay connector. 2. INSTALL JUNCTION TERMINAL (See page HB-96) 3. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 4. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 5. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 6. INSTALL DECK FLOOR BOX LH (See page HB-98) 7. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) 8. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) 9. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) A083606E02 10. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 11. INSTALL TONNEAU COVER (See page HB-99) 12. INSTALL REAR DECK TRIM COVER (See page HB100) 13. INSTALL SERVICE PLUG GRIP (See page HB-154) 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 15. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) P112 HYBRID BATTERY CONTROL – BATTERY ECU HB–151 16. INSTALL REAR DECK FLOOR BOX (See page CH-8) 17. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 18. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–152 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP SERVICE PLUG GRIP HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E14 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP HB–153 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (a) As shown in the illustration, turn the knob to release the lock. (b) Remove the rear floor board No. 2. 3. REMOVE REAR DECK FLOOR BOX (a) Remove the deck floor box rear shown in the illustration. 4. REMOVE REAR NO. 3 FLOOR BOARD (a) Remove the rear floor board shown in the illustration. FREE FREE LOCK LOCK A083547E01 A083546E01 A083544E01 HB HB–154 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative terminal of the 12 V auxiliary battery. 6. REMOVE SERVICE PLUG GRIP CAUTION: Wear insulating gloves. (a) Slide up the lever of the service plug grip. Remove the service plug grip while turning the lever to the left. (b) Insulate the service plug with insulating tape. 7. REMOVE BATTERY POSITIVE TERMINAL (a) Remove the 2 joints shown in the illustration, then remove the service plug grip cover. A077567E01 Lever A083545E03 HB A092569E02 (b) Remove the 2 bolts and electric vehicle fuse. A092570E01 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP HB–155 INSTALLATION 1. INSTALL BATTERY POSITIVE TERMINAL (a) Install the electric vehicle fuse with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (b) Fit the 2 joints, then install the service plug grip cover. 2. INSTALL SERVICE PLUG GRIP CAUTION: Wear insulating gloves. (a) Joint the service plug grip with the HV battery. (b) While pushing the service plug grip to the right, rotate the lever to the right. (c) Slide the lever down to lock the service plug grip in place. NOTICE: • The service plug grip must be locked. If not, it may cause DTCs to output. • Do not operate the power switch when the service plug grip is not properly locked. It may damage the hybrid vehicle control ECU in rare cases. A089219 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 4. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 5. INSTALL REAR DECK FLOOR BOX (See page CH-8) 6. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–156 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER BATTERY BLOWER HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124443E09 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER HB–157 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER REAR NO. 1 FLOOR BOARD HB REAR SEAT CUSHION ASSEMBLY A124453E03 HB–158 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER VENTILATOR DUCT INNER 5.0 (51, 44 in.*lbf) BATTERY BLOWER 5.0 (51, 44 in.*lbf) NO. 2 QUARTER VENT DUCT INNER DECK TRIM SIDE PANEL RH HB LUGGAGE HOLD BELT STRIKER REAR SIDE SEAT BACK FRAME RH N*m (kgf*cm, ft.*lbf) : Specified torque A124464E01 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER ON-VEHICLE INSPECTION Intelligent Tester 1. CAN VIM DLC3 A087542E04 2 HB–159 INSPECT BATTERY BLOWER (a) Check the operation. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Select the item: DIAGNOSIS / OBD/MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1 to 6. NOTICE: If the check results are normal, do not perform the following check. (b) Inspect the resistance. (1) Remove the service plug grip (see page HB153). (2) Disconnect the connector of the battery blower motor. (3) Measure the resistance between terminals 1 and 2 of the connector. Standard resistance: 9 Ω or less If the result is not as specified, replace the battery blower assembly. 1 A090450E01 GND A077570E02 (c) Inspect the voltage. (1) Connect the connector of the blower motor. (2) Measure the resistance between terminal 1 (GND) of the blower motor control connector and body ground. Standard resistance: 1 Ω or less (3) Connect the negative terminal of the auxiliary battery. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) (4) Connect the intelligent tester to the DLC3. (5) Turn the power switch ON (IG). (6) Select the item: DIAGNOSIS / OBD/MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1. Intelligent Tester CAN VIM DLC3 A087542E04 HB HB–160 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER (7) Measure the voltage between terminals 1 (GND) of the blower motor connector and the body ground. Standard voltage: 9 to 14 V NOTICE: If there is no voltage, there may be a defect in the power supply system relays or in the wire harness. (8) Turn the power switch OFF, then disconnect the cable from the negative terminal of the auxiliary battery. (9) Disconnect the battery blower motor, battery blower motor control, and connector of the battery ECU. A088189E01 Battery ECU Battery Blower Motor Battery Blower Motor Control VM B9 VM B10 B11 A125181E02 HB (10) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B9-1 - B10-4 (VM) Below 1 Ω B9-1 - B11-9 (VM) Below 1 Ω B9-1 - Body ground 10 kΩ or higher NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. HB–161 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER (11) Measure the resistance of the wire harness side connectors. Battery ECU Holder Installed on No. 1 Battery Blower Relay FCTL1 B14 B11 A125182E02 Standard resistance Tester Connection Specified Condition B14-2 - B11-10 (FCTL1) Below 1 Ω B14-2 - Body ground 10 kΩ or higher NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. (12) Reconnect all the disconnected connectors. NOTICE: Do not connect the service plug grip. (13) Connect the intelligent tester to the DLC3. (14) Turn the power switch ON (IG). (15) Select the item: DIAGNOSIS / OBD/MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1. Intelligent Tester CAN VIM DLC3 A087542E04 SI GND A077572E01 (16) Measure the voltage between terminals 1 (GND) and 2 (SI) of the battery blower motor control. Standard voltage: 1 V or more NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. HB HB–162 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER (17) Measure the voltage between the terminals on the blower motor connector. Standard voltage: 2 to 4 V NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. A088189E01 VM GND A077572E02 HB (18) Measure the voltage between terminals 1 (GND) and 4 (VM) of the blower motor control. HINT: A = (Measured voltage between terminals 1 (GND) of the blower motor connector and the body ground.) Standard condition: A - 4 V to A - 2 V NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. (19) Recheck the blower motor operation by the intelligent tester, and perform the inspection again. P112 HYBRID BATTERY CONTROL – BATTERY BLOWER HB–163 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE REAR DECK TRIM COVER (See page HB88) 6. REMOVE TONNEAU COVER (See page HB-89) 7. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) 8. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 9. REMOVE REAR SIDE SEAT BACK FRAME RH (See page HB-89) 10. REMOVE DECK TRIM SIDE PANEL RH (See page HB90) 11. REMOVE NO. 2 QUARTER VENT DUCT INNER (See page HB-91) 12. REMOVE VENTILATOR DUCT INNER (a) Remove the 3 clips and ventilator duct inner. A083529E01 Connector Clamp A083526E01 13. REMOVE BATTERY BLOWER (a) Remove the 3 nuts, then disconnect the battery blower assembly from the vehicle. (b) Remove the connector, clamp and battery blower. HB HB–164 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER INSTALLATION Connector 1. INSTALL BATTERY BLOWER (a) Connect the connector to the battery blower. (b) Install the clamp on the battery blower. (c) Install the battery blower with the 3 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 2. INSTALL VENTILATOR DUCT INNER (a) Install the ventilator duct inner with the 3 clips. 3. INSTALL NO. 2 QUARTER VENT DUCT INNER (See page HB-97) 4. INSTALL DECK TRIM SIDE PANEL RH (See page HB98) 5. INSTALL REAR SIDE SEAT BACK FRAME RH (See page HB-99) 6. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 7. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 8. INSTALL TONNEAU COVER (See page HB-99) 9. INSTALL REAR DECK TRIM COVER (See page HB100) Clamp A083526E01 A083529E01 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) HB 11. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 12. INSTALL REAR DECK FLOOR BOX (See page CH-8) 13. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.