Toyota Avalon (XX50): Hybrid/EV Battery Discharge Control Malfunction (P300000). Hybrid/EV Battery Control System Circuit Voltage Below Threshold (P300016). High Voltage Power Resource Circuit Short during Pre-Charge (P300

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / Hybrid / Battery Control / Hybrid Control System / Hybrid/EV Battery Discharge Control Malfunction (P300000). Hybrid/EV Battery Control System Circuit Voltage Below Threshold (P300016). High Voltage Power Resource Circuit Short during Pre-Charge (P300

Hybrid/EV Battery Discharge Control Malfunction (P300000)

DESCRIPTION

The hybrid vehicle control ECU alerts the driver and performs fail-safe control based on error signals received from the battery voltage sensor. This DTC is stored when the SOC (state of charge) of the HV battery has dropped excessively as a result of leaving shift lever in N, running out of fuel, or a malfunction in the hybrid system.

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P300000

Hybrid/EV Battery Discharge Control Malfunction

Discharging prohibited

Discharging of the HV battery continues even after discharging is prohibited when the hybrid system is malfunctioning and "Hybrid Battery SOC" has reached the lower limit.

(1 trip detection logic)
  • SFI system
  • Fuel level
  • HV battery

Does not come on

Master Warning Light:

Does not come on
Related Data List

DTC No.

Data List

P300000
  • Hybrid Battery SOC
  • WOUT Control Limit Power
  • Hybrid Battery Current

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click here

  1. Connect the Techstream to the DLC3.
  2. Turn the power switch on (IG) and turn the Techstream on.
  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  4. Turn the power switch off and wait for 2 minutes or more.
  5. Turn the power switch on (IG) and turn the Techstream on.
  6. Turn the power switch on (READY) with shift lever in P and cause the "Hybrid Battery SOC" to decrease. Check that the engine is started to charge the HV battery, and the value of Data List item "Hybrid Battery SOC" increases and then remains within an appropriate range.
  7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
  8. Check the DTC judgment result.

    HINT:

    • If the judgment result shows NORMAL, the system is normal.
    • If the judgment result shows ABNORMAL, the system has a malfunction.
    • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

CAUTION / NOTICE / HINT

HINT:

  • If the vehicle is left with shift lever in N (parked or stopped) for a long time, the battery cannot be charged. In this case, the SOC may drop below the lower limit and DTC P300000 may be stored. (This is not a system malfunction.)
  • When the engine cannot be started, DTC P300000 may be stored because the HV battery cannot be charged.
  • Repeated engine start checks may cause the SOC to drop, resulting in DTC P300000 being stored. In this case, charge the HV battery using the THS charger.
  • Cranking the engine once causes the SOC to drop approximately 1%.
  • Charging the HV battery once (10 minutes) using the THS charger restores the SOC approximately 2%.
  • Charging the HV battery using the THS charger takes approximately 10 minutes when the battery temperature is 25°C (77°F) or approximately 30 minutes when the battery temperature is 0°C (32°F).
  • The THS charger is a supplemental charging device that enables the hybrid system to start (READY-on state).
  • If the result of this inspection is to charge the HV battery, clear the DTCs and then charge the HV battery using the THS charger.

PROCEDURE

1.

CHECK DTC OUTPUT (HYBRID CONTROL)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes

Result

Proceed to

P300000 or P300016 only is output.

A

DTCs other than P300000 and P300016 are also output.

B

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

2.

CHECK DTC OUTPUT (ENGINE)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Engine / Trouble Codes.

(d) Check for DTCs.

Powertrain > Engine > Trouble Codes

Result

Proceed to

No DTCs are output.

A

DTCs are output.

B

(e) Turn the power switch off.

B

GO TO DTC CHART (SFI SYSTEM)

A

3.

CHECK AMOUNT OF FUEL

(a) Turn the power switch on (IG).

(b) Check the amount of fuel by referring to the fuel gauge in the meter.

HINT:

Add fuel until the low fuel level warning light turns off.

Result

Proceed to

Proper amount of fuel is in the tank.

A

There is no fuel in the tank.

B

(c) Turn the power switch off.

B

REFUEL VEHICLE
A

4.

CHECK FREEZE FRAME DATA

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Read the freeze frame data item "Shift Position" of DTC P300000.

Powertrain > Hybrid Control > Trouble Codes Powertrain > Hybrid Control

Tester Display

Shift Position

NOTICE:

  • When the freeze frame data "Shift Position" was N, DTC P300000 may be stored due to the vehicle was left with shift lever in N and the HV battery could not be charged.
  • If DTC "P300000" only is output, charge the HV battery without replacing the HV battery if necessary.

(e) Turn the power switch off.

NEXT

5.

CHECK ENGINE START

(a) Turn the power switch on (READY).

(b) Check if the engine starts.

HINT:

  • Depressing the accelerator pedal with shift lever in P will cause the engine to start.
  • Turning the power switch on (READY) and off repeatedly while the SOC is low may cause the SOC to drop further, resulting in DTC P300016 being stored. Charge the HV battery using the THS charger as necessary.
  • Cranking the engine once causes the SOC to drop approximately 1%.
  • Charging the HV battery once (10 minutes) using the THS charger restores the SOC approximately 2%.

Result

Proceed to

The engine starts.

A

The engine does not start.

B

(c) If the engine does not start, turn the power switch off.

A

LEAVE VEHICLE WITH SHIFT LEVER IN P, AND CHARGE HV BATTERY BY IDLING UNTIL IDLING STOPS
B

6.

CLEAR DTC

Click here

NEXT

CHARGE HV BATTERY (CHECK THAT ENGINE STARTS)

Hybrid/EV Battery Control System Circuit Voltage Below Threshold (P300016)

DESCRIPTION

The hybrid vehicle control ECU alerts the driver and performs fail-safe control based on error signals received from the battery voltage sensor.

This DTC is stored if the HV battery is discharged excessively or the hybrid control system malfunctions.

HINT:

If the HV battery voltage has dropped due to a malfunction in other components such as the inverter with converter assembly or the hybrid vehicle transaxle assembly, recharging the HV battery will be able to restore the voltage. If the HV battery voltage has dropped excessively after the vehicle was left for a long time, the HV battery will need to be replaced.

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P300016

Hybrid/EV Battery Control System Circuit Voltage Below Threshold

Malfunction is received from the battery voltage sensor:

Voltage of a battery block drops drastically.

(1 trip detection logic)
  • Engine
  • Hybrid vehicle transaxle assembly
  • HV battery

Does not come on

Master Warning Light:

Comes on
Related Data List

DTC No.

Data List

P300016
  • Hybrid Battery Block 1 to 11 Voltage
  • Hybrid Battery SOC
  • Hybrid Battery Voltage
  • Hybrid Battery Current
  • Engine Speed

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click here

  1. Connect the Techstream to the DLC3.
  2. Turn the power switch on (IG) and turn the Techstream on.
  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  4. Turn the power switch off and wait for 2 minutes or more.
  5. Turn the power switch on (IG) and turn the Techstream on.
  6. Turn the power switch on (READY) with shift lever in P.
  7. Wait until the engine starts and then stops.
  8. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
  9. Check the DTC judgment result.

    HINT:

    • If the judgment result shows NORMAL, the system is normal.
    • If the judgment result shows ABNORMAL, the system has a malfunction.
    • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

CAUTION / NOTICE / HINT

CAUTION:

  • Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
    • Inspecting the high-voltage system
    • Disconnecting the low voltage connector of the inverter with converter assembly
    • Disconnecting the low voltage connector of the HV battery
  • To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
  • After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
  • After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

    *a

    Without waiting for 10 minutes

    Click here

    HINT:

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

  • When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

    *a

    Dealer

    *b

    Battery Collection Agent
  • Before returning the HV battery, make sure to perform a recovery inspection.
  • Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HV battery.

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

HINT:

  • Thoroughly interview the customer as DTC P300016 may be stored if the SOC drops due to the vehicle being left with shift lever in N for a long time or running out of fuel.
  • When the engine cannot be started, DTC P300016 may be stored because the HV battery cannot be charged.

PROCEDURE

1.

CHECK DTC OUTPUT (HYBRID CONTROL)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes

Result

Proceed to

P300016 or P300000 only is output.

A

DTCs other than P300016 or P300000 are also output.

B

HINT:

If the HV battery voltage has dropped due to a malfunction in other components such as the inverter with converter assembly or the hybrid vehicle transaxle assembly, recharge the HV battery and then repair the malfunctioning part.

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

2.

CHECK DTC OUTPUT (ENGINE)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Engine / Trouble Codes.

(d) Check for DTCs.

Powertrain > Engine > Trouble Codes

Result

Proceed to

No DTCs are output.

A

DTCs are output.

B

(e) Turn the power switch off.

B

GO TO DTC CHART (SFI SYSTEM)

A

3.

CHECK ENGINE START

(a) Turn the power switch on (READY).

(b) Check if the engine starts.

NOTICE:

Do not turn the power switch on (READY) repeatedly after duplicating the problem symptom indicated by DTC P300016 and clearing the DTCs. This may cause another problem to occur.

HINT:

Depressing the accelerator pedal with shift lever in P will cause the engine to start.

Result

Proceed to

The engine does not start.

A

The engine starts.

B

(c) Turn the power switch off.

B

LEAVE VEHICLE WITH SHIFT LEVER IN P, AND CHARGE HV BATTERY BY IDLING UNTIL IDLING STOPS
A

4.

CHECK CRANKSHAFT PULLEY REVOLUTION (P POSITION)

(a) Make sure that the shift lever is in P position.

(b) Lift up the vehicle.

(c) Turn the crankshaft pulley using hand tools to check if the crankshaft can rotate smoothly.

CAUTION:

Do not turn the power switch on (READY) while performing this inspection. Be sure to turn the power switch off before performing this inspection, to prevent the engine from starting.

NOTICE:

Engine compression causes resistance when turning the crankshaft pulley. Check if the crankshaft rotates smoothly (or if it is locked) by manually applying sufficient torque to turn the crankshaft pulley. The torque required to turn the crankshaft pulley should be the same as for a known good vehicle of the same type.

Result

Proceed to

The crankshaft rotates smoothly.

A

The crankshaft does not rotate smoothly.

B

(d) Lower the vehicle.

B

GO TO STEP 6

A

5.

CHECK HV BATTERY

(a) Turn the power switch off.

(b) Wait 10 minutes or more.

(c) Connect the Techstream to the DLC3.

(d) Turn the power switch on (IG).

(e) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Block 1 to 11 Voltage.

Powertrain > Hybrid Control > Data List

Tester Display

Hybrid Battery Block 1 Voltage

Hybrid Battery Block 2 Voltage

Hybrid Battery Block 3 Voltage

Hybrid Battery Block 4 Voltage

Hybrid Battery Block 5 Voltage

Hybrid Battery Block 6 Voltage

Hybrid Battery Block 7 Voltage

Hybrid Battery Block 8 Voltage

Hybrid Battery Block 9 Voltage

Hybrid Battery Block 10 Voltage

Hybrid Battery Block 11 Voltage

(f) Read the Data List.

Result

Proceed to

Any of "Hybrid Battery Block 1, 2, 9, 10, 11 Voltage" is 12.0 V or less, or any of "Hybrid Battery Block 3, 4, 5, 6, 7, 8 Voltage" is 24.0 V or less

A

Other than above

B

(g) Turn the power switch off.

A

REPLACE HV BATTERY

B

GO TO STEP 10

6.

CHECK CRANKSHAFT PULLEY REVOLUTION (N POSITION)

(a) Lift up the vehicle.

(b) Turn the power switch on (IG).

(c) Depress the brake pedal and move the shift lever to N.

(d) Turn the crankshaft pulley using hand tools to check if the crankshaft can rotate smoothly.

CAUTION:

Do not turn the power switch on (READY) while performing this inspection. Be sure to turn the power switch on (IG) before performing this inspection, to prevent the engine from starting.

NOTICE:

Engine compression causes resistance when turning the crankshaft pulley. Check if the crankshaft rotates smoothly (or if it is locked) by manually applying sufficient torque to turn the crankshaft pulley. The torque required to turn the crankshaft pulley should be the same as for a known good vehicle of the same type.

Result

Proceed to

The crankshaft does not rotate smoothly.

A

The crankshaft rotates smoothly.

B

(e) Lower the vehicle.

(f) Turn the power switch off.

B

GO TO STEP 11

A

7.

REPAIR OR REPLACE ENGINE
NEXT

8.

CHECK ENGINE START

(a) Turn the power switch on (READY).

(b) Check if the engine starts.

NOTICE:

Do not turn the power switch on (READY) repeatedly after duplicating the problem symptom indicated by DTC P300016 and clearing the DTCs. This may cause another problem to occur.

HINT:

Depressing the accelerator pedal with shift lever in P will cause the engine to start.

Result

Proceed to

The engine does not start.

A

The engine starts.

B

(c) Turn the power switch off.

B

LEAVE VEHICLE WITH SHIFT LEVER IN P, AND CHARGE HV BATTERY BY IDLING UNTIL IDLING STOPS
A

9.

CHECK HV BATTERY

(a) Turn the power switch off.

(b) Wait 10 minutes or more.

(c) Connect the Techstream to the DLC3.

(d) Turn the power switch on (IG).

(e) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Block 1 to 11 Voltage.

Powertrain > Hybrid Control > Data List

Tester Display

Hybrid Battery Block 1 Voltage

Hybrid Battery Block 2 Voltage

Hybrid Battery Block 3 Voltage

Hybrid Battery Block 4 Voltage

Hybrid Battery Block 5 Voltage

Hybrid Battery Block 6 Voltage

Hybrid Battery Block 7 Voltage

Hybrid Battery Block 8 Voltage

Hybrid Battery Block 9 Voltage

Hybrid Battery Block 10 Voltage

Hybrid Battery Block 11 Voltage

(f) Read the Data List.

Result

Proceed to

Any of "Hybrid Battery Block 1, 2, 9, 10, 11 Voltage" is 12.0 V or less, or any of "Hybrid Battery Block 3, 4, 5, 6, 7, 8 Voltage" is 24.0 V or less

A

Other than above

B

(g) Turn the power switch off.

A

REPLACE HV BATTERY

B

GO TO STEP 14

10.

CLEAR DTC

Click here

NEXT

CHARGE HV BATTERY (ABOUT 10 MINUTES)

11.

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

Click here

NEXT

12.

CHECK ENGINE START

(a) Turn the power switch on (READY).

(b) Check if the engine starts.

NOTICE:

Do not turn the power switch on (READY) repeatedly after duplicating the problem symptom indicated by DTC P300016 and clearing the DTCs. This may cause another problem to occur.

HINT:

Depressing the accelerator pedal with shift lever in P will cause the engine to start.

Result

Proceed to

The engine does not start.

A

The engine starts.

B

(c) Turn the power switch off.

B

LEAVE VEHICLE WITH SHIFT LEVER IN P, AND CHARGE HV BATTERY BY IDLING UNTIL IDLING STOPS
A

13.

CHECK HV BATTERY

(a) Turn the power switch off.

(b) Wait 10 minutes or more.

(c) Connect the Techstream to the DLC3.

(d) Turn the power switch on (IG).

(e) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Block 1 to 11 Voltage.

Powertrain > Hybrid Control > Data List

Tester Display

Hybrid Battery Block 1 Voltage

Hybrid Battery Block 2 Voltage

Hybrid Battery Block 3 Voltage

Hybrid Battery Block 4 Voltage

Hybrid Battery Block 5 Voltage

Hybrid Battery Block 6 Voltage

Hybrid Battery Block 7 Voltage

Hybrid Battery Block 8 Voltage

Hybrid Battery Block 9 Voltage

Hybrid Battery Block 10 Voltage

Hybrid Battery Block 11 Voltage

(f) Read the Data List.

Result

Proceed to

Any of "Hybrid Battery Block 1, 2, 9, 10, 11 Voltage" is 12.0 V or less, or any of "Hybrid Battery Block 3, 4, 5, 6, 7, 8 Voltage" is 24.0 V or less

A

Other than above

B

(g) Turn the power switch off.

A

REPLACE HV BATTERY

B

GO TO STEP 15

14.

CLEAR DTC

Click here

NEXT

CHARGE HV BATTERY (ABOUT 10 MINUTES)

15.

CLEAR DTC

Click here

NEXT

CHARGE HV BATTERY (ABOUT 10 MINUTES)

High Voltage Power Resource Circuit Short during Pre-Charge (P300449)

DTC SUMMARY

MALFUNCTION DESCRIPTION

The hybrid vehicle control ECU monitors the high-voltage wiring between the HV battery and inverter with converter assembly and detects an open circuit malfunction.

The cause of this malfunction may be one of the following:

Inverter voltage sensor (VH) internal circuit malfunction
  • Voltage sensor (VH) malfunction
  • Motor generator control ECU (MG ECU) malfunction
  • Communication (wire harness) malfunction
High voltage system malfunction
  • HV battery malfunction
  • HV battery junction block assembly malfunction
  • Inverter with converter assembly malfunction
  • High-voltage wire harness malfunction
  • High-voltage connector or connection malfunction
Low-voltage circuit (12 V) malfunction
  • Hybrid vehicle control ECU malfunction
  • HV battery junction block assembly malfunction
  • Low voltage wire harness malfunction
  • Low voltage connector malfunction

INSPECTION DESCRIPTION

System Diagram Range

Inspection Content

Reason

Inspection Step

*a

Check connection condition and wire harness continuity between hybrid vehicle control ECU and HV battery junction block assembly

In order to check whether connectors are connected properly and to check for an open circuit in the SMRP and SMRB primary lines

3 to 7

*b

Check system main relay

Check whether SMRB and SMRP stuck OFF

8, 9

*c

Check connection condition and high-voltage cable continuity between HV battery junction block assembly and inverter with converter assembly

Check for open circuit and defective connection (arc marks) due to looseness

10 to 12

*d

Check high-voltage cable and connection condition between HV battery and HV battery junction block assembly

Check for open circuit and defective connection (arc marks) due to looseness

13, 14, 15, 16, 21

*e

Check HV battery

Check whether HV battery voltage has drastically dropped below normal range

17

DESCRIPTION

Refer to the description for DTC P0AE411.

Click here

The hybrid vehicle control ECU monitors the high-voltage wiring between the HV battery and the inverter with converter assembly and detects the following malfunction.

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P300449

High Voltage Power Resource Circuit Short during Pre-Charge

Although a system main relay operation signal was sent when the power switch was operated, the system voltage is not sufficiently increased after boosting and the HV battery current does not flow.

High-voltage circuit malfunctions between the HV battery and inverter with converter assembly.

The EV electric battery fuse is blown, the service plug grip is removed, the system main resistor is blown, SMRP or SMRB remains open, or the high-voltage cable has an open circuit.

(2 trip detection logic)
  • HV battery junction block assembly
  • HV floor under wire
  • Inverter with converter assembly
  • HV battery
  • Wire harness or connector
  • Hybrid battery terminal block

Does not come on

Master Warning Light:

Comes on
Related Data List

DTC No.

Data List

P300449
  • Hybrid Battery Voltage
  • Hybrid Battery Current
  • VL-Voltage before Boosting
  • VH-Voltage after Boosting

The following items can be helpful when performing repairs:

Data List
  • Ready Signal
  • Inter Lock Switch
  • SMRP Status
  • SMRB Status
  • SMRG Status

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click here

  1. Connect the Techstream to the DLC3.
  2. Turn the power switch on (IG) and turn the Techstream on.
  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  4. Turn the power switch off and wait for 2 minutes or more.
  5. Turn the power switch on (IG) and turn the Techstream on.
  6. Turn the power switch on (READY) and wait for 3 minutes or more.

    HINT:

    According to the display on the Techstream, read the Data List and monitor the values of "Hybrid Battery Voltage" and "VL-Voltage before Boosting" for 3 minutes. If the difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is always less than 50 V, the vehicle has returned to normal.

  7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
  8. Check the DTC judgment result.

    HINT:

    • If the judgment result shows NORMAL, the system is normal.
    • If the judgment result shows ABNORMAL, the system has a malfunction.
    • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AA649.

Click here

Refer to the wiring diagram for the HV battery high-voltage line circuit.

Click here

CAUTION / NOTICE / HINT

CAUTION:

  • Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
    • Inspecting the high-voltage system
    • Disconnecting the low voltage connector of the inverter with converter assembly
    • Disconnecting the low voltage connector of the HV battery
  • To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
  • After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
  • After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

    Click here

    HINT:

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

    *a

    Without waiting for 10 minutes
  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

  • When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

    *a

    Dealer

    *b

    Battery Collection Agent
  • Before returning the HV battery, make sure to perform a recovery inspection.
  • Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HV battery.

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

PROCEDURE

1.

CHECK DTC OUTPUT (HYBRID CONTROL, MOTOR GENERATOR)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control and Motor Generator / Trouble Codes.

(d) Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes Powertrain > Motor Generator > Trouble Codes

Result

Proceed to

P300449 only is output, or DTCs except the ones in the table below are also output.

A

DTCs of hybrid control system in the tables below are output.

B

DTCs of motor generator control system in the tables below are output.

C

Malfunction Content

System

Relevant DTC

Microcomputer malfunction

Hybrid control system

P0A1B49

Drive Motor "A" Control Module Internal Electronic Failure

P060647

Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure

P060687

Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message

P060A47

Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure

P060A87

Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message

P1C9E9F

Hybrid/EV System Reset Stuck Off

P0AFC96

Hybrid/EV Battery Sensor Module Component Internal Failure

P0AFC00

Hybrid/EV Battery Sensor Module

Motor generator control system

P0A1B1F

Generator Control Module Circuit Intermittent

P0A1A47

Generator Control Module Watchdog / Safety μC Failure

P0A1A49

Generator Control Module Internal Electronic Failure

P1C2A1C

Generator A/D Converter Circuit Circuit Voltage Out of Range

P1C2A49

Generator A/D Converter Circuit Internal Electronic Failure

P313383

Communication Error from Generator to Drive Motor "A" Value of Signal Protection Calculation Incorrect

P313386

Communication Error from Generator to Drive Motor "A" Signal Invalid

P313387

Communication Error from Generator to Drive Motor "A" Missing Message

Power source circuit malfunction

Hybrid control system

P0AFC16

Hybrid/EV Battery Sensor Module Circuit Voltage Below Threshold

Motor generator control system

P06D61C

Generator Control Module Offset Power Circuit Voltage Out of Range

Communication system malfunction

Hybrid control system

P312387

Lost Communication with Drive Motor Control Module "A" from Hybrid/EV Control Module Missing Message

U029A87

Lost Communication with Hybrid/EV Battery Sensor Module Missing Message

Sensor and actuator circuit malfunction

Hybrid control system

P0AD915

Hybrid/EV Battery Positive Contactor Circuit Short to Auxiliary Battery or Open

P0AD911

Hybrid/EV Battery Positive Contactor Circuit Short to Ground

P0AE415

Hybrid/EV Battery Precharge Contactor Circuit Short to Auxiliary Battery or Open

P0AE411

Hybrid/EV Battery Precharge Contactor Circuit Short to Ground

P0ADD15

Hybrid/EV Battery Negative Contactor Circuit Short to Auxiliary Battery or Open

P0ADD11

Hybrid/EV Battery Negative Contactor Circuit Short to Ground

P0ABF11

Hybrid/EV Battery Current Sensor "A" Circuit Short to Ground

P0ABF15

Hybrid/EV Battery Current Sensor "A" Circuit Short to Auxiliary Battery or Open

P0B3B14

Hybrid/EV Battery Voltage Sensor "A" Circuit Short to Ground or Open

P0B4014

Hybrid/EV Battery Voltage Sensor "B" Circuit Short to Ground or Open

P0B4514

Hybrid/EV Battery Voltage Sensor "C" Circuit Short to Ground or Open

P0B4A14

Hybrid/EV Battery Voltage Sensor "D" Circuit Short to Ground or Open

P0B4F14

Hybrid/EV Battery Voltage Sensor "E" Circuit Short to Ground or Open

P0B5414

Hybrid/EV Battery Voltage Sensor "F" Circuit Short to Ground or Open

P0B5914

Hybrid/EV Battery Voltage Sensor "G" Circuit Short to Ground or Open

P0B5E14

Hybrid/EV Battery Voltage Sensor "H" Circuit Short to Ground or Open

P0B6314

Hybrid/EV Battery Voltage Sensor "I" Circuit Short to Ground or Open

P0B6814

Hybrid/EV Battery Voltage Sensor "J" Circuit Short to Ground or Open

P0B6D14

Hybrid/EV Battery Voltage Sensor "K" Circuit Short to Ground or Open

P0B7214

Hybrid/EV Battery Voltage Sensor "L" Circuit Short to Ground or Open

P308A13

Hybrid/EV Battery Voltage Sensor All Circuit Open

P0AFC62

Hybrid/EV Battery Sensor Module Signal Compare Failure

P0B231C

Hybrid/EV Battery "A" Voltage Sensor Voltage Out of Range

P308A12

Hybrid/EV Battery Voltage Sensor All Circuit Short to Auxiliary Battery

P0ABF00

Hybrid/EV Battery Current Sensor "A" Circuit Range/Performance

P0ABF28

Hybrid/EV Battery Current Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure

P0ABF2A

Hybrid/EV Battery Current Sensor "A" Signal Stuck In Range

System malfunction

Hybrid control system

P0C7600

Hybrid/EV Battery System Discharge Time Too Long

P0D2D1C

Drive Motor "A" Inverter Voltage Sensor Voltage Out of Range

P1C8149

High Voltage Power Resource Circuit Consumption Circuit Short

P1C8249

High Voltage Power Resource Circuit Over Loading

P1C8349

High Voltage Power Resource Circuit Voltage Sensor after Boosting Malfunction

Motor generator control system

P0D2D16

Drive Motor "A" Inverter Voltage Sensor(VH) Circuit Voltage Below Threshold

P0D2D17

Drive Motor "A" Inverter Voltage Sensor(VH) Circuit Voltage Above Threshold

P1CB69E

Drive Motor "A" Inverter Voltage Sensor(VH) Stuck On

P0CA300

DC/DC Converter Step Up Voltage Performance

HINT:

  • P300449 may be output as a result of the malfunction indicated by the DTCs above.
    1. The chart above is listed in inspection order of priority.
    2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

C

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)

A

2.

CHECK FREEZE FRAME DATA (HYBRID CONTROL)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Read the freeze frame data of DTC P300449.

Powertrain > Hybrid Control > Trouble Codes

Result

Proceed to

Both of the following conditions are met:

  • "VH-Voltage after Boosting" is below 50 V.
  • Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is 40 V or less.

A

Except above

B

(e) Turn the power switch off.

A

REPLACE INVERTER WITH CONVERTER ASSEMBLY

B

3.

CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

Click here

NG

CONNECT SECURELY
OK

4.

CHECK CONNECTOR CONNECTION CONDITION (FLOOR WIRE CONNECTOR)

Click here

Result

Proceed to

OK

A

NG (The connector is not connected securely.)

B

NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)

C
B

CONNECT SECURELY
C

REPAIR OR REPLACE HARNESS OR CONNECTOR
A

5.

CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

Click here

NG

CONNECT SECURELY
OK

6.

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HV BATTERY JUNCTION BLOCK ASSEMBLY)

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery cover panel RH.

Click here

(c) Disconnect the K18 HV battery junction block assembly connector.

(d) Disconnect the G46 hybrid vehicle control ECU connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

G46-4 (SMRB) - K18-1 (SMRB)

Power switch off

Below 1 Ω

G46-3 (SMRP) - K18-2 (SMRP)

Power switch off

Below 1 Ω

*a

Rear view of wire harness connector

(to Hybrid Vehicle Control ECU)

*b

Front view of wire harness connector

(to HV Battery Junction Block Assembly)

(f) Reconnect the G46 hybrid vehicle control ECU connector.

(g) Reconnect the K18 HV battery junction block assembly connector.

(h) Install the No. 1 HV battery cover panel RH.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

7.

CHECK HARNESS AND CONNECTOR (HV BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery cover panel RH.

Click here

(c) Disconnect the K18 HV battery junction block assembly connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

K18-3 (GND) - Body ground

Power switch off

Below 1 Ω

*a

Front view of wire harness connector

(to HV Battery Junction Block Assembly)

(e) Reconnect the K18 HV battery junction block assembly connector.

(f) Install the No. 1 HV battery cover panel RH.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

8.

INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the HV battery junction block assembly.

Click here

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

*a

Component without harness connected

(HV Battery Junction Block Assembly)

-

-

Standard Resistance:

Tester Connection

Condition

Specified Condition

y5-1 (+) - S2-1 (CBI)

Auxiliary battery voltage applied between terminals K18-1 (SMRB) and K18-3 (GND)

Below 1 Ω

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

K18-1 (SMRB) - K18-3 (GND)

-40 to 80°C (-40 to 176°F)

25.0 to 59.0 Ω

(e) Install the HV battery junction block assembly.

NG

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

OK

9.

INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRP)

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the HV battery junction block assembly.

Click here

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

*a

Component without harness connected

(HV Battery Junction Block Assembly)

-

-

Standard Resistance:

Tester Connection

Condition

Specified Condition

y3-1 (-) - S3-1 (CEI)

Auxiliary battery voltage applied between terminals k18-2 (SMRP) and k18-3 (GND)

24.3 to 29.7 Ω

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

K18-2 (SMRP) - K18-3 (GND)

-40 to 80°C (-40 to 176°F)

140 to 290 Ω

(e) Install the HV battery junction block assembly.

NG

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

OK

10.

CHECK INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER WIRE)

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Check that the bolts for the HV floor under wire is tightened to the specified torque, the HV floor under wire is connected securely, and there are no contact problems.

Specified Condition:

T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

(c) Disconnect the HV floor under wire from the inverter with converter assembly.

(d) Check for arc marks on the terminals for the HV floor under wire and inverter with converter assembly.

Result

Proceed to

The terminals are connected securely and there are no contact problems.

There are no arc marks.

A

The terminals are not connected securely and there is a contact problem.

There are arc marks.

B

The terminals are not connected securely and there is a contact problem.

There are no arc marks.

C

The terminals are connected securely and there are no contact problems.

There are arc marks.

B

(e) Reconnect the HV floor under wire.

B

REPLACE MALFUNCTIONING PARTS
C

CONNECT SECURELY
A

11.

CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER WIRE)

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery cover panel RH.

Click here

(c) Check that the HV floor under wire is connected securely, and there are no contact problems.

(d) Disconnect the HV floor under wire connectors from the HV battery junction block assembly.

(e) Check for arc marks on the terminals of the HV floor wire and the HV battery junction block assembly.

Result

Proceed to

The terminals are connected securely and there are no contact problems.

There are no arc marks.

A

The terminals are not connected securely and there is a contact problem.

There are arc marks.

B

The terminals are not connected securely and there is a contact problem.

There are no arc marks.

C

The terminals are connected securely and there are no contact problems.

There are arc marks.

B

(f) Reconnect the HV floor under wire.

(g) Install the No. 1 HV battery cover panel RH.

B

REPLACE MALFUNCTIONING PARTS
C

CONNECT SECURELY
A

12.

CHECK HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery cover panel RH.

Click here

(c) Disconnect the HV floor under wire connectors from the HV battery junction block assembly.

(d) Disconnect the HV floor under wire connector from the inverter with converter assembly.

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

*a

HV Floor Under Wire

(Inverter with Converter Assembly Side)

*b

HV Floor Under Wire

(HV Battery Junction Block Assembly Side)

Standard Resistance:

Tester Connection

Condition

Specified Condition

S1-1 (CBI) - S2-1 (CBI)

Power switch off

Below 1 Ω

S1-2 (CEI) - S3-1 (CEI)

Power switch off

Below 1 Ω

NOTICE:

Be sure not to damage or deform the terminal being inspected.

(f) Reconnect the HV floor under wire connector to the inverter with converter assembly.

(g) Reconnect the HV floor under wire connectors to the HV battery junction block assembly.

(h) Install the No. 1 HV battery cover panel RH.

NG

REPLACE HV FLOOR UNDER WIRE

OK

13.

CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV BATTERY HIGH VOLTAGE CONNECTOR CONNECTION CONDITION)

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery cover panel RH.

Click here

(c) Check the 2 HV battery high voltage connectors are connected securely, and there are no contact problems.

(d) Disconnect the 2 HV battery high voltage connectors from the HV battery junction block assembly.

NOTICE:

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

(e) Check for arc marks on the terminals of the HV battery high voltage connectors and HV battery junction block assembly.

Result

Proceed to

The terminals are connected securely and there are no contact problems.

There are no arc marks.

A

The terminals are not connected securely and there is a contact problem.

There are arc marks.

B

The terminals are not connected securely and there is a contact problem.

There are no arc marks.

C

The terminals are connected securely and there are no contact problems.

There are arc marks.

B

(f) Reconnect the 2 HV battery high voltage connectors.

(g) Install the No. 1 HV battery cover panel RH.

B

REPLACE MALFUNCTIONING PARTS
C

CONNECT SECURELY
A

14.

CHECK HV BATTERY HIGH VOLTAGE CABLE

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery cover panel RH.

Click here

(c) Disconnect the y5 HV battery high voltage cable connector from the HV battery junction block assembly.

NOTICE:

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

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

y5-1 (+) - Service plug grip connecting terminal 2

Power switch off

Below 1 Ω

*a

High Voltage Cable

(HV Battery Junction Block Assembly Side)

*b

Service Plug Grip Removed

(Service Plug Grip Connecting Terminals)

(e) Reconnect the y5 HV battery high voltage cable connector.

(f) Install the No. 1 HV battery cover panel RH.

NG

REPLACE HV BATTERY

OK

15.

CHECK HV BATTERY

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery cover panel RH.

Click here

(c) Disconnect the y3 HV battery high voltage cable connector from the HV battery junction block assembly.

NOTICE:

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

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

Standard Voltage:

Tester Connection

Condition

Specified Condition

y3-1 (-) - Service plug grip connecting terminal 1

Power switch off

100 V or higher

CAUTION:

Do not allow the probes of the electrical tester to contact each other during this inspection.

*a

High Voltage Cable

(HV Battery Junction Block Assembly Side)

*b

Service Plug Grip Removed

(Service Plug Grip Connecting Terminals)

(e) Reconnect the y3 HV battery high voltage cable connector.

(f) Install the No. 1 HV battery cover panel RH.

NG

GO TO STEP 19

OK

16.

CHECK FOR INTERMITTENT PROBLEMS

(a) Check for intermittent problems.

Click here

Result

Proceed to

Problem symptom does not recur.

A

Problem symptom recurs.

B

HINT:

  • Since 2 trip detection logic is used, the DTC detection condition must be met twice.
  • If DTC P300449 is output again after performing the inspection, replace the inverter with converter assembly. If DTC P300449 is not output again, replace the HV battery junction block assembly.
B

REPLACE INVERTER WITH CONVERTER ASSEMBLY

A

17.

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

Click here

NEXT

18.

CHECK HYBRID VEHICLE CONTROL ECU (CHECK FOR NORMAL OPERATION)

Click here

Result

Proceed to

Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is always less than 50 V.

A

Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is 50 V or more.

B
A

END
B

REPLACE HYBRID VEHICLE CONTROL ECU

19.

CHECK HYBRID BATTERY TERMINAL BLOCK (HV BATTERY HIGH VOLTAGE CONNECTOR CONNECTION CONDITION)

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery shield panel.

Click here

(c) Check that the 2 HV battery high voltage connectors are connected securely, and there are no contact problems.

(d) Remove the hybrid battery terminal block.

Click here

NOTICE:

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

(e) Check for arc marks on the terminals of the HV battery high voltage connectors and hybrid battery terminal block.

Result

Proceed to

The terminals are connected securely and there are no contact problems.

There are no arc marks.

A

The terminals are not connected securely and there is a contact problem.

There are arc marks.

B

The terminals are not connected securely and there is a contact problem.

There are no arc marks.

C

The terminals are connected securely and there are no contact problems.

There are arc marks.

B

(f) Install the hybrid battery terminal block.

(g) Install the No. 1 HV battery shield panel.

B

REPLACE MALFUNCTIONING PARTS
C

CONNECT SECURELY
A

20.

CHECK HV BATTERY HIGH VOLTAGE CABLE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that the service plug grip is not installed.

NOTICE:

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

(b) Remove the No. 1 HV battery shield panel.

Click here

(c) Remove the bolt from the hybrid battery terminal block.

(d) Disconnect the y4 high voltage connector from the hybrid battery terminal block.

NOTICE:

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

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

y4-1 - Service plug grip connecting terminal 1

Power switch off

Below 1 Ω

*a

High Voltage Cable

(Hybrid Battery Terminal Block Side)

*b

Service Plug Grip Removed

(Service Plug Grip Connecting Terminals)

(f) Reconnect the y4 high voltage connector to the hybrid battery terminal block.

(g) Install the bolt to the hybrid battery terminal block.

Click here

(h) Install the No. 1 HV battery shield panel.

NG

REPLACE HV BATTERY

OK

21.

CHECK HYBRID BATTERY TERMINAL BLOCK

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the Hybrid battery terminal block.

Click here

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

Hybrid battery terminal block

Always

Below 1 Ω

*1

Hybrid Battery Terminal Block

(c) Install the Hybrid battery terminal block.

OK

REPLACE HV BATTERY

NG

REPLACE HYBRID BATTERY TERMINAL BLOCK

Collision detected or Collision Sensor Connection (Open) (P160600,P160604). Throttle/Pedal Position Sensor/Switch "D" Circuit Short to Auxiliary Battery (P212012,...,P21382B). IG2 Signal Circuit Short

Hybrid/EV Battery Block 1 Circuit Resistance Out of Range (Extreme) (P301100,...,P30211E)

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Toyota Avalon (XX50) 2019-2022 Service & Repair Manual

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