RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604232 HYBRID CONTROL SYSTEM J

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  ECU Power Source Circuit  


DESCRIPTION

If the ignition switch is ON, the hybrid vehicle control ECU applies current to the MREL terminal to turn the IGCT relay on. This supplies power to the +B1 terminal.

WIRING DIAGRAM

A514382E07
5.344,4.01 7.073,4.25 1.729,0.24 10 false Hybrid Vehicle Control ECU 1.771,2.406 4.042,2.792 2.271,0.385 10 false No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly 0.292,3.292 1.167,3.74 0.875,0.448 10 false from Auxiliary Battery 1.396,1.26 2.104,1.594 0.708,0.333 10 false IGCT-MAIN NO. 1 3.448,1.271 4.323,1.49 0.875,0.219 10 false PM-IGCT 2.396,1.958 3.115,2.344 0.719,0.385 10 false IGCT-MAIN NO. 1 5.865,1.156 6.302,1.375 0.438,0.219 10 false +B1 5.875,1.594 6.313,1.813 0.438,0.219 10 false MREL 5.896,3.365 6.333,3.583 0.438,0.219 10 false E12 5.865,2.156 6.302,2.375 0.438,0.219 10 false E01 5.875,2.906 6.313,3.125 0.438,0.219 10 false E1 5.5,1.563 5.938,1.781 0.438,0.219 10 false I278 5.5,1.115 5.938,1.333 0.438,0.219 10 false I278 5.51,2.906 5.948,3.125 0.438,0.219 10 false I278 5.469,3.333 5.906,3.552 0.438,0.219 10 false A197 5.458,2.156 5.896,2.375 0.438,0.219 10 false A197 5.542,1.969 5.979,2.188 0.438,0.219 10 false 12 5.573,2.729 6.01,2.948 0.438,0.219 10 false 1 5.531,1.375 5.969,1.594 0.438,0.219 10 false 10 5.563,0.917 6,1.135 0.438,0.219 10 false 8 3.406,1.021 3.844,1.24 0.438,0.219 10 false 1 3.875,1.031 4.313,1.25 0.438,0.219 10 false 2 3.125,1.479 3.563,1.698 0.438,0.219 10 false 1 2.25,1.479 2.688,1.698 0.438,0.219 10 false 2 1.875,1.031 2.313,1.25 0.438,0.219 10 false 2 1.438,1.031 1.875,1.25 0.438,0.219 10 false 1 2.25,1.031 2.688,1.25 0.438,0.219 10 false 5 3.135,1.031 3.344,1.25 0.208,0.219 10 false 3 5.563,3.167 6,3.385 0.438,0.219 10 false 24

CAUTION / NOTICE / HINT

NOTICE:
·

After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY

·

When disconnecting and reconnecting the auxiliary battery

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART




PROCEDURE

1.CHECK HYBRID VEHICLE CONTROL ECU (+B1 VOLTAGE)
a.

Turn the ignition switch to ON.


b.

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

A535056C22
4.688,0.25 5.115,0.552 0.427,0.302 5.542,2.333 4.875,1.281 true 0.313,0.24 0.625,0.396 0.313,0.156 10 false *a 4.781,0.302 5.417,0.552 0.635,0.25 10 false I278 5.458,2.375 6.094,2.625 0.635,0.25 10 false +B1
*a Component with harness connected
(Hybrid Vehicle Control ECU) 		- -


Standard Voltage:
Tester Connection Condition Specified Condition
I278-8 (+B1) - Body ground Ignition switch ON 11 to 14 V



c.

Turn the ignition switch off.


Result:
Proceed to
OK
NG



OK

2.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BODY GROUND)

NG

3.CHECK HYBRID VEHICLE CONTROL ECU (MREL TERMINAL VOLTAGE)
2.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BODY GROUND)
a.

Disconnect the hybrid vehicle control ECU connectors.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
A197-12 (E01) - Body ground Always Below 1 Ω
A197-24 (E12) - Body ground Always Below 1 Ω
I278-1 (E1) - Body ground Always Below 1 Ω



c.

Reconnect the hybrid vehicle control ECU connectors.


Result:
Proceed to
OK
NG



OK

GO TO PROBLEM SYMPTOMS TABLE

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PROBLEM SYMPTOMS TABLE


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

3.CHECK HYBRID VEHICLE CONTROL ECU (MREL TERMINAL VOLTAGE)
a.

Turn the ignition switch to ON.


b.

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

A535056C23
4.656,0.25 5.125,0.552 0.469,0.302 4.052,2.302 4.396,1.292 true 0.313,0.24 0.625,0.396 0.313,0.156 10 false *a 4.76,0.302 5.396,0.552 0.635,0.25 10 false I278 3.885,2.333 4.521,2.583 0.635,0.25 10 false MREL
*a Component with harness connected
(Hybrid Vehicle Control ECU) 		- -


Standard Voltage:
Tester Connection Condition Specified Condition
I278-10 (MREL) - Body ground Ignition switch ON 11 to 14 V



c.

Turn the Ignition switch off.


Result:
Proceed to
OK
NG



OK

4.CHECK FUSE (PM-IGCT)

NG

REPLACE HYBRID VEHICLE CONTROL ECU

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID VEHICLE CONTROL ECU>REMOVAL


4.CHECK FUSE (PM-IGCT)
a.

Remove the PM-IGCT fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
PM-IGCT fuse Always Below 1 Ω



c.

Install the PM-IGCT fuse.


Result:
Proceed to
OK
NG



OK

5.CHECK FUSE (IGCT-MAIN NO. 1)

NG

11.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
5.CHECK FUSE (IGCT-MAIN NO. 1)
a.

Remove the IGCT-MAIN NO. 1 fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
IGCT-MAIN NO. 1 fuse Always Below 1 Ω



c.

Install the IGCT-MAIN NO. 1 fuse.


Result:
Proceed to
OK
NG



OK

6.INSPECT RELAY (IGCT-MAIN NO. 1)

NG

12.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
6.INSPECT RELAY (IGCT-MAIN NO. 1)
a.

Remove the IGCT-MAIN NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.
A167865C11
2.615,0.552 2.708,0.198 2.708,0.198 2.792,0.198 true 2.031,0.563 1.938,0.198 1.938,0.198 1.854,0.198 true 2.531,1.125 2.948,1.125 true 2.531,1.625 2.948,1.625 true 0.094,0.083 0.406,0.24 0.313,0.156 10 *1 0.229,0.792 0.542,0.948 0.313,0.156 10 5 0.24,1.333 0.552,1.49 0.313,0.156 10 2 1.198,1.333 1.51,1.49 0.313,0.156 10 1 1.208,0.792 1.521,0.948 0.313,0.156 10 3 1.75,0.135 2.063,0.292 0.313,0.156 10 1 2.844,0.125 3.156,0.281 0.313,0.156 10 2 3,1.063 3.313,1.219 0.313,0.156 10 5 3,1.563 3.313,1.719 0.313,0.156 10 3
*1 IGCT-MAIN NO. 1 Relay


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

Standard Resistance:
Tester Connection Condition Specified Condition
3 - 5 Auxiliary battery voltage not applied between terminals 1 and 2 10 kΩ or higher
Auxiliary battery voltage applied between terminals 1 and 2 Below 1 Ω



c.

Install the IGCT-MAIN NO. 1 relay.


Result:
Proceed to
OK
NG



OK

7.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)

NG

REPLACE RELAY (IGCT-MAIN NO. 1)

7.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
a.

Disconnect the hybrid vehicle control ECU connector.


b.

Remove the PM-IGCT fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
I278-8 (+B1) - 2 (PM-IGCT fuse holder) Always Below 1 Ω



d.

Install the PM-IGCT fuse.


e.

Reconnect the hybrid vehicle control ECU connector.


Result:
Proceed to
OK
NG



OK

8.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

8.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
a.

Remove the IGCT-MAIN NO. 1 fuse, PM-IGCT fuse and IGCT-MAIN NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
5 (IGCT-MAIN NO. 1 relay holder) - 2 (IGCT-MAIN NO. 1 fuse holder) Always Below 1 Ω
3 (IGCT-MAIN NO. 1 relay holder) - 1 (PM-IGCT fuse holder) Always Below 1 Ω



c.

Install the IGCT-MAIN NO. 1 fuse, PM-IGCT fuse and IGCT-MAIN NO. 1 relay.


Result:
Proceed to
OK
NG



OK

9.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

9.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
a.

Disconnect the hybrid vehicle control ECU connector.


b.

Remove the IGCT-MAIN NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
I278-10 (MREL) - 1 (IGCT-MAIN NO. 1 relay holder) Always Below 1 Ω
I278-10 (MREL) or 1 (IGCT-MAIN NO. 1 relay holder) - Body ground and other terminals Always 10 kΩ or higher



d.

Install the IGCT-MAIN NO. 1 relay.


e.

Reconnect the hybrid vehicle control ECU connector.


Result:
Proceed to
OK
NG



OK

10.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - BODY GROUND)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

10.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - BODY GROUND)
a.

Remove the IGCT-MAIN NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
2 (IGCT-MAIN NO. 1 relay holder) - Body ground Always Below 1 Ω



c.

Install the IGCT-MAIN NO. 1 relay.


Result:
Proceed to
OK
NG



OK

CHECK FOR INTERMITTENT PROBLEMS

Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>HOW TO PROCEED WITH TROUBLESHOOTING


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

11.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
a.

Remove the PM-IGCT fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

Disconnect the hybrid vehicle control ECU connector.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
I278-8 (+B1) or 2 (PM-IGCT fuse holder) - Body ground and other terminals Always 10 kΩ or higher



d.

Reconnect the hybrid vehicle control ECU connector.


e.

Install the PM-IGCT fuse.


Result:
Proceed to
OK
NG



OK

REPLACE FUSE (IGCT SCENE)

NG

13.REPAIR OR REPLACE HARNESS OR CONNECTOR
12.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
a.

Remove the IGCT-MAIN NO. 1 fuse, PM-IGCT fuse and IGCT-MAIN NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
5 (IGCT-MAIN NO. 1 relay holder) or 2 (IGCT-MAIN NO. 1 fuse holder) - Body ground and other terminals Always 10 kΩ or higher
3 (IGCT-MAIN NO. 1 relay holder) or 1 (PM-IGCT fuse holder) - Body ground and other terminals Always 10 kΩ or higher



c.

Install the IGCT-MAIN NO. 1 fuse, PM-IGCT fuse and IGCT-MAIN NO. 1 relay.


Result:
Proceed to
OK
NG



OK

REPLACE FUSE (IGCT-MAIN NO. 1)

NG

14.REPAIR OR REPLACE HARNESS OR CONNECTOR
13.REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
Proceed to
NEXT



NEXT

REPLACE FUSE (IGCT-MAIN NO. 1)

14.REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
Proceed to
NEXT



NEXT

REPLACE FUSE (IGCT-MAIN NO. 1)