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

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  Cooling System  


DESCRIPTION

The cause of the malfunction may be the cooling system.

Check whether the grille is blocked, whether coolant is leaking, the radiator fan operating condition and whether coolant has frozen.

Related Parts Check
Area Inspection
Grille blockage, coolant amount, coolant hoses, radiator fan Check for overheating due to hybrid cooling system malfunction.
Inverter coolant temperature sensor (built-in inverter) Check for temperature sensor malfunction.
Coolant freezing check Check freeze frame values to determine whether the hybrid coolant was frozen when the DTC was stored.

SYSTEM DESCRIPTION

The inverter converts the high-voltage direct current of the HV battery into alternating current for the generator (MG1) and motor (MG2). The inverter generates heat during the conversion process. Therefore, the inverter is cooled by a special cooling system consisting of the inverter water pump assembly, the cooling fan, and a radiator. This cooling system is independent of the engine cooling system. The hybrid vehicle control ECU monitors the inverter water pump assembly, cooling fan and cooling system, and detects malfunctions.

WIRING DIAGRAM

A500396E13
5.427,5.604 7.135,5.865 1.708,0.26 10 false Hybrid Vehicle Control ECU 5.74,5.104 6.052,5.302 0.313,0.198 10 false E1 5.719,4.5 6.281,4.74 0.563,0.24 10 false MREL 5.719,3 6.281,3.24 0.563,0.24 10 false NIWP 5.74,1.5 6.302,1.74 0.563,0.24 10 false IWP 6.479,2.615 6.802,2.885 0.323,0.271 10 false +B 6.646,3.927 6.969,4.198 0.323,0.271 10 false +B 5.375,5.083 5.688,5.281 0.313,0.198 10 false I278 5.469,4.885 5.781,5.083 0.313,0.198 10 false 1 2.844,4.042 3.396,4.292 0.552,0.25 10 false A190 5.406,4.385 5.719,4.583 0.313,0.198 10 false 10 5.333,3.094 5.708,3.292 0.375,0.198 10 false A197 5.333,1.583 5.792,1.781 0.458,0.198 10 false A197 5.448,2.906 5.76,3.104 0.313,0.198 10 false 33 5.438,1.396 5.75,1.594 0.313,0.198 10 false 32 5,3.625 5.313,3.823 0.313,0.198 10 false 1 4.615,3.74 5.063,3.99 0.448,0.25 10 false GND 4.573,3.01 5.135,3.25 0.563,0.24 10 false NWP 5.01,3 5.323,3.198 0.313,0.198 10 false 2 4.594,1.5 5.156,1.74 0.563,0.24 10 false SWP 5.031,1.49 5.344,1.688 0.313,0.198 10 false 3 3.167,2.094 4.094,2.438 0.927,0.344 10 false Drive Circuit 2.656,1.177 3.219,1.417 0.563,0.24 10 false +BWP 2.469,1.177 2.781,1.375 0.313,0.198 10 false 4 1.052,4.958 2.313,5.167 1.26,0.208 10 false IGCT-MAIN NO. 2 1.885,4.365 3.167,4.594 1.281,0.229 10 false INV W/PMP 1.792,1.573 2.104,1.771 0.313,0.198 10 false 1 1.781,1.188 2.094,1.385 0.313,0.198 10 false 3 0.073,5.688 1.479,5.948 1.406,0.26 10 false from Auxiliary Battery 0.354,6.094 3.219,6.292 2.865,0.198 10 false IWP: Inverter water pump assembly drive duty 0.333,6.438 3.396,6.635 3.063,0.198 10 false NIWP: Inverter water pump assembly speed signal 2.833,4.198 4.781,4.438 1.948,0.24 10 false Inverter Water Pump Assembly 5.365,4.594 5.677,4.792 0.313,0.198 10 false I278 0.333,1.417 1.104,1.906 0.771,0.49 10 false INV W/PMP NO. 2 1.031,1.177 1.344,1.375 0.313,0.198 10 false 5 1.031,1.563 1.344,1.76 0.313,0.198 10 false 2 0.354,4.344 1.063,4.781 0.708,0.438 10 false IGCT-MAIN NO. 2 1.781,4.135 2.094,4.333 0.313,0.198 10 false 3 1.021,4.125 1.333,4.323 0.313,0.198 10 false 5 1,4.5 1.313,4.698 0.313,0.198 10 false 2 1.771,4.49 2.083,4.688 0.313,0.198 10 false 1 0.854,1.146 1.167,1.344 0.313,0.198 10 false 2 0.563,1.146 0.875,1.344 0.313,0.198 10 false 1 0.51,4.073 0.823,4.271 0.313,0.198 10 false 1 2,4.094 2.313,4.292 0.313,0.198 10 false 1 0.854,4.073 1.167,4.271 0.313,0.198 10 false 2 2.323,4.094 2.635,4.292 0.313,0.198 10 false 2 1.042,2 1.875,2.292 0.833,0.292 10 false INV W/PMP 0.052,2.906 1.458,3.167 1.406,0.26 10 false from Auxiliary Battery

CAUTION / NOTICE / HINT

This diagnostic procedure is referenced to in the diagnostic procedure of several DTCs.

If the result of this diagnostic procedure is normal, proceed as directed in the procedure for the DTC.

CAUTION:

Refer to the precautions before inspecting high voltage circuit.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PRECAUTION


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 VEHICLE CONDITION
a.

Make sure that the front side of the radiator grille is not blocked with anything.


b.

Ask the customer if the front side of the radiator grille was blocked with anything.


Result:
Result Proceed to
Not blocked. A
Is/was blocked. B


HINT:

If the radiator grille is blocked, the inverter coolant temperature will increase and this DTC may be stored.



A

2.CHECK QUANTITY OF HV COOLANT

B

IF EQUIPPED, EXPLAIN TO CUSTOMER THAT OPTIONAL COMPONENTS WILL BE REMOVED

2.CHECK QUANTITY OF HV COOLANT
a.

Check the HV coolant level in the inverter reserve tank.


b.

Check for HV coolant leaks.

Result:
Result Proceed to
No leaks are found and the HV coolant level in the inverter reserve tank assembly is above the low line. A
No leaks are found and the HV coolant level in the inverter reserve tank assembly is below the low line. B
HV coolant leaks are evident. C


HINT:
·

After repairing the HV coolant leaks and adding coolant, perform the Active Tests "Activate the Inverter Water Pump" (Hybrid Control System) and "Control the Cooling Fan" (Engine Control System) and make sure that there are no malfunctions.

·

If there are signs of coolant leakage around the connecting parts of a hose and the inverter with converter assembly, replace the hose with a new one.





A

3.CHECK COOLANT HOSE

B

ADD HV COOLANT

C

INSPECT FOR COOLANT LEAK AND ADD COOLANT

3.CHECK COOLANT HOSE
a.

Check that the cooling system hoses are not kinked or clogged.

OK:

The cooling system hoses are not kinked or clogged.



Result:
Proceed to
OK
NG



OK

4.PERFORM ACTIVE TEST USING GTS (CONTROL THE ENGINE COOLING FAN)

NG

REPAIR OR REPLACE COOLANT HOSE

4.PERFORM ACTIVE TEST USING GTS (CONTROL THE ENGINE COOLING FAN)
a.

Perform the "Control the Engine Cooling Fan" Active Test.

Powertrain > Engine > Active Test
Tester Display
Control the Engine Cooling Fan
50004 372 26

Result:
Result Proceed to
Cooling fan operate A
Cooling fan does not operate B
Cooling fan do not stop


b.

Turn the ignition switch off.



A

5.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE INVERTER WATER PUMP)

B

CHECK COOLING FAN SYSTEM

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (COOLING)>COOLING FAN SYSTEM>Cooling Fan Circuit


5.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE INVERTER WATER PUMP)
NOTICE:
·

Make sure that the HV coolant level is above the low line of the inverter reserve tank.

·

Be sure to perform the inspection with the auxiliary battery voltage at 11 V or more.



HINT:

When the auxiliary battery voltage is low, the inverter water pump assembly may not operate.


a.

According to the display on the GTS, perform the Active Test "Activate the Inverter Water Pump" and check the value of the Data List item "Inverter Water Pump Revolution".

Powertrain > Hybrid Control > Active Test
Active Test Display
Activate the Inverter Water Pump
Data List Display
Inverter Water Pump Revolution
50004 397 1 60
OK:
Tester Display Condition Specified Condition
Inverter Water Pump Revolution Ignition switch ON
During Active Test 		3000 to 9500 rpm


HINT:
·

Perform the Active Test with the inverter coolant temperature between -15 and 65°C (5 to 149°F).

·

When the inverter water pump assembly is not operating, the Data List item "Inverter Water Pump Revolution" displays a value 200 rpm or less.




b.

Turn the ignition switch off.


Result:
Proceed to
OK
NG



OK

6.READ VALUE USING GTS (DATA LIST)

NG

8.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)
6.READ VALUE USING GTS (DATA LIST)
a.

Turn the ignition switch to ON (READY) and wait for 1 minute with the engine stopped.


b.

Read the Data List with the engine stopped.

Powertrain > Hybrid Control > Data List
Tester Display
Generator Inverter Temperature
Motor Inverter Temperature
Boosting Converter Temperature (Upper)
Boosting Converter Temperature (Lower)
Inverter Coolant Water Temperature
50003 397 510,130,136,137,152
Result:
Result Proceed to
Other than below. A
"Inverter Coolant Water Temperature" value is higher than the displayed temperature of any other Data List item by 20°C (68°F) or more. B


HINT:

The lower limit temperature that can be displayed for "Generator Inverter Temperature", "Motor Inverter Temperature", "Boosting Converter Temperature (Upper)" and "Boosting Converter Temperature (Lower)" is 0°C (32°F). The lower limit temperature for "Inverter Coolant Water Temperature" is -40°C (-40°F). The "Inverter Coolant Water Temperature" value displayed on the GTS may be lower than the others, but this is not a malfunction.



c.

Turn the ignition switch off.



A

7.CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING)

B

REPLACE INVERTER WITH CONVERTER ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER>REMOVAL


7.CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING)
a.

Read the Freeze Frame Data item "Ambient Temperature" using the GTS.

Powertrain > Hybrid Control > Trouble Codes
50001 397

b.

Check if the Freeze Frame Data item "Ambient Temperature" is below the freezing temperature of the HV coolant.

Result:
Result Proceed to
Ambient Temperature value is above freezing temperature of the HV coolant. A
Ambient Temperature value is below freezing temperature of the HV coolant. B


HINT:
·

HV coolant (SLLC) with a 30% concentration freezes at -15°C (5°F) and HV coolant (SLLC) with a 50% concentration freezes at -35°C (-31°F).

·

If the HV coolant freezes in the HV radiator or inverter water pump, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be stored.

·

A DTC is stored when the inverter water pump impeller cannot rotate due to freezing of the HV coolant.

·

If DTCs are output due to freezing of the LLC, the problem symptom cannot be reproduced. Check the LLC replacement history and whether the LLC was frozen based on the ambient temperature when the DTCs were stored.




c.

Turn the ignition switch off.



A

COOLING SYSTEM NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

B

REPLACE HV COOLANT

Click hereGeneral>MAINTENANCE>COOLANT (for Inverter)>REPLACEMENT


8.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>P056014

Result:
Proceed to
OK
NG



OK

9.CHECK CONNECTOR CONNECTION CONDITION (INVERTER WATER PUMP ASSEMBLY CONNECTOR)

NG

CONNECT SECURELY

9.CHECK CONNECTOR CONNECTION CONDITION (INVERTER WATER PUMP ASSEMBLY CONNECTOR)
a.
A517720N03
1.635,0.448 2.083,0.708 0.448,0.26 1.677,0.469 2.063,0.677 0.385,0.208 10 true A190

Check the connector connections and contact pressure of the relevant terminals for the inverter water pump assembly connector.

Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>ELECTRONIC CIRCUIT INSPECTION PROCEDURE

OK:

The connector is connected securely, the terminals are not deformed or corroded and there are no contact problems.



Result:
Proceed to
OK
NG



OK

10.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WATER PUMP ASSEMBLY)

NG

CONNECT SECURELY

10.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WATER PUMP ASSEMBLY)
a.

Disconnect the hybrid vehicle control ECU connector.


b.

Disconnect the inverter water pump assembly connector.


c.

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

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A197-32 (IWP) - A190-3 (SWP) Ignition switch off Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
A197-32 (IWP) or A190-3 (SWP) - Body ground and other terminals Ignition switch off 10 kΩ or higher



d.

Reconnect the inverter water pump assembly connector.


e.

Reconnect the hybrid vehicle control ECU connector.


Result:
Proceed to
OK
NG



OK

11.READ VALUE USING GTS (INVERTER WATER PUMP REVOLUTION)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

11.READ VALUE USING GTS (INVERTER WATER PUMP REVOLUTION)
NOTICE:

Be sure to perform the inspection with the auxiliary battery voltage at 11 V or more.


HINT:

When the auxiliary battery voltage is low, the inverter water pump assembly may not operate.


a.

Remove the INV W/PMP fuse from No. 1 engine room relay block and No. 1 junction block assembly.


b.

According to the display on the GTS, read the Data List.

Powertrain > Hybrid Control > Data List
Tester Display
Inverter Water Pump Revolution
50003 397 60
OK:
Tester Display Condition Specified Condition
Inverter Water Pump Revolution Ignition switch ON 200 rpm or less



c.

Turn the ignition switch off.


d.

Install the INV W/PMP fuse.


Result:
Proceed to
OK
NG



OK

12.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WATER PUMP ASSEMBLY)

NG

REPLACE HYBRID VEHICLE CONTROL ECU

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


12.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WATER PUMP ASSEMBLY)
a.

Disconnect the hybrid vehicle control ECU connector.


b.

Turn the ignition switch to ON.


c.

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

A458551C65
4.771,0.031 5.156,0.25 0.385,0.219 1.104,2.479 1.542,2.771 0.438,0.292 3.406,3.354 3.146,2.875 true 6.177,1.99 5.823,0.948 true 0.375,2.135 0.688,2.333 0.313,0.198 10 false *b 0.156,0.104 0.469,0.302 0.313,0.198 10 false *a 4.833,0.052 5.208,0.25 0.375,0.198 10 false I278 1.156,2.521 1.604,2.75 0.448,0.229 10 false A197 3.365,3.396 3.823,3.594 0.458,0.198 10 false IWP 6.177,2.042 6.635,2.24 0.458,0.198 10 false E1
*a Component with harness connected
(Hybrid Vehicle Control ECU) 		*b Front view of wire harness connector
(to Hybrid Vehicle Control ECU)


Standard Voltage:
Tester Connection Condition Specified Condition
A197-32 (IWP) - I278-1 (E1) Ignition switch ON 11 to 14 V


NOTICE:

Make sure to check for and clear DTCs after performing this inspection.



d.

Turn the ignition switch off.


e.

Reconnect the hybrid vehicle control ECU connector.


Result:
Proceed to
OK
NG



OK

13.CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM)

NG

14.REPLACE INVERTER WATER PUMP ASSEMBLY
13.CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM)
a.

Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the table below.


b.

Turn the ignition switch to ON.


c.

Check the waveform while turning the ignition switch to ON.

A502139C81
4.719,0.281 5.198,0.563 0.479,0.281 2.49,0.271 2.969,0.552 0.479,0.281 1.885,2.427 2.365,1.521 true 6.219,2.323 5.813,1.281 true 0.271,0.167 0.583,0.323 0.313,0.156 10 false *a 2.563,0.313 3.042,0.552 0.479,0.24 10 false A197 6.219,2.365 6.531,2.521 0.313,0.156 10 false E1 4.823,0.323 5.188,0.552 0.365,0.229 10 false I278 1.667,2.448 1.979,2.604 0.313,0.156 10 false IWP
*a Component with harness connected
(Hybrid Vehicle Control ECU) 		- -


Item Content
Terminal A197-32 (IWP) - I278-1 (E1)
Equipment Setting 5 V/DIV., 50 ms./DIV.
Condition Ignition switch ON

OK:

Waveform duty ratio is between 3% and 9%.



d.

Turn the ignition switch off.


Result:
Proceed to
OK
NG



OK

14.REPLACE INVERTER WATER PUMP ASSEMBLY

NG

REPLACE HYBRID VEHICLE CONTROL ECU

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


14.REPLACE INVERTER WATER PUMP ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>WATER PUMP WITH MOTOR>REMOVAL

Result:
Proceed to
NEXT



NEXT

15.ADD HV COOLANT AND PERFORM AIR BLEEDING
15.ADD HV COOLANT AND PERFORM AIR BLEEDING
a.

After replacing the inverter water pump assembly, add HV coolant and perform air bleeding.

Click hereGeneral>MAINTENANCE>COOLANT (for Inverter)>REPLACEMENT


Result:
Proceed to
NEXT



NEXT

END