RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604234 HYBRID BATTERY SYSTEM J

HYBRID / BATTERY CONTROL  HYBRID BATTERY SYSTEM  ECU Power Source Circuit  


DESCRIPTION

If the ignition switch is ON, the battery ECU assembly applies current to the MREL terminal to turn the IGCT relay on. This supplies power to the IGCT terminals.

WIRING DIAGRAM

A512993E11
3.021,1.104 4.208,1.667 1.188,0.563 10 false IGCT-MAIN NO. 1 4.542,0.74 5.979,1.344 1.438,0.604 10 false IGCT NO. 2 5.854,0.563 7.042,1.125 1.188,0.563 10 false IGCT 5.865,1.604 7.052,2.167 1.188,0.563 10 false GND 5.625,2.198 6,2.5 0.375,0.302 10 false O217 5.615,1.479 5.958,1.76 0.344,0.281 10 false 10 5.604,0.479 5.958,0.76 0.354,0.281 10 false 12 4.677,0.5 5.021,0.781 0.344,0.281 10 false 1 5.073,0.49 5.417,0.708 0.344,0.219 10 false 2 5.615,2.375 7.156,2.646 1.542,0.271 10 false Battery ECU Assembly 3.813,0.51 4.156,0.792 0.344,0.281 10 false 3 3.219,0.51 3.563,0.792 0.344,0.281 10 false 5 3.823,0.75 4.167,1.031 0.344,0.281 10 false 2 3.229,0.75 3.573,1.031 0.344,0.281 10 false 1 1.344,1.365 2.031,1.771 0.688,0.406 10 false MREL 0.448,2.292 2.24,2.635 1.792,0.344 10 false Hybrid Vehicle Control ECU 0.01,0.563 0.896,0.948 0.885,0.385 10 false from Auxiliary Battery 1.844,1.354 2.156,1.552 0.313,0.198 10 false 10 0.448,2.125 0.76,2.323 0.313,0.198 10 false I278

CAUTION / NOTICE / HINT

CAUTION:

Refer to the precautions before inspecting high voltage circuit.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID BATTERY 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 BATTERY ECU ASSEMBLY (IGCT VOLTAGE)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517709N09
1.083,0.25 1.583,0.5 0.5,0.25 1.135,0.271 1.521,0.479 0.385,0.208 10 true O217

Disconnect the battery ECU assembly connector.

NOTICE:

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



c.

Connect the cable to the negative (-) auxiliary battery terminal.


d.

Turn the ignition switch to ON.


e.

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

Standard Voltage:
Tester Connection Condition Specified Condition
O217-12 (IGCT) - Body ground Ignition switch ON 11 to 14 V


NOTICE:
·

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

·

If the ignition switch is turned to ON with the connectors disconnected, other DTCs will be stored. Be sure to clear the DTCs after the inspection.




f.

Turn the ignition switch off.


g.

Disconnect the cable from the negative (-) auxiliary battery terminal.


h.

Reconnect the battery ECU assembly connector.


Result:
Proceed to
OK
NG



OK

2.CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - BODY GROUND)

NG

3.CHECK FUSE (IGCT NO. 2)
2.CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - BODY GROUND)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517709N09
1.083,0.25 1.583,0.5 0.5,0.25 1.135,0.271 1.521,0.479 0.385,0.208 10 true O217

Disconnect the battery ECU assembly connector.

NOTICE:

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



c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O217-10 (GND) - Body ground Always Below 1 Ω



d.

Reconnect the battery ECU assembly connector.


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 FUSE (IGCT NO. 2)
a.

Remove the IGCT NO. 2 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 NO. 2 fuse Always Below 1 Ω



c.

Install the IGCT NO. 2 fuse.


Result:
Proceed to
OK
NG



OK

4.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - BATTERY ECU ASSEMBLY)

NG

6.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - BATTERY ECU ASSEMBLY)
4.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - BATTERY ECU ASSEMBLY)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517709N09
1.083,0.25 1.583,0.5 0.5,0.25 1.135,0.271 1.521,0.479 0.385,0.208 10 true O217

Disconnect the battery ECU assembly connector.

NOTICE:

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



c.

Remove the IGCT NO. 2 fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


d.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O217-12 (IGCT) - 2 (IGCT NO. 2 fuse holder) Always Below 1 Ω



e.

Install the IGCT NO. 2 fuse.


f.

Reconnect the battery ECU assembly connector.


Result:
Proceed to
OK
NG



OK

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

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

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

Remove the IGCT-MAIN NO. 1 relay and IGCT NO. 2 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
3 (IGCT-MAIN NO. 1 relay holder) - 1 (IGCT NO. 2 fuse holder) Always Below 1 Ω



c.

Install the IGCT-MAIN NO. 1 relay and IGCT NO. 2 fuse.


Result:
Proceed to
OK
NG



OK

CHECK ECU Power Source Circuit (HYBRID CONTROL SYSTEM)

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>ECU Power Source Circuit


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

6.CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - BATTERY ECU ASSEMBLY)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517709N09
1.083,0.25 1.583,0.5 0.5,0.25 1.135,0.271 1.521,0.479 0.385,0.208 10 true O217

Disconnect the battery ECU assembly connector.

NOTICE:

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



c.

Remove the IGCT NO. 2 fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


d.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O217-12 (IGCT) or 2 (IGCT NO. 2 fuse holder) - Body ground and other terminals Always 10 kΩ or higher



e.

Install the IGCT NO. 2 fuse.


f.

Reconnect the battery ECU assembly connector.


Result:
Proceed to
OK
NG



OK

REPLACE FUSE (IGCT NO. 2)

NG

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



NEXT

REPLACE FUSE (IGCT NO. 2)