RM36D0EC _51 Engine / Hybrid System _083048 HYBRID / BATTERY CONTROL _0709511 HYBRID CONTROL SYSTEM J

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  ECU Power Source Circuit  


DESCRIPTION

If the power switch is on (IG), the hybrid vehicle control ECU assembly applies current to the MREL terminal to turn the IGCT relay on. This supplies power to the +B1 and +B2 terminals.

WIRING DIAGRAM

A550258E03
4.76,4 7.146,4.198 2.385,0.198 10 false Hybrid Vehicle Control ECU Assembly 1.198,2.354 4.229,2.583 3.031,0.229 10 false No. 3 Relay Block and Junction Block Assembly 0.135,3.198 1.292,3.646 1.156,0.448 10 false Auxiliary Battery 1.5,1.219 1.885,1.406 0.385,0.188 10 false IGCT 3.323,1.24 4.083,1.458 0.76,0.219 10 false IGCT NO. 2 2.531,1.927 2.969,2.146 0.438,0.219 10 false IGCT 5.833,0.667 6.271,0.885 0.438,0.219 10 false +B1 5.833,1.073 6.271,1.292 0.438,0.219 10 false +B2 5.854,1.51 6.292,1.729 0.438,0.219 10 false MREL 5.844,1.99 6.281,2.208 0.438,0.219 10 false E1 5.844,2.479 6.281,2.698 0.438,0.219 10 false E12 5.844,3.146 6.281,3.365 0.438,0.219 10 false E01 5.458,0.656 5.896,0.875 0.438,0.219 10 false A30 5.448,1.51 5.885,1.729 0.438,0.219 10 false A30 5.448,1.073 5.885,1.292 0.438,0.219 10 false A30 5.458,2.052 5.896,2.271 0.438,0.219 10 false A30 5.458,2.49 5.896,2.708 0.438,0.219 10 false A30 5.458,3.146 5.896,3.365 0.438,0.219 10 false A31 5.49,2.917 5.927,3.135 0.438,0.219 10 false 10 5.531,2.292 5.969,2.51 0.438,0.219 10 false 1 5.49,1.854 5.927,2.073 0.438,0.219 10 false 15 5.49,1.302 5.927,1.521 0.438,0.219 10 false 47 5.531,0.865 5.969,1.083 0.438,0.219 10 false 8 5.531,0.438 5.969,0.656 0.438,0.219 10 false 7 3.469,0.948 3.906,1.167 0.438,0.219 10 false 1 3.74,0.948 4.177,1.167 0.438,0.219 10 false 2 3.073,1.396 3.51,1.615 0.438,0.219 10 false 1 2.177,1.396 2.615,1.615 0.438,0.219 10 false 2 1.75,0.958 2.188,1.177 0.438,0.219 10 false 2 1.469,0.958 1.906,1.177 0.438,0.219 10 false 1 2.177,0.958 2.615,1.177 0.438,0.219 10 false 3 3.083,0.948 3.292,1.167 0.208,0.219 10 false 5

PROCEDURE

1.CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY (+B1, +B2 VOLTAGE)
a.

Turn the power switch on (IG).


b.

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

A494136C18
4.688,0.25 5.115,0.552 0.427,0.302 5.552,2.344 4.969,1.271 true 4.375,2.333 4.833,1.26 true 0.313,0.24 0.625,0.396 0.313,0.156 10 false *a 4.802,0.344 5.438,0.594 0.635,0.25 10 false A30 4.167,2.354 4.802,2.604 0.635,0.25 10 false +B2 5.563,2.354 6.198,2.604 0.635,0.25 10 false +B1
*a Component with harness connected
(Hybrid Vehicle Control ECU Assembly) 		- -


Standard Voltage:
Tester Connection Condition Specified Condition
A30-7 (+B1) - Body ground Power switch on (IG) 11 to 14 V
A30-8 (+B2) - Body ground Power switch on (IG) 11 to 14 V



c.

Turn the power switch off.


Result:
Proceed to
OK
NG



OK

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

NG

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

Disconnect the A31 and A30 hybrid vehicle control ECU assembly connectors.


b.

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

A368649C67
3.583,0.729 4,0.958 0.417,0.229 0.385,0.74 0.802,0.969 0.417,0.229 4.635,0.938 4.958,0.229 true 4.188,0.26 4.406,0.844 true 2.521,0.885 2.927,0.323 true 0.302,0.24 0.615,0.396 0.313,0.156 10 false *a 0.469,0.771 0.781,0.927 0.313,0.156 10 false A31 3.667,0.76 3.979,0.917 0.313,0.156 10 false A30 4.99,0.083 5.302,0.24 0.313,0.156 10 false E1 3.969,0.083 4.281,0.24 0.313,0.156 10 false E12 2.938,0.146 3.25,0.302 0.313,0.156 10 false E01
*a Front view of wire harness connector
(to Hybrid Vehicle Control ECU Assembly) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
A30-15 (E1) - Body ground Always Below 1 Ω
A31-10 (E01) - Body ground Always Below 1 Ω
A30-1 (E12) - Body ground Always Below 1 Ω



c.

Reconnect the A31 and A30 hybrid vehicle control ECU assembly 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 ASSEMBLY (MREL VOLTAGE)
a.

Turn the power switch on (IG).


b.

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

A494137C51
4.49,0.25 4.958,0.552 0.469,0.302 4.385,2.375 4.938,1.635 true 0.313,0.24 0.625,0.396 0.313,0.156 10 false *a 4.615,0.323 5.271,0.563 0.656,0.24 10 false A30 4.104,2.396 4.74,2.646 0.635,0.25 10 false MREL
*a Component with harness connected
(Hybrid Vehicle Control ECU Assembly) 		- -


Standard Voltage:
Tester Connection Condition Specified Condition
A30-47 (MREL) - Body ground Power switch on (IG) 11 to 14 V



c.

Turn the power switch off.


Result:
Proceed to
OK
NG



OK

4.CHECK FUSE (IGCT NO. 2)

NG

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY

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


4.CHECK FUSE (IGCT NO. 2)
a.
C408100C01
0.885,2.896 1.521,2.844 true 0.146,0.167 0.458,0.365 0.313,0.198 10 false *1 0.698,2.823 1.01,3.021 0.313,0.198 10 false *2
*1 No. 3 Relay Block and Junction Block Assembly
*2 IGCT NO. 2 Fuse


Remove the IGCT NO. 2 fuse from the No. 3 relay block and 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 terminals Always Below 1 Ω



c.

Install the IGCT NO. 2 fuse.


Result:
Proceed to
OK
NG



OK

5.CHECK FUSE (IGCT)

NG

11.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY - HYBRID VEHICLE CONTROL ECU ASSEMBLY)
5.CHECK FUSE (IGCT)
a.
C408106C01
1.917,2.615 2.552,2.563 true 0.146,0.167 0.458,0.365 0.313,0.198 10 false *1 2.615,2.49 2.927,2.688 0.313,0.198 10 false *2
*1 No. 3 Relay Block and Junction Block Assembly
*2 IGCT Fuse


Remove the IGCT fuse from the No. 3 relay block and junction block assembly.


b.

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

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



c.

Install the IGCT fuse.


Result:
Proceed to
OK
NG



OK

6.INSPECT RELAY (IGCT)

NG

12.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY)
6.INSPECT RELAY (IGCT)
a.
C408040C01
0.969,2.521 1.583,2.198 true 0.146,0.167 0.458,0.365 0.313,0.198 10 false *1 0.76,2.469 1.073,2.667 0.313,0.198 10 false *2
*1 No. 3 Relay Block and Junction Block Assembly
*2 IGCT Relay


Remove the IGCT relay from the No. 3 relay block and junction block assembly.


b.
A253297C01
0.146,0.056 0.409,0.261 0.263,0.205 10 *1
*1 IGCT 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 relay.


Result:
Proceed to
OK
NG



OK

7.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY - HYBRID VEHICLE CONTROL ECU ASSEMBLY)

NG

REPLACE RELAY (IGCT)

7.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY - HYBRID VEHICLE CONTROL ECU ASSEMBLY)
a.

Disconnect the A30 hybrid vehicle control ECU assembly connectors.


b.

Remove the IGCT NO. 2 fuse from the No. 3 relay block and junction block assembly.


c.

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

A556752C02
4.833,1.021 5.24,1.313 0.406,0.292 5.302,2.76 5.125,2.021 true 4.5,2.792 4.99,2.073 true 0.573,0.417 0.885,0.573 0.313,0.156 10 false *1 2.063,2.844 2.375,3 0.313,0.156 10 false *2 2.594,0.417 2.906,0.573 0.313,0.156 10 false *a 5.229,2.792 5.615,3.052 0.385,0.26 10 false +B2 4.344,2.844 4.729,3.104 0.385,0.26 10 false +B1 4.917,1.063 5.302,1.323 0.385,0.26 10 false A30
*1 No. 3 Relay Block and Junction Block Assembly *2 IGCT NO. 2 Fuse
*a Front view of wire harness connector
(to Hybrid Vehicle Control ECU Assembly) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
A30-7 (+B1) - 2 (IGCT NO. 2 fuse terminal) Always Below 1 Ω
A30-8 (+B2) - 2 (IGCT NO. 2 fuse terminal) Always Below 1 Ω



d.

Reconnect the A30 hybrid vehicle control ECU assembly connectors.


e.

Install the IGCT NO. 2 fuse.


Result:
Proceed to
OK
NG



OK

8.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

8.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY)
a.

Disconnect the IGCT fuse, IGCT NO. 2 fuse and IGCT relay from the No. 3 relay block and junction block assembly.


b.

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

C408102C01
1.031,0.26 1.344,0.417 0.313,0.156 10 false *1 2.125,2.781 2.438,2.938 0.313,0.156 10 false *2 4.448,0.719 4.635,0.917 0.188,0.198 10 false *3 4.448,2.333 4.76,2.49 0.313,0.156 10 false *4
*1 No. 3 Relay Block and Junction Block Assembly *2 IGCT NO. 2 Fuse
*3 IGCT Relay *4 IGCT Fuse


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



c.

Install the IGCT fuse, IGCT NO. 2 fuse and IGCT relay.


Result:
Proceed to
OK
NG



OK

9.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY)

NG

REPLACE FUSE HOLDER

9.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY)
a.

Disconnect the A30 hybrid vehicle control ECU assembly connector.


b.

Remove the IGCT relay from the No. 3 relay block and junction block assembly.


c.

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

A556753C02
5.229,0.865 5.583,1.146 0.354,0.281 5.115,2.76 5.365,2.25 true 0.375,0.188 0.688,0.385 0.313,0.198 10 false *1 2.375,1.917 2.688,2.115 0.313,0.198 10 false *2 3.813,0.25 4.125,0.448 0.313,0.198 10 false *a 5.292,0.938 5.75,1.135 0.458,0.198 10 false A30 4.917,2.802 5.531,3 0.615,0.198 10 false MREL
*1 No. 3 Relay Block and Junction Block Assembly *2 IGCT Relay
*a Front view of wire harness connector
(to Hybrid Vehicle Control ECU Assembly) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
A30-47 (MREL) - 1 (IGCT relay) Always Below 1 Ω
A30-47 (MREL) or 1 (IGCT relay) - Body ground and other terminals Always 10 kΩ or higher



d.

Install the IGCT relay.


e.

Reconnect the A30 hybrid vehicle control ECU assembly connector.


Result:
Proceed to
OK
NG



OK

10.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY - BODY GROUND)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

10.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY - BODY GROUND)
a.

Remove the IGCT relay from the No. 3 relay block and junction block assembly


b.
C408104C01
0.115,0.125 0.427,0.323 0.313,0.198 10 false *1 0.417,1.333 0.729,1.531 0.313,0.198 10 false *2
*1 No. 3 Relay Block and Junction Block Assembly
*2 IGCT Relay


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

Standard Resistance:
Tester Connection Condition Specified Condition
2 (IGCT relay) - Body ground Always Below 1 Ω



c.

Install the IGCT relay.


Result:
Proceed to
OK
NG



OK

CHECK FOR INTERMITTENT PROBLEMS

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>CHECK FOR INTERMITTENT PROBLEMS


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

11.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY - HYBRID VEHICLE CONTROL ECU ASSEMBLY)
a.

Remove the IGCT NO. 2 fuse from the No. 3 relay block and junction block assembly.


b.

Disconnect the A30 hybrid vehicle control ECU assembly connectors.


c.

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

A556752C03
4.917,1 5.323,1.292 0.406,0.292 5.302,2.76 5.125,2.021 true 4.5,2.792 4.99,2.073 true 0.573,0.417 0.885,0.573 0.313,0.156 10 false *1 2.063,2.844 2.375,3 0.313,0.156 10 false *2 2.594,0.417 2.906,0.573 0.313,0.156 10 false *a 5.229,2.792 5.615,3.052 0.385,0.26 10 false +B2 4.344,2.844 4.729,3.104 0.385,0.26 10 false +B1 4.979,1.073 5.365,1.333 0.385,0.26 10 false A30
*1 No. 3 Relay Block and Junction Block Assembly *2 IGCT No. 2 Fuse
*a Front view of wire harness connector
(to Hybrid Vehicle Control ECU Assembly) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
A30-7 (+B1) or 2(IGCT No. 2 fuse terminal) - Body ground and other terminals Always 10 kΩ or higher
A30-8 (+B2) or 2(IGCT No. 2 fuse terminal) - Body ground and other terminals Always 10 kΩ or higher



d.

Reconnect the A30 hybrid vehicle control ECU assembly connectors.


e.

Install the IGCT No. 2 fuse.


Result:
Proceed to
OK
NG



OK

REPLACE FUSE (IGCT NO. 2)

NG

13.REPAIR OR REPLACE HARNESS OR CONNECTOR
12.CHECK HARNESS AND CONNECTOR (NO. 3 RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY)
a.

Disconnect the IGCT fuse, IGCT NO. 2 fuse and IGCT relay from the No. 3 relay block and junction block assembly.


b.

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

C408102C01
1.031,0.26 1.344,0.417 0.313,0.156 10 false *1 2.125,2.781 2.438,2.938 0.313,0.156 10 false *2 4.448,0.719 4.635,0.917 0.188,0.198 10 false *3 4.448,2.333 4.76,2.49 0.313,0.156 10 false *4
*1 No. 3 Relay Block and Junction Block Assembly *2 IGCT NO. 2 Fuse
*3 IGCT Relay *4 IGCT Fuse


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



c.

Install the IGCT fuse, IGCT NO. 2 fuse and IGCT relay.


Result:
Proceed to
OK
NG



OK

REPLACE FUSE (IGCT)

NG

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



NEXT

REPLACE FUSE (IGCT NO. 2)

14.REPLACE FUSE HOLDER
Result:
Proceed to
NEXT



NEXT

REPLACE FUSE (IGCT)