RM36D0EC _51 Engine / Hybrid System _083048 HYBRID / BATTERY CONTROL _0709511 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.

Related Data List
Data List
·

Inverter Coolant Water Temperature

·

Motor Inverter Temperature

·

Rear Motor Inverter Temperature

·

Generator Inverter Calculated Temperature

·

Boosting Converter Temperature (Upper)

·

Boosting Converter Temperature (Lower)

·

Ambient Temperature

·

Inverter Water Pump Revolution



SYSTEM DESCRIPTION

The inverter converts the high-voltage direct current of the HV battery into alternating current for the generator (MG1), motor (MG2) and rear motor (MGR). 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 assembly monitors the inverter water pump assembly, cooling fan and cooling system, and detects malfunctions.

C412492C02
6.042,1.51 6.292,1.094 6.292,1.094 6.458,1.094 true 3.708,0.698 3.458,0.281 3.458,0.281 3.292,0.281 true 5.938,3.76 6.104,4.344 6.104,4.344 6.271,4.344 true 4.49,3.813 4.656,4.396 4.656,4.396 4.823,4.396 true 1.031,3.906 2.021,4.333 2.021,4.333 2.167,4.333 true 2.219,4.229 2.531,4.385 0.313,0.156 10 false *1 3.063,0.188 3.375,0.344 0.313,0.156 10 false *2 6.49,1.01 6.802,1.167 0.313,0.156 10 false *3 4.885,4.313 5.198,4.469 0.313,0.156 10 false *4 6.344,4.25 6.656,4.406 0.313,0.156 10 false *5
*1 Inverter Water Pump Assembly *2 Inverter Reserve Tank Assembly
*3 Inverter with Converter Assembly *4 Radiator Assembly (HV)
*5 Hybrid Vehicle Transaxle Assembly - -


WIRING DIAGRAM

C408113E20
5.365,5.604 7.073,6.365 1.708,0.76 10 false Hybrid Vehicle Control ECU Assembly 5.781,5.115 6.094,5.313 0.313,0.198 10 false E1 5.792,4.5 6.354,4.74 0.563,0.24 10 false MREL 5.781,3 6.344,3.24 0.563,0.24 10 false NIWP 5.781,1.5 6.344,1.74 0.563,0.24 10 false IWP 6.531,2.615 6.854,2.885 0.323,0.271 10 false +B 6.563,3.896 6.885,4.167 0.323,0.271 10 false +B 5.375,5.094 5.688,5.292 0.313,0.198 10 false A30 5.417,4.885 5.729,5.083 0.313,0.198 10 false 15 2.854,4.063 3.167,4.26 0.313,0.198 10 false A53 5.427,4.385 5.74,4.583 0.313,0.198 10 false 47 5.365,3.104 5.677,3.302 0.313,0.198 10 false A31 5.365,1.594 5.677,1.792 0.313,0.198 10 false A31 5.396,2.896 5.708,3.094 0.313,0.198 10 false 32 5.406,1.385 5.719,1.583 0.313,0.198 10 false 31 5.042,3.625 5.354,3.823 0.313,0.198 10 false 1 4.615,3.74 5.063,3.99 0.448,0.25 10 false GND 4.594,3.01 5.156,3.25 0.563,0.24 10 false NWP 5.042,3 5.354,3.198 0.313,0.198 10 false 2 4.594,1.51 5.156,1.75 0.563,0.24 10 false SWP 5.052,1.49 5.365,1.688 0.313,0.198 10 false 3 3.177,2.135 4.104,2.479 0.927,0.344 10 false Drive Circuit 2.646,1.188 3.208,1.427 0.563,0.24 10 false +BWP 2.479,1.188 2.792,1.385 0.313,0.198 10 false 4 1.26,4.938 1.792,5.271 0.531,0.333 10 false IGCT 1.823,4.354 2.792,4.573 0.969,0.219 10 false INV W/P NO. 1 1.792,1.563 2.104,1.76 0.313,0.198 10 false 1 1.781,1.167 2.094,1.365 0.313,0.198 10 false 3 0.396,2.865 0.802,3.052 0.406,0.188 10 false MAIN 0.073,5.667 1.479,5.927 1.406,0.26 10 false from Auxiliary Battery 0.354,6.135 3.219,6.333 2.865,0.198 10 false IWP: Inverter water pump assembly drive duty 0.333,6.458 3.396,6.656 3.063,0.198 10 false NIWP: Inverter water pump assembly speed signal 2.854,4.229 4.802,4.469 1.948,0.24 10 false Inverter Water Pump Assembly 5.365,4.604 5.677,4.802 0.313,0.198 10 false A30 0.281,1.417 1.104,1.885 0.823,0.469 10 false INV W/PMP NO. 2 1.177,2.031 1.74,2.25 0.563,0.219 10 false INV W/P 1.042,1.167 1.354,1.365 0.313,0.198 10 false 5 1.031,1.552 1.344,1.75 0.313,0.198 10 false 2 0.635,4.375 1.094,4.552 0.458,0.177 10 false IGCT 1.771,4.125 2.083,4.323 0.313,0.198 10 false 5 1.031,4.115 1.344,4.313 0.313,0.198 10 false 3 1.031,4.479 1.344,4.677 0.313,0.198 10 false 2 1.771,4.5 2.083,4.698 0.313,0.198 10 false 1 0.823,1.146 1.135,1.344 0.313,0.198 10 false 2 0.594,1.146 0.906,1.344 0.313,0.198 10 false 1 0.615,4.094 0.927,4.292 0.313,0.198 10 false 1 2.042,4.094 2.354,4.292 0.313,0.198 10 false 1 0.823,4.104 1.135,4.302 0.313,0.198 10 false 2 2.281,4.083 2.594,4.281 0.313,0.198 10 false 2

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


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 Duty Ratio" (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 DUTY RATIO)

NG

REPAIR OR REPLACE COOLANT HOSE

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

Connect the GTS to the DLC3.


b.

Turn the power switch on (IG).


c.

Enter the following menus: Powertrain / Engine / Active Test / Control the Engine Cooling Fan Duty Ratio.

Powertrain > Engine > Active Test
Tester Display
Control the Engine Cooling Fan Duty Ratio
50004 372 11

d.

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

OK:
Tester Operation Fan Operation
30 - 100% Cooling fan operates
0% Cooling fan stops



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


e.

Turn the power switch off.



A

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

B

CHECK COOLING FAN SYSTEM

for A25B-FXS:

Click hereEngine / Hybrid System>A25B-FXS (COOLING)>COOLING FAN SYSTEM>Cooling Fan Circuit

for A25D-FXS:

Click hereEngine / Hybrid System>A25D-FXS (COOLING)>COOLING FAN SYSTEM>Cooling Fan Circuit

for A25F-FXS:

Click hereEngine / Hybrid System>A25F-FXS (COOLING)>COOLING FAN SYSTEM (Production date from 2021/08)>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.

Connect the GTS to the DLC3.


b.

Turn the power switch on (IG).


c.

Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Inverter Water Pump.

Powertrain > Hybrid Control > Active Test
Active Test Display
Activate the Inverter Water Pump
Data List Display
Inverter Water Pump Revolution
50004 397 1 60

d.

Select the Data List item "Inverter Water Pump Revolution".


e.

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".

OK:
Tester Display Condition Specified Condition
Inverter Water Pump Revolution Power switch on (IG)
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.




f.

Turn the power 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 ASSEMBLY CONNECTOR)
6.READ VALUE USING GTS (DATA LIST)
a.

Connect the GTS to the DLC3.


b.

Turn the power switch on (READY) and wait for 1 minute with the engine stopped.


c.

Enter the following menus: Powertrain / Hybrid Control / Data List / Generator Inverter Calculated Temperature, Motor Inverter Temperature, Rear Motor Inverter Temperature, Boosting Converter Temperature (Upper), Boosting Converter Temperature (Lower) and Inverter Coolant Water Temperature.

Powertrain > Hybrid Control > Data List
Tester Display
Generator Inverter Calculated Temperature
Motor Inverter Temperature
Rear Motor Inverter Temperature
Boosting Converter Temperature (Upper)
Boosting Converter Temperature (Lower)
Inverter Coolant Water Temperature
50003 397 127,130,133,136,137,152

d.

Read the Data List with the engine stopped.

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 Calculated 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.



e.

Turn the power switch off.



A

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

B

REPLACE INVERTER WITH CONVERTER ASSEMBLY

for 2WD:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER (for 2WD)>REMOVAL

for AWD:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER (for AWD)>REMOVAL


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

Connect the GTS to the DLC3.


b.

Turn the power switch on (IG).


c.

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

Powertrain > Hybrid Control > Trouble Codes
50001 397

d.

Read the freeze frame data item "Ambient Temperature" using the GTS.


e.

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.




f.

Turn the power switch off.



A

COOLING SYSTEM NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

B

REPLACE HV COOLANT

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>COOLANT (for Inverter)>REPLACEMENT


8.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY 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.
C412493

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 ASSEMBLY - INVERTER WATER PUMP ASSEMBLY)

NG

CONNECT SECURELY

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

Disconnect the A31 hybrid vehicle control ECU assembly connector.


b.

Disconnect the A53 inverter water pump assembly connector.


c.
A556741C03
1.542,2.688 1.896,2.958 0.354,0.271 1.427,0.333 1.823,0.594 0.396,0.26 2.375,2.323 2.073,1.698 true 1.708,4.094 1.823,3.552 true 0.167,0.156 0.479,0.354 0.313,0.198 10 false *a 0.188,2.729 0.5,2.927 0.313,0.198 10 false *b 1.552,4.135 2.104,4.427 0.552,0.292 10 false SWP 2.26,2.365 2.635,2.563 0.375,0.198 10 false IWP 1.51,0.375 2.063,0.667 0.552,0.292 10 false A31 1.583,2.729 2.135,3.021 0.552,0.292 10 false A53
*a Front view of wire harness connector
(to Hybrid Vehicle Control ECU Assembly)
*b Front view of wire harness connector
(to Inverter Water Pump Assembly)


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

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A31-31 (IWP) - A53-3 (SWP) Power switch off Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
A31-31 (IWP) or A53-3 (SWP) - Body ground and other terminals Power switch off 10 kΩ or higher



d.

Reconnect the A53 inverter water pump assembly connector.


e.

Reconnect the A31 hybrid vehicle control ECU assembly 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.

Connect the GTS to the DLC3.


b.
C531440C01
1.177,1.208 0.635,1.417 true 0.156,0.135 0.469,0.333 0.313,0.198 10 false *1 0.448,1.333 0.76,1.531 0.313,0.198 10 false *2
*1 No. 1 Engine Room Relay Block and Junction Block Assembly
*2 INV W/PMP NO. 2 Fuse


Remove the INV W/PMP NO. 2 fuse from No. 1 engine room relay block and junction block assembly.


c.

Turn the power switch on (IG).


d.

Enter the following menus: Powertrain / Hybrid Control / Data List / Inverter Water Pump Revolution.

Powertrain > Hybrid Control > Data List
Tester Display
Inverter Water Pump Revolution
50003 397 60

e.

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

OK:
Tester Display Condition Specified Condition
Inverter Water Pump Revolution Power switch on (IG) 200 rpm or less



f.

Turn the power switch off.


g.

Install the INV W/PMP NO. 2 fuse.


Result:
Proceed to
OK
NG



OK

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

NG

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY

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


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

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


b.
C408963C01
0.146,0.115 0.458,0.313 0.313,0.198 10 false *1 2.563,2.135 2.875,2.333 0.313,0.198 10 false *2
*1 No. 1 Engine Room Relay Block and Junction Block Assembly
*2 INV W/P Relay Holder


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


c.

Connect terminals 3 and 5 of the INV W/P relay holder.

HINT:

Make a short circuit between terminals 3 and 5 to supply +B voltage to the inverter water pump.



d.

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

A458551C76
4.771,0.042 5.208,0.281 0.438,0.24 1.104,2.479 1.542,2.771 0.438,0.292 3.156,3.281 3,2.854 true 5.927,2.104 5.573,1.063 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 4.854,0.073 5.229,0.271 0.375,0.198 10 false A30 1.198,2.542 1.51,2.74 0.313,0.198 10 false A31 3.208,3.344 3.667,3.542 0.458,0.198 10 false IWP 5.948,2.146 6.406,2.344 0.458,0.198 10 false E1
*a Component with harness connected
(Hybrid Vehicle Control ECU Assembly) 		*b Front view of wire harness connector
(to Hybrid Vehicle Control ECU Assembly)


Standard Voltage:
Tester Connection Condition Specified Condition
A31-31 (IWP) - A30-3 (E1) INV W/P relay holder terminals 3 and 5 connected
Power switch off 		11 to 14 V


NOTICE:

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



e.

Install the INV W/P relay.


f.

Reconnect the A31 and A30 hybrid vehicle control ECU assembly connector.


Result:
Proceed to
OK
NG



OK

13.CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY (CHECK WAVEFORM)

NG

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

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


b.

Turn the power switch on (IG).


c.

Check the waveform while turning the power switch on (IG).

A573127C01
4.708,0.271 5.188,0.552 0.479,0.281 2.49,0.271 2.969,0.552 0.479,0.281 2.042,2.417 2.521,1.51 true 5.958,2.438 5.552,1.396 true 0.76,0.354 1.073,0.51 0.313,0.156 10 false *a 2.615,0.354 2.927,0.51 0.313,0.156 10 false A31 5.99,2.427 6.302,2.583 0.313,0.156 10 false E1 4.844,0.344 5.156,0.5 0.313,0.156 10 false A30 1.813,2.438 2.125,2.594 0.313,0.156 10 false IWP
*a Component with harness connected
(Hybrid Vehicle Control ECU Assembly) 		- -


Item Content
Terminal A31-31 (IWP) - A30-15 (E1)
Equipment Setting 5 V/DIV., 50 ms./DIV.
Condition Power switch on (IG)

OK:

Waveform duty ratio is between 3% and 9%.



d.

Turn the power switch off.


Result:
Proceed to
OK
NG



OK

14.REPLACE INVERTER WATER PUMP ASSEMBLY

NG

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY

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 hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>COOLANT (for Inverter)>REPLACEMENT


Result:
Proceed to
NEXT



NEXT

END