PRECAUTION
| CAUTION | The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures below. |
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- DISCONNECT POWER SOURCE WHEN PERFORMING WORK ON HIGH VOLTAGE SYSTEM Ensure that the power switch is OFF. Disconnect the negative terminal cable from the auxiliary battery (see SERVICE PLUG GRIP ). Always wear insulating gloves (see item 2 below). NOTE: DTCs will also be erased, so if necessary check DTCs before disconnecting the power source OFF. Remove the service plug grip (see SERVICE PLUG GRIP ). NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. Keep the removed service plug grip in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. Leave the vehicle for 5 minutes. HINT: It takes 5 minutes for the high voltage condenser in the inverter to discharge its electricity.
- PRECAUTIONS FOR INSULATING GLOVES Before wearing, ensure that the insulating gloves are not damaged with tears, holes or cracks. Do not wear wet gloves.
- PRECAUTIONS FOR WIRE HARNESS AND CONNECTOR The wire harnesses and connectors with high voltage circuits are colored orange. In addition, high voltage parts such as the HV battery are affixed with a "High Voltage" caution label. Be careful not to touch these wires.
- PRECAUTIONS WHEN PERFORMING SERVICE OR INSPECTIONS Always disconnect the power source before starting work (see item 1 above). Always wear insulating gloves when inspecting or servicing any high voltage wires and parts. Alert other technicians that you are working on the high voltage systems with a warning sign such as "High Voltage Work: Do Not Touch". Do not carry any metal objects such as a mechanical pencil or a measuring tape that could fall and cause a short circuit. After removing any high voltage wires, insulate them immediately with insulation tape. Always tighten the high voltage screw terminals to the specified torque. Insufficient or excessive torque will cause malfunctions. After finishing work on the high voltage systems and before reinstalling the service plug, reconfirm that you have not left any parts or tools lying around, that the high voltage terminals are tightened and that the connectors are connected.
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- INSPECT INVERTER NOTE: Wear insulating gloves. HINT: Check DTCs before performing the inspections of the converter and inverter, and perform the appropriate troubleshooting. Turn the power switch OFF. Remove the service plug grip (see SERVICE PLUG GRIP ). Remove the inverter cover (see W/CONVERTER INVERTER ASSY ). Disconnect the connectors A and B shown in the illustration. Turn the power switch ON (IG). If turning the power switch ON (IG) with the service plug grip removed, the DTC of the inter lock switch system will be output. Using a voltmeter, measure the voltage. Also, using an ohmmeter, measure the resistance. NOTE: The inspection should be performed on the wire harness side, not on the terminal side. Standard
- INSPECT CONVERTER NOTE: Wear insulating gloves. HINT: If the HV system warning, master warning lamp and charge warning come on at the same time, check the DTCs and perform the appropriate troubleshooting. Check the operation. Using a voltmeter, measure the voltage of the auxiliary battery terminal when the "READY" lamp is OFF and ON. Standard: LAMP CONDITION "READY" Lamp Voltage ON 14 V OFF 12 V HINT: When the "READY" lamp is ON, the converter outputs the voltage. When it is OFF, the auxiliary battery outputs the voltage. Inspect the output current. Disconnect the MG1 and MG2 power cables from the inverter (see W/CONVERTER INVERTER ASSY ). Install a voltmeter and the AC/DC 400 A probe to the locations shown in the illustration. Connect the MG1 and MG2 power cables to the inverter (see W/CONVERTER INVERTER ASSY ). With the "READY" lamp ON, operate the 12 V electrical devices one by one, then measure the output current. Standard: Approximately 80 A or less HINT: If the output current is 0 A or greater than 80 A, check the input output signal. Check the input/output signal. Disconnect the connectors shown in the illustration. Using a voltmeter, measure the voltage between the body ground and the terminal of the vehicle side wire harness connector. Standard: Equal to the auxiliary battery terminal voltage Disconnect the connectors shown in the illustration. Turn the power switch ON (IG). Using a voltmeter and ohmmeter, measure the voltage and resistance between the connector terminals on the vehicle harness side. Standard: TESTER CONNECTION SPECIFIED CONDITION Tester connection Specified condition Terminal 1 - Body ground (IGCT - Body ground) 8 to 16 V Terminal 3 - Body ground (S - Body ground) Equal to the auxiliary battery voltage Terminal 4 - Body ground (NODD - Body ground) 120 to 140 kohm (when power switch is OFF) If the standards are not met, replace the with inverter converter assembly.
- INSPECT SPEED SENSOR (RESOLVER) Using an ohmmeter, measure the resistance between the terminals. Standard: If the standards are not met, replace the hybrid vehicle transaxle assembly.
- INSPECT TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Standard: HINT: The standard varies according to the sensor temperature. If the standards are not met, replace the hybrid vehicle transaxle assembly.
- INSPECT ACCELERATOR POSITION NOTE: Do not remove the accelerator position sensor from the accelerator pedal. Perform the inspection on the hybrid vehicle control ECU side of the connector. Turn the power switch ON (IG). Using a voltmeter, measure the voltage between the terminals. Standard: TERMINALS SPECIFIED CONDITION Terminals Measuring Condition Specified Condition B25 - B27 (VCP1 - EP1) Normal 4.5 to 5.5 V B26 - B27 (VPA1 - EP1) Do not depress the accelerator pedal 0.5 to 1.1 V B26 - B27 (VPA1 - EP1) Gradually depress the accelerator pedal The voltage increases slowly B26 - B27 (VPA1 - EP1) Fully depress the accelerator pedal 2.6 to 4.5 V B33 - B35 (VCP2 - EP2) Normal 4.5 to 5.5 V B34 - B35 (VPA2 - EP2) Do not depress the accelerator pedal 1.2 to 2.0 V B34 - B35 (VPA2 - EP2) Gradually depress the accelerator pedal The voltage increases slowly B34 - B35 (VPA2 - EP2) Fully depress the accelerator pedal 3.4 to 5.3 V If the standards are not met, replace the accelerator pedal rod assembly.
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- INSPECT INTEGRATION RELAY (IGCT RELAY) Check the HEV fuse. Remove the 20 A fuse. Using an ohmmeter, measure the resistance between the terminals. Standard: Below 1 ohm If the standard is not met, replace the fuse. Check the IGCT relay. Using an ohmmeter, measure the resistance between the terminals. Standard: TESTER CONNECTION SPECIFIED CONDITION Tester Connection Specified Condition 7J-1 - 7J-4 10 kohm or higher 7J-1 - 7K-1 Below 1 ohm 7J-2 - 7J-3 Below 1 ohm 7J-4 - 7K-1 10 kohm or higher If the standards are not met, replace the integration relay. Using an ohmmeter, measure the resistance between the terminals when battery voltage is applied to terminals 7J-2 and 7J-3. Standard: TESTER CONNECTION SPECIFIED CONDITION Tester Connection Specified Condition 7J-1 - 7J-4 Below 1 ohm 7J-1 - 7K-1 Below 1 ohm If the standards are not met, replace the integration relay.
- INSPECT WATER W/MOTOR & BRACKET PUMP ASSY Check the operation. Connect the battery positive terminal to terminal 1 and the battery negative terminal to terminal 2, then check that the pump motor operates properly. NOTE: Do not connect the positive and negative poles of the battery to the wrong terminals. Complete the check within 10 seconds of connection. If it does not operate properly, replace the water pump with motor and bracket.
