HV Battery Control System

HYBRID BATTERY SYSTEM
ON-VEHICLE INSPECTION
1. INSPECT BATTERY BLOWER ASSEMBLY





a. Check the operation.
1. Connect the hand held tester to the DLC3.
2. Turn the power switch ON (IG).
3. Select the item: DIAGNOSIS / OBD / MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1 to 6.

NOTICE: If the check results are normal, do not perform the following check.





b. Inspect the resistance.
1. Remove the service plug grip.
2. Disconnect the connector of the battery blower motor.
3. Using an ohmmeter, measure the resistance between terminals 1 and 2 of the connector.
Standard: 9 ohms or less
If the standard is not met, replace the battery blower assembly.
c. Inspect the voltage.
1. Connect the connector of the blower motor.





2. Using ohmmeter, measure the resistance between terminal 1 (GND) of the blower motor control connector and body ground.
Standard: 1 ohms or less
3. Connect the negative terminal of the auxiliary battery.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)





4. Connect the hand held tester to the DLC3.
5. Turn the power switch ON (IG).
6. Select the item: DIAGNOSIS / OBD / MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1.





7. Using a voltmeter, measure the voltage between terminals 1 (GND) of the blower motor connector and the body ground.
Standard: 9 to 14 V

NOTICE: If the standard is not met (there is no voltage), there may be a defect in the power supply system relays or in the wire harness.

8. Turn the power switch OFF, then disconnect the negative terminal of the auxiliary battery.
9. Disconnect the battery blower motor, battery blower motor control, and connector of the battery ECU assembly.
10. Using an ohmmeter, measure the resistance between the 2 terminals on the connectors of the battery blower motors on both sides of the vehicle, between the 4 terminals (VM) on the battery blower motor control, and between terminals B8 and 9 on the battery ECU assembly.
Standard: All the terminals 1 ohms or less





NOTICE: If the standard is not met, repair or replace the wire harness and go back to step (a).

11. Using an ohmmeter, measure the resistance between the terminal B8-10 (FCTL) on the connectors of the battery ECU assembly on both sides of the vehicle and terminal 1 on the holder installed on the battery blower relay No. 1.
Standard: 1 ohms or less

NOTICE: If the standard is not met, repair or replace the wire harness and go back to step (a).

12. Reconnect all the disconnected connectors.





NOTICE: Do not connect the service plug grip.





13. Connect the hand held tester to the DLC3.
14. Turn the power switch ON (IG).
15. Select the item: DIAGNOSIS / OBD/MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1.





16. Using a voltmeter, measure the voltage between terminals 1 (GND) and 2 (SI) of the battery blower motor control.
Standard: 1 V or more

NOTICE: If the standard is not met, repair or replace the wire harness and go back to step (a).





17. Using a voltmeter, measure the voltage between the terminals on the blower motor connector.
Standard: 2 to 4 V

NOTICE: If the standard is not met, repair or replace the wire harness and go back to step (a).





18. Using a voltmeter, measure the voltage between terminals 1 (GND) and 4 (VM) of the blower motor control.
Standard: A-4 V to A-2V (A=(c)-(6))

NOTICE: If the standard is not met, repair or replace the wire harness and go back to step (a).

19. Return to step (a) and perform the inspection again to reconfirm.

INSPECTION
1. INSPECT BATTERY PLUG
a. Check the continuity.





1. Using an ohmmeter, check the continuity between the terminals.
Standard: 10 kohms or higher
If the standard is not met, replace the battery plug.





2. Install the service plug grip to the socket.
3. Using an ohmmeter, check the continuity between the terminals.
Standard: Below 1 ohms
If the standard is not met, replace the battery plug.
2. INSPECT SYSTEM MAIN RELAY NO.1








NOTICE: Connectors B and C have the same shape. Identify each connector by the wire harness length (L) and the wire harness color on the terminal 1 side.

a. Check the continuity.
1. Using an ohmmeter, measure the resistance between the connectors.





Standard

If the standards are not met, replace the system main relay No. 1.
2. Using an ohmmeter, apply voltage between the positive and negative terminals, then measure the resistance between terminals 6 and A1 (CONT1).
Standard: Below 1 ohms
If the standard is not met, replace the system main relay No. 1.
b. Inspect the resistance.
1. Using an ohmmeter, measure the resistance between terminals 6 and A1 (CONT1).
Standard: 70 to 160 ohms
If the standard is not met, replace the system main relay No. 1.





3. INSPECT SYSTEM MAIN RELAY NO.2
a. Install the 2 installed nuts to the negative and positive terminals.
Torque: 5.6 Nm (57 kgf-cm, 50 inch lbs.)
b. Check the continuity.
1. Using an ohmmeter, measure the resistance between the positive and negative terminals.
Standard: 10 kohms or higher
If the standard is not met, replace the system main relay No. 2.
2. Using an ohmmeter, apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals.
Standard: Below 1 ohms
If the standard is not met, replace the system main relay No. 2.
c. Inspect the resistance.
1. Using an ohmmeter, measure the resistance between the connector terminals.
Standard: 20 to 50 ohms
If the standard is not met, replace the system main relay No. 2.





4. INSPECT SYSTEM MAIN RELAY NO.3
a. Install the 2 installed nuts to the negative and positive terminals.
Torque: 5.6 Nm (57 kgf-cm, 50 inch lbs.)
b. Check the continuity.
1. Using an ohmmeter, measure the resistance between the positive and negative terminals.
Standard: 10 kohms or higher
If the standard is not met, replace the system main relay No. 3.
2. Using an ohmmeter, apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals.
Standard: Below 1 ohms
If the standard is not met, replace the system main relay No. 3.
c. Inspect the resistance.
1. Using an ohmmeter, measure the resistance between the connector terminals.
Standard: 20 to 50 ohms
If the standard is not met, replace the system main relay No. 3.





5. INSPECT BATTERY CURRENT SENSOR
a. Inspect the resistance.
1. Using an ohmmeter, measure the resistance between terminals 1 (VIB) and 2 (GIB).





Standard

If the standards are not met, replace the battery current sensor.
2. Using an ohmmeter, measure the resistance between terminals 1 (VIB) and 3 (IB).





Standard

If the standards are not met, replace the battery current sensor.
3. Using an ohmmeter, measure the resistance between terminals 2 (GIB) and 3 (IB).
Standard: 0.2 kohms or less

NOTICE: Even if the probes are changed around, the resistance will not vary.

If the standard is not met, replace the battery current sensor.





6. INSPECT SYSTEM MAIN RESISTOR
a. Inspect the resistance.
1. Using an ohmmeter, measure the resistance between the terminals.
Standard: 18 to 22 ohms
If the standard is not met, replace the system main resistor.





7. INSPECT BATTERY BLOWER RELAY NO.1
a. Inspect the resistance.
1. Using an ohmmeter, measure the resistance between the terminals.





Standard

If the standards are not met, replace the battery blower relay No. 1.