Canada - Hybrid System - MIL ON/DTC P3000/P0356 and Others
Bulletin
TSB2076
Issue Date
September 07, 2004
Market
Canada
Title
M.I.L. "ON" HV BATTERY DTCs P3000, P3056 AND/OR OTHER DTCs
Component
ENGINE ELECTRICAL
Models
'04 Prius
Some 2004 model year Prius vehicles may exhibit a Hybrid System & M.I.L. Warning Lights "ON" with DTCs P3000, P3056 and/or other DTCs. Review of freeze frame data may indicate that all HV Battery Cell Voltages are 0, however, the vehicle operates correctly. The following procedure has been developed to improve this condition.
NOTE:
This TSB only applies to cases with HV Battery ECU related DTCs.
APPLICABLE VEHICLES:
- 2004 model year Prius vehicles produced BEFORE the Production Change Effective VINs shown below.
PRODUCTION CHANGE INFORMATION:
PARTS INFORMATION:
WARRANTY INFORMATION:
PARTS INFORMATION:
REQUIRED SSTs:
DIAGNOSTIC INFORMATION;
REMOVAL PROCEDURE:
CAUTION:
- When working on high voltage systems, always wear insulating gloves.
- 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 in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
- After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
1. Disconnect Negative Battery Terminal.
a. Disconnect the negative terminal of the 12 V auxiliary battery.
2. Remove Service Plug Grip.
NOTE:
Wear insulating gloves.
a. Slide up the lever of the service plug grip. Remove the service plug grip while turning the lever to the left.
b. Insulate the service plug socket on the HV battery with insulating tape.
3. Remove Trunk Floor Panels and Trim Panels to Access the HV Battery on the Driver's Side of the Vehicle as shown.
4. Remove Battery Carrier Bracket.
a. Remove the 7 bolts and battery carrier bracket from the driver's side.
5. Remove Battery Carrier Panel No. 6.
a. Remove the 3 bolts, 2 nuts and battery carrier panel No. 6.
INSTALLATION PROCEDURE:
1. Prepare For Floor Wire No. 3 Installation.
NOTE:
For proper wiring harness service procedures, please refer to the "Connector Guidelines".
a. Remove the connector (A) from the Floor Wire No. 3. It is only included for the protection of the terminals during shipping and will no longer be needed.
2. Install Floor Wire No. 3.
a. Disconnect B11 connector from the HV battery ECU.
b. Remove #2: terminal IGCT (blue) from B11 connector.
c. Remove #12: terminal GND (white-black) from B11 connector.
NOTE:
Be careful not to damage the terminal.
d. Remove the cap from the white plastic 6 pin connector from floor wire No. 3.
e. Install #2: terminal IGCT wire (blue), which was removed from the B11 connector, to the #1 pin of the #6 pin floor wire No. 3 connector.
f. Install #12: terminal GND wire (white-black), which was removed from the B11 connector, to the #2 pin of the floor wire No. 3 connector.
NOTE:
Be careful not to damage the terminal.
g. Replace the cap for the white plastic 6 pin connector on floor wire No. 3.
h. Install the terminal (blue) of the floor wire No. 3 to #2: terminal IGCT of B11 connector.
i. Install the terminal (white-black) of the floor wire No. 3 to #12: terminal GND of B11 connector.
j. Wrap the floor wire No. 3 with included self--adhesive sponge as shown in the illustration.
k. Connect the B11 connector to the HV battery ECU.
NOTE:
Insert the floor wire #3 wrapped with sponge between the battery ECU and the battery plug.
RE-ASSEMBLY PROCEDURE:
1. Install Battery Carrier Panel No. 6.
a. Install the battery carrier panel No. 6 with the bolt and 2 nuts.
Torque: 7.5 N-m (76 kgf-cm, 66 in.-lbf)
2. Install Battery Carrier Bracket.
a. Install the battery carrier bracket with the 7 bolts.
Torque: 28 N-m (286 kgf-cm, 21 ft-lbf)
3. Install Service Plug Grip.
NOTE:
Wear insulating gloves.
a. Join the service plug grip with the HV battery.
b. While pushing the service plug grip to the right, rotate the lever to the right.
c. Be sure to slide the lever down to lock the service plug grip in place.
NOTE:
- The service plug grip must be locked. If not, it may cause DTCs.
- Do not operate the power switch when the service plug grip is not properly locked. It may damage the hybrid vehicle control ECU in rare cases.
4. Connect Battery Negative Terminal.
Torque: 6.0 N-m (61 kgf-cm, 53 in.-lbf)
5. Initialize Power Window Control System.
6. Replace interior pieces in reverse order from removal.
7. Using the recorded Freeze Frame Data as a guide, attempt to duplicate the conditions under which the codes originally set. If the codes return, proceed with Repair Manual diagnosis.
CONNECTOR GUIDELINES:
NOTE:
The Connector Guidelines section is for informational purposes ONLY.
1. Prepare Special Tool.
NOTE:
To remove the terminal from the connector, use SST# 00002--217958 or equivalent.
2. Disconnect Connector.
3. Disengage Secondary Locking Device Or Terminal Retainer.
a. The locking device must be disengaged before the terminal locking clip is released and the terminal is removed from the connector.
b. Use SST or a terminal pick to unlock the secondary locking device or terminal retainer.
NOTE:
Do not remove the terminal retainer from the connector body.
c. Release the locking lug from the terminal and pull the terminal out from the rear.
4. Install Terminal To Connector.
a. The locking device must be disengaged before the terminal locking clip is released and the terminal is removed from the connector.
NOTE:
- Make sure that the terminal is positioned correctly.
- Insert the terminal until the locking lug locks firmly.
- Insert the terminal with the terminal retainer in the temporary lock position.
b. Push the secondary lock device or terminal retainer into the full lock position.
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.