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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 60 (Hybrid Control System (AWD) - Circuit Tests (2 Of 2)) >> HYBRID CONTROL SYSTEM (for AWD) >> HV Battery High-voltage Line Circuit [12/2019 - 11/2023] >> Procedure

HV Battery High-voltage Line Circuit [12/2019 - 11/2023]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. CHECK INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Check that the bolts for the HV floor under wire is tightened to the specified torque, the HV floor under wire is connected securely, and there are no contact problems.

      Specified Condition

      T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

      GTY922274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the HV floor under wire from the inverter with converter assembly.
    4. Check for arc marks on the terminals for the HV floor under wire and inverter with converter assembly.

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    5. Reconnect the HV floor under wire.

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  2

  2. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK

      Dirt or foreign matter has not entered the connectors, and there is no evidence of contamination.

    2. Install the service plug grip.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE SERVICE PLUG GRIP 

    Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    Result: 

    OK 

    See step  3

  3. INSPECT SERVICE PLUG GRIP 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the service plug grip.

      Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    2. Measure the resistance according to the value(s) in the table below.
      GTY583877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip

      Standard Resistance

      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω
    3. Install the service plug grip.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE SERVICE PLUG GRIP 

    Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    Result: 

    OK 

    See step  4

  4. CHECK HYBRID BATTERY TERMINAL BLOCK 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Remove the Hybrid battery terminal block.

      Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      Hybrid battery terminal block Always Below 1 Ω
      GTY579731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Hybrid Battery Terminal Block
    3. Install the Hybrid battery terminal block.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE HYBRID BATTERY TERMINAL BLOCK 

    Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    Result: 

    OK 

    See step  5

  5. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the No. 10 HV battery shield panel.

      Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    3. Check that the HV floor under wire is connected securely, and there are no contact problems.
      GTY905700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the HV floor under wire connectors from the HV battery junction block assembly.
    5. Check for arc marks on the terminals of the HV floor under wire and the HV battery junction block assembly.

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    6. Reconnect the HV floor under wire.
    7. Install the No. 10 HV battery shield panel.

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  6

  6. CHECK FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the No. 10 HV battery shield panel.

      Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    3. Disconnect the HV floor under wire connectors from the HV battery junction block assembly.
      GTY905700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the HV floor under wire connector from the inverter with converter assembly.
      GTY895926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the resistance according to the value(s) in the table below.
      GTY891734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground - -
      *a HV Floor Under Wire
      (Inverter with Converter Assembly Side)      		 *b HV Floor Under Wire
      (HV Battery Junction Block Assembly Side)

      Standard Resistance

      Tester Connection Condition Specified Condition
      k1-1 (CBI) - k2-1 (CBI) Ignition switch off Below 1 Ω
      k1-2 (CEI) - k3-1 (CEI) Ignition switch off Below 1 Ω
      NOTE:

      Be sure not to damage or deform the terminal being inspected.

    6. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      NOTE:

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance

      Tester Connection Condition Specified Condition
      k1-1 (CBI) or k2-1 (CBI) - Body ground and shield ground Ignition switch off 10 MΩ or higher
      k1-2 (CEI) or k3-1 (CEI) - Body ground and shield ground Ignition switch off 10 MΩ or higher
      k1-1 (CBI) - k1-2 (CEI) Ignition switch off 10 MΩ or higher
      k2-1 (CBI) - k3-1 (CEI) Ignition switch off 10 MΩ or higher
    7. Reconnect the HV floor under wire connector to the inverter with converter assembly.
    8. Reconnect the HV floor under wire connectors to the HV battery junction block assembly.
    9. Install the No. 10 HV battery shield panel.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE FLOOR UNDER WIRE 

    Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    Result: 

    OK 

    See step  7

  7. INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the HV battery junction block assembly.

      Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    3. Measure the resistance according to the value(s) in the table below.
      GTY934790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (HV Battery Junction Block Assembly)      		 - -

      Standard Resistance

      Tester Connection Condition Specified Condition
      z11-1 (+) - k2-1 (CBI) Auxiliary battery voltage not applied between terminals M56-1 (SMRB) and M56-3 (GND) 10 kΩ or higher
      z11-1 (+) - k2-1 (CBI) Auxiliary battery voltage applied between terminals M56-1 (SMRB) and M56-3 (GND) Below 1 Ω
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      M56-1 (SMRB) - M56-3 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 Ω
    5. Install the HV battery junction block assembly.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    Result: 

    OK 

    See step  8

  8. INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRG) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the HV battery junction block assembly.

      Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

    3. Measure the resistance according to the value(s) in the table below.
      GTY877347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (HV Battery Junction Block Assembly)      		 - -

      Standard Resistance

      Tester Connection Condition Specified Condition
      z9-1 (-) - k3-1 (CEI) Auxiliary battery voltage not applied between terminals M56-4 (SMRG) and M56-3 (GND) 10 kΩ or higher
      z9-1 (-) - k3-1 (CEI) Auxiliary battery voltage applied between terminals M56-4 (SMRG) and M56-3 (GND) Below 1 Ω
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      M56-4 (SMRG) - M56-3 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 Ω
    5. Install the HV battery junction block assembly.

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    HV BATTERY HIGH-VOLTAGE LINE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC) 

    Result: 

    NG 

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

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