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HYBRID CONTROL SYSTEM > HV Battery cannot be Charged Using the
Plug-in Function
for Preparation Click here
DESCRIPTION
When the power management control ECU (HV CPU) receives the CPLT signal from the electric
vehicle charger assembly, the power source control ECU closes the IGCT relay to enable the
plug-in HV system. Also, the power management control ECU (HV CPU) judges the charge
voltage status received from the electric vehicle charger cable assembly and prepares for
charging.
WIRING DIAGRAM
INSPECTION PROCEDURE
1.CHECK DTC OUTPUT (ALL)
a. Connect the intelligent tester to the DLC3.
b. Turn the power switch on (IG).
c. Check for DTCs of all system by following the prompts on the intelligent tester screen.
Result:
Result
Proceed to
No DTCs are output.
A
DTCs are output.
B
d. Turn the power switch off.
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B
GO TO DTC CHART
A
2.REPLACE ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY (INSPECTION BY
REPLACEMENT)
a. Replace the electric vehicle charger cable assembly with a known good one.
NEXT
3.CHECK INDICATOR ASSEMBLY
a. Connect the electric vehicle charger cable assembly to an outlet (AC).
b. Connect the charge connector of the electric vehicle charger cable assembly to the charge
inlet of the vehicle.
c. Check if the charge indicator light comes on.
OK:
The charge indicator light comes on.
NG
Go to step 5
OK
4.READ VALUE USING INTELLIGENT TESTER (BAT NO. 1, NO. 2, NO. 3 STATE OF
CHRGE)
a. Connect the intelligent tester to the DLC3.
b. Turn the power switch on (IG).
c. Enter the following menus: Powertrain / Hybrid Control / Data List / Bat No. 1 State of
Chrge, Bat No. 2 State of Chrge, Bat No. 3 State of Chrge.
d. Read the Data List.
OK:
The SOC of one of the Data List items increases.
e. Turn the power switch off.
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NG
Go to step 9
OK
REPLACE ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY
5.INSPECT INDICATOR ASSEMBLY
a. Remove the indicator assembly.
b. Inspect the indicator assembly.
Standard:
Tester
Connection
Switch
Condition
Specified
Condition
I7-2
(ACT+) I7-1 (E)
When the
auxiliary
battery positive
terminal and
indicator
assembly
terminal ACT+,
Illuminates
and the
auxiliary
battery
negative
terminal and
terminal E are
connected
I7-2
(ACT+) I7-1 (E)
When the
auxiliary
battery positive
terminal and
indicator
assembly
terminal ACT+, Does not
and the
illuminate
auxiliary
battery
negative
terminal and
terminal E are
not connected
Text in Illustration
Component without harness
*a connected
(Indicator Assembly)
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c. Install the indicator assembly.
REPLACE INDICATOR ASSEMBLY
(Click here)
NG
OK
6.READ VALUE USING INTELLIGENT TESTER (CPLT OUTPUT VOLTAGE)
a. Connect the intelligent tester to the DLC3.
b. Turn the power switch on (IG).
c. Enter the following menus: Powertrain / Hybrid Control / Data List / CPLT Output Voltage.
d. Read the Data List.
OK:
Tester
Display
CPLT Output
Voltage
Condition
Specified
Condition
Power switch
on (IG)
Charge cable
not connected
12 V
Power switch
on (IG)
Charge cable
connected
(during
charging
preparation)
9V
Power switch
on (IG)
Charge cable
connected
(when charging
preparation
completed)
6V
e. Turn the power switch off.
NG
REPLACE POWER MANAGEMENT
CONTROL ECU (Click here)
OK
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7.CHECK HARNESS AND CONNECTOR (INDICATOR ASSEMBLY - BODY GROUND)
a. Disconnect the indicator assembly connector
b. Measure the resistance according to the value(s)
in the table below.
Standard Resistance:
Tester
Connection
Switch
Condition
Specified
Condition
I7-1 (E) - Body
ground
Power
switch off
Below 1 Ω
Text in Illustration
*a
Front view of wire harness connector
(to Indicator Assembly)
c. Connect the indicator assembly connector.
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
8.CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU INDICATOR ASSEMBLY)
a. Disconnect connector L116 from the power management control ECU.
b. Disconnect the indicator assembly connector
c. Measure the resistance according to the value(s)
in the table below.
Standard Resistance:
Tester
Connection
Switch
Condition
Specified
Condition
L116-9 (PIL) I7-2 (ACT+)
Power
switch off
Below 1 Ω
L116-9 (PIL) or
I7-2 (ACT+) Body ground
Power
switch off
10 kΩ or
higher
Text in Illustration
*a
Rear view of wire harness connector
(to Power Management Control ECU)
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Front view of wire harness connector
(to Indicator Assembly)
*b
d. Turn the power switch on (IG).
e. Measure the voltage according to the value(s) in
the table below.
Standard Voltage:
Tester
Connection
Switch
Condition
Specified
Condition
L116-9 (PIL) or
I7-2 (ACT+) Body ground
Power
switch on
(IG)
Below 1 V
f. Turn the power switch off.
g. Connect the power management control ECU
connector.
h. Connect the indicator assembly connector.
REPAIR OR REPLACE HARNESS OR
CONNECTOR
NG
OK
REPLACE POWER MANAGEMENT CONTROL ECU (Click here)
9.READ VALUE USING INTELLIGENT TESTER (CPLT OUTPUT VOLTAGE)
a. Connect the intelligent tester to the DLC3.
b. Turn the power switch on (IG).
c. Enter the following menus: Powertrain / Hybrid Control / Data List / CPLT Output Voltage.
d. Read the Data List.
OK:
Tester
Display
Condition
Specified
Condition
Power switch
on (IG)
Charge cable
not connected
12 V
Power switch
on (IG)
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CPLT Output
Voltage
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Charge cable
connected
(during
charging
preparation)
9V
Power switch
on (IG)
Charge cable
connected
(when charging
preparation
completed)
6V
e. Turn the power switch off.
NG
REPLACE POWER MANAGEMENT
CONTROL ECU (Click here)
OK
10.CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU CHARGE INLET)
a. Disconnect connector A22 from the power management control ECU.
b. Open the lid of charge inlet.
c. Measure the resistance according to the value(s)
in the table below.
Standard Resistance (Check for Open):
Tester Connection
Switch Specified
Condition Condition
A22-23(CPLT) - t14(CPLT)
Power
switch
off
Below 1
Ω
A22-10(CPG) - t1-3
(GND) or Body
ground
Power
switch
off
Below 1
Ω
Standard Resistance (Check for Short):
Tester Connection
Switch Specified
Condition Condition
A22-23(CPLT) or
t1-4(CPLT) - Body
ground and other
terminals
Power
switch
off
A22-10(CPG) or t1-
Power
10 kΩ or
higher
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3(GND) - Other
terminals
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switch
off
10 kΩ or
higher
Text in Illustration
*a
Rear view of wire harness connector
(to Power Management Control ECU)
*b
Front view of wire harness connector
(Charge Inlet)
d. Close the lid of charge inlet.
e. Connect the power management control ECU
connector.
NG
Go to step 11
OK
REPLACE ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY
11.CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - EV
CHARGER CABLE)
a. Disconnect connector A22 from the power management control ECU.
b. Disconnect connector At1 from the electric vehicle
charger cable.
c. Measure the resistance according to the value(s)
in the table below.
Standard Resistance (Check for Open):
Tester Connection
Switch
Specified
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Condition Condition
A22-23(CPLT) At1-1(CPLT)
Power
switch
off
Below 1
Ω
A22-10(CPG) - At13(CPG)
Power
switch
off
Below 1
Ω
Standard Resistance (Check for Short):
Tester Connection
Switch Specified
Condition Condition
A22-23(CPLT) or
At1-1(CPLT) - Body
ground and other
terminals
Power
switch
off
10 kΩ or
higher
A22-10(CPG) or
At1-3(CPG) - Body
ground and other
terminals
Power
switch
off
10 kΩ or
higher
Text in Illustration
*a
Rear view of wire harness connector
(to Power Management Control ECU)
*b
Front view of wire harness connector
(to Electric Vehicle Charger Cable)
d. Connect the electric vehicle charger cable connector.
e. Connect the power management control ECU connector.
NG
REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
REPLACE ELECTRIC VEHICLE CHARGER CABLE (Click here)
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