Evb Nissan Leaf VE

ELECTRIC POWER TRAIN
EVB
A
B
SECTION
EV BATTERY SYSTEM EVB
E
CONTENTS
PRECAUTION ............................................... 5 LI-ION BATTERY HEATER CONTROL SYSTEM F
: System Description ................................................25
PRECAUTIONS ................................................... 5 Circuit Diagram ........................................................27
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Precaution for Technicians Using Medical Electric...... 5 G
Point to Be Checked Before Starting Maintenance HANDLING PRECAUTION ............................... 32
Work .......................................................................... 5 EV Battery System ..................................................32
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
DIAGNOSIS SYSTEM (LBC) ............................ 33 H
CONSULT Function .................................................33
SIONER" ................................................................... 5
Precaution for Procedure without Cowl Top Cover...... 6 ECU DIAGNOSIS INFORMATION .............. 35
Precaution for Removing 12V Battery ....................... 6 I
High Voltage Precautions .......................................... 7 EV BATTERY SYSTEM .................................... 35
Reference Value ......................................................35
PREPARATION ............................................ 9 Fail-safe ...................................................................40 J
PREPARATION ................................................... 9 DTC Index ...............................................................45
Special Service Tools ................................................ 9 WIRING DIAGRAM ...................................... 50
Commercial Service Tools ...................................... 10 K
Sealant or/and Lubricant ......................................... 13 VCM ................................................................... 50
Wiring Diagram ........................................................50
SYSTEM DESCRIPTION ............................. 14 L
BASIC INSPECTION ................................... 69
COMPONENT PARTS .......................................14
Component Parts Location ...................................... 14 DIAGNOSIS AND REPAIR WORK FLOW ....... 69
Li-ion Battery ........................................................... 16 Work Flow ................................................................69 M
Li-ion Battery Controller .......................................... 16 Diagnostic Work Sheet ............................................70
Module .................................................................... 17
Heater Relay Unit .................................................... 18 ADDITIONAL SERVICE WHEN REPLACING N
Li-ion Battery Heater ............................................... 18 LI-ION BATTERY CONTROLLER .................... 72
Battery Current Sensor ........................................... 19 Description ...............................................................72
Battery Temperature Sensor ................................... 19 Work Procedure .......................................................72
Battery Junction Box ............................................... 20 O
Service Plug ............................................................ 20 MODULE CHARGE BALANCE ........................ 73
High Voltage Warning Label ................................... 20 Description ...............................................................73
Work Procedure .......................................................73 P
SYSTEM .............................................................22
DTC/CIRCUIT DIAGNOSIS ......................... 75
LI-ION BATTERY CONTROL SYSTEM .................... 22
LI-ION BATTERY CONTROL SYSTEM : System P0A0D HV SYSTEM INTERLOCK ERROR ..... 75
Description .............................................................. 22 DTC Logic ................................................................75
Diagnosis Procedure ...............................................75
LI-ION BATTERY HEATER CONTROL SYSTEM .... 24 Component Inspection .............................................76
Revision: June 2014 EVB-1 2015 Leaf NAM

P0A1F BATTERY ENERGY CONTROL MOD- P30E4 DLC DIAGNOSIS PDM(POWER DE-
ULE .................................................................... 77 LIVERY MODULE) ............................................ 97
DTC Logic ............................................................... 77 DTC Logic ............................................................... 97
Diagnosis Procedure .............................................. 77 Diagnosis Procedure ............................................... 97
P3030 CELL CONTROLLER LIN ...................... 78 P30FC OVER CURRENT .................................. 98

P3031-P303C CELL CONTROLLER ASIC ....... 79 P318D COMMUNICATION ERROR .................. 99

P303D-P3048 CELL CONTROLLER ASIC ....... 80 P318E COMMUNICATION ERROR ................. 100
DTC Logic ............................................................... 80 DTC Logic ............................................................. 100
Diagnosis Procedure .............................................. 80 Diagnosis Procedure ............................................. 100
P3049-P3054 CELL CONTROLLER ASIC P3191 COMMUNICATION ERROR ................. 101

VOLTAGE .......................................................... 81 DTC Logic ............................................................. 101
DTC Logic ............................................................... 81 Diagnosis Procedure ............................................. 101
Diagnosis Procedure .............................................. 81
P3196 COMMUNICATION ERROR ................. 102
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P3055-P3060 CELL CONTROLLER ASIC DTC Logic ............................................................. 102
VOLTAGE .......................................................... 83 Diagnosis Procedure ............................................. 102
DTC Logic ............................................................... 83
DTC Logic ............................................................. 103
P3061 CELL BATTERY VOLTAGE .................. 85 Diagnosis Procedure ............................................. 103
DTC Logic ............................................................... 85
DTC Logic ............................................................. 104
P3062 BYPASS SWITCH .................................. 86 Diagnosis Procedure ............................................. 104
DTC Logic ............................................................... 86
P319C COMMUNICATION ERROR ................. 105
DTC Logic ............................................................. 105
P3064 CELL CONT ASIC .................................. 87 Diagnosis Procedure ............................................. 105
DTC Logic ............................................................... 87
P31A4 CAN ERROR VCM ............................... 106
DTC Logic ............................................................. 106
P308B-P3096 CELL CONTROLLER ASIC Diagnosis Procedure ............................................. 106
OPEN ................................................................. 88
P31A7 CAN ERROR INV/MC ........................... 107
DTC Logic ............................................................... 88
DTC Logic ............................................................. 107
Diagnosis Procedure ............................................. 107
P3097-P30A2 CELL CONTROLLER ASIC
P3302-P330D CELL OVER VOLTAGE ............ 108
OPEN ................................................................. 91 DTC Logic ............................................................. 108
DTC Logic ............................................................... 91
Component Inspection .......................................... 111
P30E0 DLC DIAGNOSIS VCM .......................... 94 P330E-P3319 CELL OVER VOLTAGE ............ 112
DTC Logic ............................................................... 94
DTC Logic ............................................................. 112
P30E2 DLC DIAGNOSIS HVAC ........................ 95 Component Inspection .......................................... 115
DTC Logic ............................................................... 95 P331A-P3325 CELL OVER VOLTAGE ............ 116
DTC Logic ............................................................. 116
P30E3 DLC DIAGNOSIS MC ............................ 96 Diagnosis Procedure ............................................. 116
DTC Logic ............................................................... 96 Component Inspection .......................................... 118
Diagnosis Procedure .............................................. 96 P3326-P3331 CELL OVER VOLTAGE ............ 119
DTC Logic ............................................................. 119

Diagnosis Procedure ............................................. 119 P33EA BATTERY HEATER RELAY .............. 152
Component Inspection .......................................... 121 DTC Logic .............................................................. 152 A
P3375-P3380 CELL OVER DISCHARGE ........ 122
DTC Logic ............................................................. 122 P33EB TEMPERATURE SENSOR ................. 154
Diagnosis Procedure ............................................. 122 B
DTC Logic .............................................................. 154
Component Inspection .......................................... 125 Diagnosis Procedure ............................................. 154
Component Inspection ........................................... 155
P3381-P338C CELL OVER DISCHARGE ....... 126 EVB
DTC Logic ............................................................. 126 P33ED BATTERY PARALLEL DIAGNOSIS .. 156
Diagnosis Procedure ............................................. 126 DTC Logic .............................................................. 156
Component Inspection .......................................... 129 Diagnosis Procedure ............................................. 156 D
P338D-P3398 CELL OVER DISCHARGE ....... 130 P33EE BATTERY HEATER CONTROL SYS-
DTC Logic ............................................................. 130 TEM ................................................................. 158
Diagnosis Procedure ............................................. 130 DTC Logic .............................................................. 158 E
P3399-P33A4 CELL OVER DISCHARGE ....... 133 U1000 CAN COMM CIRCUIT ......................... 160
DTC Logic ............................................................. 133 F
Description ............................................................. 160
Diagnosis Procedure ............................................. 133 DTC Logic .............................................................. 160
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P33D4 BATTERY DETERIORATION DIAG- HIGH VOLTAGE CIRCUIT .............................. 161
NOSIS ............................................................... 136 Diagnosis Procedure ............................................. 161
DTC Logic ............................................................. 136 H
Diagnosis Procedure ............................................. 136 LI-ION BATTERY INSULATION RESIS-
TANCE LOSS CHECK .................................... 163
P33D5 CURRENT SENSOR ............................ 137 Component Inspection ........................................... 163
DTC Logic ............................................................. 137 I
Diagnosis Procedure ............................................. 137 LI-ION BATTERY HEATER SYSTEM INSU-
LATION RESISTANCE CHECK ..................... 173
P33D6 CURRENT SENSOR ............................ 139 Diagnosis Procedure ............................................. 173 J
DTC Logic ............................................................. 139
Diagnosis Procedure ............................................. 139 POWER SUPPLY AND GROUND CIRCUIT .. 176
P33D7, P33D9, P33DD TEMPERATURE K
SENSOR ........................................................... 141 SYMPTOM DIAGNOSIS ............................ 179
DTC Logic ............................................................. 141
Diagnosis Procedure ............................................. 141 REDUCTION IN THE DRIVING RANGE ......... 179
L
Component Inspection .......................................... 142 Description ............................................................. 179
P33DF BAT VOLTAGE ISOLATION SEN ....... 143
DTC Logic ............................................................. 143 PERIODIC MAINTENANCE ...................... 180 M
EV BATTERY USAGE REPORT .................... 180
P33E0 BAT VOLTAGE ISOLATION SEN ....... 144 Inspection .............................................................. 180
N
DTC Logic ............................................................. 144
Diagnosis Procedure ............................................. 144 UNIT REMOVAL AND INSTALLATION .... 181
P33E1 BAT VOLTAGE ISOLATION SEN ....... 145 LI-ION BATTERY ............................................ 181 O
DTC Logic ............................................................. 145 Exploded View ....................................................... 181
Diagnosis Procedure ............................................. 145 Removal and Installation ....................................... 181
Inspection .............................................................. 188
P33E2 BATT PACK OVER TEMP ................... 146 P
DTC Logic ............................................................. 146 UNIT DISASSEMBLY AND ASSEMBLY . 190
LI-ION BATTERY ............................................ 190
P33E6 CELL CONTROLLER ........................... 147 BATTERY PACK UPPER CASE ............................. 190
DTC Logic ............................................................. 147 BATTERY PACK UPPER CASE : Exploded View.. 190

BATTERY PACK UPPER CASE : Removal and LI-ION BATTERY HEATER RELAY UNIT : Disas-
Installation .............................................................191 sembly and Assembly ........................................... 221
LI-ION BATTERY CONTROLLER ...........................200 FRONT MODULE STACK ....................................... 222

LI-ION BATTERY CONTROLLER : Exploded FRONT MODULE STACK : Exploded View ......... 222
View .......................................................................201 FRONT MODULE STACK : Removal and Installa-
LI-ION BATTERY CONTROLLER : Removal and tion ........................................................................ 226
Installation .............................................................201 FRONT MODULE STACK : Disassembly and As-
sembly ................................................................... 233
BATTERY JUNCTION BOX AND BATTERY HAR-
NESS ........................................................................203 REAR MODULE STACK ......................................... 238
BATTERY JUNCTION BOX AND BATTERY REAR MODULE STACK : Exploded View ............ 238
HARNESS : Exploded View ..................................204 REAR MODULE STACK : Removal and Installa-
BATTERY JUNCTION BOX AND BATTERY tion ........................................................................ 241
HARNESS : Disassembly and Assembly ..............206 REAR MODULE STACK : Disassembly and As-
sembly ................................................................... 248
LI-ION BATTERY HEATER .....................................213 Inspection .............................................................. 256
LI-ION BATTERY HEATER : Exploded view .........214
LI-ION BATTERY HEATER : Disassembly and SERVICE DATA AND SPECIFICATIONS
Assembly ...............................................................215 (SDS) ......................................................... 259
LI-ION BATTERY HEATER RELAY UNIT ...............219 SERVICE DATA AND SPECIFICATIONS
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LI-ION BATTERY HEATER RELAY UNIT : Ex-
(SDS) ................................................................ 259
ploded view ............................................................220
Li-ion Battery ......................................................... 259

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Technicians Using Medical Electric INFOID:0000000010640502
B
OPERATION PROHIBITION
WARNING: EVB
• Parts with strong magnet is used in this vehicle.
• Technicians using a medical electric device such as pacemaker must never perform operation on the
vehicle, as magnetic field can affect the device function by approaching to such parts.
D
NORMAL CHARGE PRECAUTION
WARNING:
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an E
implantable cardioverter defibrillator, the possible effects on the devices must be checked with the
device manufacturer before starting the charge operation.
• As radiated electromagnetic wave generated by on board charger at normal charge operation may
F
effect medical electric devices, a technician using a medical electric device such as implantable car-
diac pacemaker or an implantable cardioverter defibrillator must not enter the vehicle compartment
(including luggage room) during normal charge operation.
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G
PRECAUTION AT TELEMATICS SYSTEM OPERATION
WARNING:
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), H
avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from inte-
rior/exterior antenna.
• The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or
the implantable cardioverter defibrillator (ICD), when using the service, etc. I
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant-
able cardioverter defibrillator (ICD), the electromagnetic wave of TCU might affect the function of the
device. The possible effects on the devices must be checked with the device manufacturer before J
TCU use.
PRECAUTION AT INTELLIGENT KEY SYSTEM OPERATION
WARNING: K
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD),
avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from inte-
rior/exterior antenna. L
• The electromagnetic wave of intelligent key might affect the function of the implantable cardiac
pacemaker or the implantable cardioverter defibrillator (ICD), at door operation, at each request
switch operation, or at engine starting.
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant- M
able cardioverter defibrillator (ICD), the electromagnetic wave of intelligent key might affect the func-
tion of the device. The possible effects on the devices must be checked with the device
manufacturer before intelligent key use. N
Point to Be Checked Before Starting Maintenance Work INFOID:0000000010640503
The high voltage system may starts automatically. It is required to check that the timer air conditioner O
and timer charge (during EVSE connection) are not set before starting maintenance work.
NOTE:
If the timer air conditioner or timer charge (during EVSE connection) is set, the high voltage system starts
P
automatically even when the power switch is in OFF state.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000010640504
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
PRECAUTIONS
< PRECAUTION >
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
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• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery and wait at least three minutes before performing any service.
Precaution for Procedure without Cowl Top Cover INFOID:0000000010640505
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
Precaution for Removing 12V Battery INFOID:0000000010640506
1. Check that EVSE is not connected.

NOTE:
If EVSE is connected, the air conditioning system may be automatically activated by the timer A/C func-
tion.
2. Turn the power switch OFF → ON → OFF. Get out of the vehicle. Close all doors (including back door).
3. Check that the charge status indicator lamp does not blink and wait for 5 minutes or more.
NOTE:
If the battery is removed within 5 minutes after the power switch is turned OFF, plural DTCs may be
detected.
4. Remove 12V battery within 1 hour after turning the power switch OFF → ON → OFF.
NOTE:
• The 12V battery automatic charge control may start automatically even when the power switch is in
OFF state.
• Once the power switch is turned ON → OFF, the 12V battery automatic charge control does not start for
approximately 1 hour.
CAUTION:
• After all doors (including back door) are closed, if a door (including back door) is opened before
battery terminals are disconnected, start over from Step 1.
• After turning the power switch OFF, if “Remote A/C” is activated by user operation, stop the air
conditioner and start over from Step 1.

PRECAUTIONS
< PRECAUTION >
High Voltage Precautions INFOID:0000000010640507
A
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec-
tric shock, electric leakage, or similar accidents if the high voltage component and vehicle are han- B
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts. EVB
• To prevent the removed service plug from being connected by mistake during the procedure, always
carry it in your pocket or put it in the tool box.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield, and glasses D
before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or sim-
E
ilar item to prevent other persons from contacting them.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do F
so in the Service Manual.
HIGH VOLTAGE HARNESS AND EQUIPMENT IDENTIFICATION
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The colors of the high voltage harnesses and connectors are all orange. Orange “High Voltage” labels are G
applied to the Li-ion battery and other high voltage devices. Do not carelessly touch these harnesses and
parts.
H
HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS
Immediately insulate disconnected high voltage connectors and terminals with insulating tape.
REGULATIONS ON WORKERS WITH MEDICAL ELECTRONICS I
WARNING:
The vehicle contains parts that contain powerful magnets. If a person who is wearing a heart pace-
maker or other medical device is close to these parts, the medical device may be affected by the mag- J
nets. Such persons must not perform work on the vehicle.
PROHIBITED ITEMS TO CARRY DURING THE WORK
Because this vehicle uses components that contain high voltage and powerful magnetism, do not carry any K
metal products which may cause short circuits, or any magnetic media (cash cards, prepaid cards, etc.) which
may be damaged on your person when working.
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT” L

PRECAUTIONS
< PRECAUTION >
To call the attention of other workers, indicate “High voltage work in progress. Do not touch!” on vehicles
where work is being performed on the high voltage systems.
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JSAIA1600GB

PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000010640508
B
The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.) EVB
Tool name
— When removing/installing Li-ion battery.
(J-50583) D
Palette
JPCIA0239ZZ
F
KV99111300 When installing Li-ion battery.
(J-50306) 2 piece/set
Battery location guide pin
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G
H
JPCIA0023ZZ
KV99111400 When checking air leaks after disassem-

(—) bling/assembling Li-ion battery.
Air leak tester I
JSCIA0257ZZ
KV99111500 Protect module terminals (for LEAF) K

(—) 24 pieces/set
Module terminal cover
JPCIA0069ZZ
M
— Module voltage adjustment
(J-50346)
Module charge balancer
N
O
JPCIA0070ZZ
— Module voltage adjustment

(J-51031) Use with the module charge balancer (J- P
Module charge balancer module box 50346).
JSCIA0726ZZ

PREPARATION
< PREPARATION >
Commercial Service Tools INFOID:0000000010640509
Tool name Description
Removing and installing high voltage components

Insulated gloves [Guaranteed insulation performance for 1000V/
300A]
JMCIA0149ZZ
• Removing and installing high voltage compo-

nents
Leather gloves
• Protect insulated gloves
[Use leather gloves that can fasten the wrist tight]
JPCIA0066ZZ
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Insulated safety shoes Removing and installing high voltage components
JPCIA0011ZZ

nents
Safety glasses • To protect eye from the spatter on the work to
electric line
[ANSI Z87.1]
JPCIA0012ZZ

nents
Face shield
• To protect face from the spatter on the work to
electric line
JPCIA0167ZZ
Insulated helmet Removing and installing high voltage components
JPCIA0013ZZ

PREPARATION
< PREPARATION >
A
B
Insulated rubber sheet Removing and installing high voltage components
EVB
JPCIA0019ZZ
Insulated cover sheet Removing and installing high voltage components
JPCIA0018ZZ
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Battery lift table Removing and installing Li-ion battery G
JPCIA0024ZZ
H
I
Stacker Removing and installing Li-ion battery
J
JPCIA0015ZZ
Insulation resistance tester Measuring insulation resistance, voltage, and re-

(Multi tester) sistance
L
JPCIA0014ZZ
Insulated hand tools Removing and installing high voltage components N
JPCIA0067ZZ
O
P
Insulated torque wrench Removing and installing high voltage components
JPCIA0068ZZ

PREPARATION
< PREPARATION >
• Removing and installing battery module stack

• Installing battery pack upper case
NOTE:
Carabineer [small] • D: 8.0 mm (0.31 in)
• L: 74.0 mm (2.91 in)
• S: 10.0 mm (0.39 in)
• W: 22.5 mm (0.89 in)
JPCIA0016ZZ
Removing and installing battery module stack

NOTE:
• D: 14.0 mm (0.55 in)
Carabineer [large]
• L: 204.0 mm (8.03 in)
• S: 47.0 mm (1.85 in)
• W: 105.0 mm (4.13 in)
JPCIA0017ZZ
Removing and installing battery module stack
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Belt slinger NOTE:
Length: 2.0 m (6.562 ft)
JPCIA0021ZZ
Mobile floor crane Removing and installing battery module stack
JPCIA0020ZZ
Lashing belt Removing and installing battery rear module stack
JPCIA0022ZZ
Removing battery pack upper case

Windshield cutter [Gasket cutter]
(Cut the adhesive)
JSCIA0640ZZ
Installing battery pack upper case

(Cut the adhesive)
Piano wire with handles
NOTE:
Wire size: φ 0.5 mm (0.02 in)
JSCIA0641ZZ

PREPARATION
< PREPARATION >
A
Installing battery pack upper case B

Scraper
(Smooth the adhesive)
EVB
JSCIA0643ZZ
D
Tube presser [Gasket material ap- Installing battery pack upper case
plicator] (Apply the adhesive)
E
JSCIA0639ZZ
Assembling battery module stack
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NOTE:
Metal bar G
• D: φ 7 mm (0.28 in)
• L: 1 m (3.28 ft)
JSCIA0735ZZ
H
Sealant or/and Lubricant INFOID:0000000010640510
I
Tool name
Description
Tool number
Adhesive J
999MP-57302NP
Dam rubber
KA390-0059U K
Installing battery pack upper case
Primer (Adhesive primer)
999MP-43533PP
Primer sufacer (anti-corrosion praimer) L
—

COMPONENT PARTS
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION
COMPONENT PARTS
Component Parts Location INFOID:0000000010640511
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JSCIA0505ZZ

COMPONENT PARTS
Front of battery pack Back of battery pack A

: Vehicle front
B
No. Component Function
Li-ion battery EVB-16, "Li-ion Battery"
Service plug EVB-20, "Service Plug" EVB

Front module stack RH EVB-17, "Module"
Battery junction box EVB-20, "Battery Junction Box" D

Battery current sensor EVB-19, "Battery Current Sensor"
Front module stack LH EVB-17, "Module"

E
Li-ion battery controller EVB-16, "Li-ion Battery Controller"
Rear module stack EVB-17, "Module"
Battery temperature sensor 1 EVB-19, "Battery Temperature Sensor"

F
Battery temperature sensor 4 EVB-19, "Battery Temperature Sensor"
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Battery temperature sensor 2 EVB-19, "Battery Temperature Sensor" G
JSCIA0771ZZ O
: Vehicle front
P
Li-ion battery heater RH 1 EVB-18, "Li-ion Battery Heater"
Li-ion battery heater RH 2 EVB-18, "Li-ion Battery Heater"
Li-ion battery heater RR 2 EVB-18, "Li-ion Battery Heater"
Li-ion battery heater LH 1 EVB-18, "Li-ion Battery Heater"

COMPONENT PARTS
Li-ion battery heater LH 2 EVB-18, "Li-ion Battery Heater"
Heater relay unit EVB-18, "Heater Relay Unit"
Li-ion battery heater RR 1 EVB-18, "Li-ion Battery Heater"
Li-ion Battery INFOID:0000000010640512
• A Li-ion battery with flat construction is placed under floor.

• The battery pack is equipped with necessary devices, such as Li-
ion battery controller, battery junction box, and service plug in addi-
tion to a battery storing electricity.
JSCIA0701ZZ
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• Four cells are integrated into a single module. The Li-ion battery consists of 48 modules placed in series.
JSCIA0702ZZ
Li-ion Battery Controller INFOID:0000000010640513
• Li-ion battery controller (LBC) is included in the battery pack and

installed on the left surface of the rear module stack.
JSCIA0071ZZ
• The LBC is the core of battery control. Li-ion battery controller detects the voltage and current of the assem-
bled battery, the temperature of each module, and the voltage of each cell to judge state of charge. LBC also
calculates possible input/output values, meter indication values, and chargeable values, and send this data
to VCM (Vehicle control module). VCM controls the vehicle, according to the battery state.
Main Role of Li-ion Battery Controller
1. Li-ion battery state check
• State of charge
• Possible output value
• Possible input value
• Temperature
2. Optimization of Li-ion battery voltage

COMPONENT PARTS
3. Prevention of overvoltage and overcurrent
4. Prevention of overheat A
5. Detection of decrease in insulation resistance of high-voltage circuit
6. Detection of a fit of high voltage harness connector and service plug
B
Module INFOID:0000000010640514
• Four laminated cells are integrated into one module.

EVB
• The Li-ion battery is equipped with 48 modules.
• There are two kinds of modules, according to the location of posi-
tive and negative terminals.
D
Positive terminal : Red
Negative terminal : Black
E
JSCIA0703ZZ
F
MODULE INTERNAL CIRCUIT
A module consists of two parallel-connected cells placed in series.
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The Li-ion battery has 48 modules placed in series in total. Ninety-six G
parallel-connected cell pairs are connected in series.
NOTE:
Cell voltage displayed on the data monitor of CONSULT means the
potential difference between the upstream and the downstream of H
the parallel circuit.
JPCIA0197GB
J
MODULE LAYOUT
O
JSCIA0704GB
NOTE:
The highest potential is module (MD) 1 and the lowest is module (MD) 48. P
CELL

COMPONENT PARTS
These are thin laminated cells with excellent cooling performance.
JSCIA0274ZZ
The Features of Laminated Cell

• Large surface area with excellent cooling performance reduces heat load to the battery and improves bat-
tery life.
• Light and thin structure increases flexibility in layout.
Heater Relay Unit INFOID:0000000010640515
• The heater relay unit is installed in the battery pack (under the ser-
vice plug).
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• When receiving a relay control signal from LBC (Li-ion battery con-
troller), the heater relay unit turns ON the built-in relay and sup-
plies high-voltage power to each Li-ion battery heater.
JSCIA0772ZZ
Li-ion Battery Heater INFOID:0000000010640516
• Li-ion battery heater is installed in the battery pack.

• High voltage power is supplied from the heater relay unit.
• Each Li-ion battery heater is connected in parallel.
FRONT LI-ION BATTERY HEATER
• Two front Li-ion battery heaters are installed to each front module
stack.
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REAR LI-ION BATTERY HEATER

COMPONENT PARTS
• Two rear Li-ion battery heaters are installed to the rear module
stack. A
EVB
JPCIA0213ZZ
D
Battery Current Sensor INFOID:0000000010640517
• The battery current sensor is installed to bus bar between battery

junction box and rear module stack. E
• This sensor measures charge/discharge current sent to Li-ion bat-
tery and transmits a current signal to Li-ion battery controller
(LBC). F
• Li-ion Battery controller (LBC) measures remaining battery level
according to charge/discharge current and sends the data to VCM.
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G
JSCIA0507ZZ
H
Battery Temperature Sensor INFOID:0000000010640518
• Three battery temperature sensors mounted in the battery pack

measure the temperature. I
• The installation position of the sensors are;
- Front module stack RH: Two for front and rear
- Rear module stack: One J
JSCIA0705ZZ
L
• The sensor uses a thermistor with a resistance value that varies

according to changes in temperature. The electrical resistance of
the thermistor decreases as the temperature increases. M
JPCIA0295GB

COMPONENT PARTS
Battery Junction Box INFOID:0000000010640519
• The battery junction box is installed to the front side in the battery
pack.
• The battery junction box includes:
- System main relay to provide/interrupt DC current sent from Li-ion
battery.
- Pre-charge relay to protect the high voltage circuit from a high cur-
rent immediately after power switch ON.
• Installed to both positive side and negative side, the system main
relay provides DC current to each high voltage part. In addition, the
system main relay provides DC current to the Li-ion battery during
motor regeneration or charge.
JSCIA0276ZZ
• When an error occurs in the system, the system main relay is
turned OFF and the Li-ion battery is interrupted for ensuring safety, based on a command from VCM (Vehi-
cle control module).
Service Plug INFOID:0000000010640520
• The service plug is included in the Li-ion battery to securely dis-

connect the high voltage during high voltage part inspection and
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maintenance.
• The service plug is installed on the upper surface of the battery
pack. The plug can be removed when the leg-room mounted ser-
vice plug cover is removed.
• Always use insulating protective equipment when removing and
installing service plug.
JSCIA0706ZZ
High Voltage Warning Label INFOID:0000000010640521
High voltage warning label is affixed to each of the following component parts.
After replacing a part, check that the part is affixed with a label. If the label is not affixed, be sure to affix the
label in the original position.
Li-ion Battery
• The label is affixed to the rear end of Li-ion battery.
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: Vehicle front : Direction of the label

COMPONENT PARTS
• The label is affixed to the body panel near the high voltage harness
connector. A
: Vehicle front
EVB
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D
Li-ion Battery Controller
The label is affixed to the main body of controller.
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G
JSCIA0111ZZ
Service Plug H
The label is affixed to the inspection hole cover .
: Direction of the label

I
K
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SYSTEM
SYSTEM
LI-ION BATTERY CONTROL SYSTEM
LI-ION BATTERY CONTROL SYSTEM : System Description INFOID:0000000010640522
SYSTEM DIAGRAM
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JSCIA0731GB
INPUT/OUTPUT SIGNAL ITEM

Input Signal Item
Transmit unit Signal name

VCM EV system CAN Target Li-ion battery remained energy signal
Output Signal Item

SYSTEM
Received unit Signal name A

High voltage discharge permit signal
Li-ion battery main relay cut request signal
B
Li-ion battery connector interlock signal
Li-ion battery voltage signal
Li-ion battery current signal EVB
Li-ion battery chargeable power signal
VCM EV system CAN
Li-ion battery dischargeable power signal
D
Li-ion battery chargeable completion signal
Li-ion battery available charge signal
Li-ion battery capacity signal E
Li-ion battery gradual capacity loss signal
Insulation resistance signal
F
DESCRIPTION
The Li-ion battery controller (LBC) monitors the status of the inside of the Li-ion battery at all times and sends
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information, such as the charging status of Li-ion battery and possible power, to VCM (vehicle control module) G
via EV system CAN communication.
The Li-ion battery controller performs control as per the following.
• Monitors the battery state and transfers chargeable/dischargeable power to VCM to prevent an error, such
as overvoltage, over discharge or excessive temperature rise in the battery. H
• Detects an error (overvoltage, over discharge, overcurrent, or excessive temperature rise) immediately at
the time of error occurrence and requests VCM to disconnect the system main relay to interrupt the dis-
charge/charge line. I
• Maintains the optimum battery state constantly with a cell capacity adjustment function to prevent a reduc-
tion in charging/discharging capacity caused by cell capacity variations.
• Detects the connector fit state with the function to detect the fit of the high voltage harness connector and
transfers the detected state to VCM so that the vehicle does not start with an unsteady state. J
• Detects the insulation resistance state with the function to detect the insulation resistance between high and
low voltage and transfers the detected state to VCM so that the vehicle does not start with an unusual state.
• Estimates a battery charge state and low battery state, based on the data obtained with the battery state K
detection function, and reflects on the battery capacity meter.
BATTERY PROTECTION
The Li-ion battery has a voltage range capable of charge/discharge. If charged/discharged exceeding the L
range, excessive low capacity or malfunction may be caused. To prevent this, the Li-ion battery controller
detects voltage of each cell and requests the control of charging/discharging energy to VCM so that the cell
voltage stays within the voltage range. M
Control item Control Operating condition
Gradual control of charging energy as the cell voltage ap-
Charging energy control N
Overvoltage/overcurrent protec- proaches the upper limit of the voltage capable of charging.
tion Cell voltage exceeds the voltage judged as overvoltage and
System main relay cut
maintains the voltage for more than the specified time.
O
Gradual control of discharging energy as the cell voltage ap-
Discharging energy control
proaches the lower limit of the voltage capable of discharging.
Over discharge protection
Cell voltage exceeds the voltage judged as over discharge and
System main relay cut P
maintains the voltage for more than the specified time.
Gradual control of charging/discharging energy as Li-ion bat-
Charging/discharging energy
tery temperature approaches the upper limit of the temperature
control
Excessive temperature rise pro- capable of use.
tection Li-ion battery temperature exceeds the temperature judged as
System main relay cut excessive temperature rise and maintains the temperature for
more than the specified time.

SYSTEM
HOW TO ADJUST CELL CAPACITY
During cell capacity adjustment, the capacity of each cell is estimated based on the no-load voltage when the
system starts, and the capacities are adjusted so that they are all at the target level. The voltage of each cell is
detected inside the Li-ion battery controller. The bypass switches are then turned ON to discharge the cells
that have excess capacity. In this way, capacity adjustment by the Li-ion battery controller allows the capacity
of all cells to be fully utilized.
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JPCIA0094GB
INSULATION RESISTANCE LOSS DETECTION FUNCTION

The insulation resistance detection circuit mounted inside the Li-ion battery controller measures the insulation
resistance of each high voltage part and sends the measurement results to VCM via EV system CAN commu-
nication.
VCM judges abnormal insulation resistance in each high voltage part, based on the received insulation resis-
tance value.
JSCIA0732GB
LI-ION BATTERY HEATER CONTROL SYSTEM

SYSTEM
LI-ION BATTERY HEATER CONTROL SYSTEM : System Description INFOID:0000000010640523
A
SYSTEM DIAGRAM
EVB
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G
JSCIA0793GB J
INPUT/OUTPUT SIGNAL ITEM
Input Signal Item K
Transmit unit Signal name

VCM EV system CAN communication Keep SOC request signal L
Output Signal Item

M
Receive unit Signal name
VCM EV system CAN communication Next start time signal
N
DESCRIPTION
• When the temperature decreases [approximately −20°C (−4°F)] extremely in the battery pack, the Li-ion bat-
tery heater control system automatically activates the Li-ion battery heater to warm the inside of the battery
pack for protecting Li-ion battery from freezing and preventing the decline in battery output. In addition, when O
the temperature in the battery pack is restored [approximately −10°C (14°F)], the Li-ion battery heater stops.
• The Li-ion battery controller (LBC) detects a temperature in the battery pack, according to a signal transmit-
ted from the battery temperature sensor installed to the battery pack. P
• The LBC judges the activation of the Li-ion battery heater, according to a temperature in the battery pack
and state of charge.
• Even when the temperature decreases extremely in the battery pack, the Li-ion battery heater is not acti-
vated if the state of charge is less than 30% (approx.). On the contrary, the Li-ion battery heater can be acti-
vated even when the state of charge is less than 30% (approx.) if normal charge or quick charge is in
operation or if EVSE is connected to the charge port of the vehicle.

SYSTEM
Activation of the Li-ion battery heater
Temperature in the battery pack

State of charge
Lower than −20°C (approx.) −20°C or higher (approx.)
30% or more (approx.) Active Inactive
Lless than 30% (approx.) Inactive* Inactive
*: The Li-ion battery heater is activated under the conditions listed below:
- During normal charge operation
- During quick charge operation
- When EVSE is connected
• When the relay built in the heater relay unit turns ON, high voltage power is supplied to each Li-ion battery
heater.
• The LBC detects the ON/OFF status of the relay built in to heater relay unit.
• Even when the power switch is OFF, VCM periodically activates LBC to protect Li-ion battery from freezing.
• When the temperature in Li-ion battery pack is low with no necessity of Li-ion battery heater operation, LBC
estimates the time that Li-ion battery may freeze and transmits a next start time signal to VCM via EV sys-
tem CAN communication to prepare for starting the Li-ion battery heater next time.
• When receiving a next start time signal via EV system CAN communication, VCM transmits a start request
signal (CHG-IGN) to LBC after a lapse of the set time. When receiving a start request signal (CHG-IGN),
LBC activates the Li-ion battery heater.
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When EVSE is connected (normal charge)
JSCIA0430ZZ
• When the temperature in the battery pack is low outside the timer charge set time, VCM transmits a keep
SOC request signal to LBC via EV system CAN communication. In this case Li-ion battery is not charged,
and only Li-ion battery heater is activated.
• When timer charge starts at the set time, Li-ion batter is charged, and the Li-ion battery heater is activated.
When EVSE is not connected (normal charge)
JSCIA0431ZZ

SYSTEM
• When the state of charge of Li-ion battery becomes less than 30% (approx.), LBC does not activate the Li-
ion battery heater even when the temperature decreases extremely in the battery pack. A
• Even when the Li-ion battery heater is in operation, LBC deactivates the Li-ion battery heater if the charge
state of Li-ion battery becomes less than 30% (approx.).
• When the charge level of the Li-ion battery is low during the Li-ion battery heater operation, LBC stops the
B
Li-ion battery heater operation even if the temperature in the battery pack is insufficient.
Circuit Diagram INFOID:0000000010640524
EVB
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G
JSCIA0805GB

SYSTEM
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SYSTEM
EVB
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G
JSCIA0799GB
K
HARNESS LAYOUT

SYSTEM
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JSCIA0796ZZ
: Vehicle front

SYSTEM
EVB
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G
JSCIA0797GB
P
: Vehicle front

HANDLING PRECAUTION
HANDLING PRECAUTION
EV Battery System INFOID:0000000010640525
• To improve the Li-ion battery life, never perform quick charge heavily.
• Use the method of nighttime normal charge or timer-controlled charge.
• Never perform rapid acceleration/deceleration.
• Never place EV battery in an area exposed to direct sunlight or under high temperature conditions.
PRECAUTIONS FOR STORAGE OF THE LI-ION BATTERY
• Apply insulating tape to the service plug and high voltage harness connector, and protect the terminals so
that nothing contacts them.
• Store in a well-ventilated location that is not exposed to direct sunlight.
(Storing outdoors or unprotected is prohibited.)
• Never set directly on the floor.
• Lay an anti-static rubber sheet underneath the battery.
• Never invert the battery.
• Never stack batteries.
• Cover with an anti-static cover sheet.
• Put a caution display stating "CAUTION! HIGH VOLTAGE" on the insulated cover sheet.
• Put identification display showing the name of person in charge on the insulated cover sheet.
• Never allow water to contact the battery.
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• Prevent other objects from falling onto the battery.

DIAGNOSIS SYSTEM (LBC)
A
CONSULT Function INFOID:0000000010640526
APPLICATION ITEM B
CONSULT performs the following functions via CAN communication with Li-ion battery controller (LBC).
Item Function EVB

ECU Identification LBC parts number can be read.
Self-diagnostic results Self-diagnostic results and freeze frame data can be read and erased quickly.*
Data Monitor Input/Output data in LBC can be read. D
Active Test Activates the actuator via LBC.
This mode enables a technician to adjust some devices faster and more accurately by following the in-
Work Support E
dications on the CONSULT.
CAN Diagnosis Displays the CAN diagnosis results.
CAN Diagnosis Support Mon- F
Displays the CAN communication status.
itor
*: The following diagnosis information is cleared when the VCM memory is erased.
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• Diagnostic trouble codes G
• Freeze frame data
ECU IDENTIFICATION
Part number of LBC can be checked. H
SELF-DIAGNOSTIC RESULTS
Self Diagnostic Item I
Regarding items of DTC, refer to EVB-45, "DTC Index".
How to Erase DTC
1. Select “HV BAT”with CONSULT. J
2. “SELF-DIAGNOSTIC RESULTS”.
3. Touch “ERASE”. (DTC in LBC will be erased.)
FREEZE FRAME DATA (FFD) K
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT.
Monitored item (Unit) Remarks L

DTC Displays the DTC which caused FFD memory
BATT ELECTRIC CURRENT A Displays the Li-ion battery current value
12V BATTERY VOLTAGE mV Displays 12V battery power supply voltage
M
Displays the maximum to minimum difference of voltage magnitude of the on-

IR SEN SHORT PULSE mV
board isolation resistance monitoring system
N
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug
CLOSE
CELL VOLTAGE 01 - 96 mV Displays each cell voltage
O
TOTAL BATTERY VOLTAGE V Displays the total voltage of the Li-ion battery
Displays the temperature calculated with a signal voltage from battery temper-
BATTERY TEMPERATURE 1 °C
ature 1
P
ature 2
ature 4
DATA MONITOR
NOTE:

The following table includes information (items) inapplicable to this vehicle. For information (items) applicable
to this vehicle, refer to CONSULT display items.
Monitored item Unit Remark

BATT ELECTRIC CURRENT A Displays the Li-ion battery current value
12V BATTERY VOLTAGE mV Displays 12V battery power supply voltage
Displays the maximum to minimum difference of voltage magnitude of the on-
IR SEN SHORT PULSE mV
board isolation resistance monitoring system
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug
CLOSE
CELL VOLTAGE 01 - 96 mV Displays each cell voltage
TOTAL BATTERY VOLTAGE V Displays the total voltage of the Li-ion battery
MAXIMUM CELL VOLTAGE mV Displays the maximum cell voltage value
MINIMUM CELL VOLTAGE mV Displays the minimum cell voltage value
ature 1
ature 2
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ature 4
ACTIVE TEST
Operation
Test item Operation status
item
Turns ON the relay built into the heater relay unit to supply high voltage power to the Li-ion
On
battery heater.
HEATER RELAY UNIT
Turns OFF the relay built into the heater relay unit to stop high voltage power supply to the
Off
Li-ion battery heater.
WORK SUPPORT
Work item Description Usage

SAVE BATTERY INFORMATION When Li-ion battery and LBC are
Data saved in LBC is stored in CONSULT.
DATA replaced.
WRITE BATTERY INFORMA- When Li-ion battery and LBC are
The CONSULT-stored data can be written in LBC.
TION DATA replaced.
This inspection identifies a cell of which cell voltage is on
CELL VOLTAGE LOSS INSPEC- When checking voltage of all
the decrease. If identified, this type of cell may be judged as
TION cells.
an abnormal cell, unless it is replaced.

EV BATTERY SYSTEM
< ECU DIAGNOSIS INFORMATION >
ECU DIAGNOSIS INFORMATION A
EV BATTERY SYSTEM
Reference Value INFOID:0000000010640527
B
VALUE ON THE DIAGNOSIS TOOL

NOTE: EVB
• Specification data are reference values.
• The following table includes information (items) inapplicable to this vehicle. For information (items) applica-
ble to this vehicle, refer to CONSULT display items.
D
Monitor item Condition Values / Status
BATT ELECTRIC CURRENT READY Stop the vehicle Approx. (−10) - (+20) A
E
12V BATTERY VOLTAGE READY Approx. 1,100 – 1,400 mV
IR SEN SHORT PULSE READY Approx. 4,100 – 4,300 mV
SERVICE PLUG INTER- READY Connect service plug REQ F

LOCK READY Disconnect service plug NOT REQ
Total battery voltage 317 V Approx. 3,200 - 3,400 mV
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CELL VOLTAGE 01 READY G
CELL VOLTAGE 02 READY
Total battery voltage 393 V Approx. 4,000 - 4,200 mV H
Total battery voltage 317 V Approx. 3,200 - 3,400 mV I
CELL VOLTAGE 05 READY J
Total battery voltage 393 V Approx. 4,000 - 4,200 mV K
L
Total battery voltage 317 V Approx. 3,200 - 3,400 mV M
CELL VOLTAGE 10 READY N
Total battery voltage 393 V Approx. 4,000 - 4,200 mV O
Total battery voltage 317 V Approx. 3,200 - 3,400 mV P

EV BATTERY SYSTEM
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EV BATTERY SYSTEM
A
Total battery voltage 317 V Approx. 3,200 - 3,400 mV B
CELL VOLTAGE 40 READY EVB
D
Total battery voltage 317 V Approx. 3,200 - 3,400 mV E
CELL VOLTAGE 44 READY F
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Total battery voltage 393 V Approx. 4,000 - 4,200 mV G
H
K
Total battery voltage 317 V Approx. 3,200 - 3,400 mV L
CELL VOLTAGE 53 READY M
Total battery voltage 393 V Approx. 4,000 - 4,200 mV N
O
Total battery voltage 317 V Approx. 3,200 - 3,400 mV P

EV BATTERY SYSTEM
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EV BATTERY SYSTEM
A
Total battery voltage 317 V Approx. 3,200 - 3,400 mV B
CELL VOLTAGE 84 READY EVB
D
Total battery voltage 317 V Approx. 3,200 - 3,400 mV E
CELL VOLTAGE 88 READY F
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Total battery voltage 393 V Approx. 4,000 - 4,200 mV G
H
K
Total battery voltage 317 V Approx. 3,200 - 3,400 mV L
TOTAL BATTERY VOLTAGE READY Approx. 240 - 420 V
M
MAXIMUM CELL VOLTAGE READY
Total battery voltage 317 V Approx. 3,300 - 3,500 mV N
MINIMUM CELL VOLTAGE READY
20°C - 30°C (68°F - 86°F)
READY (Stop the vehi- O
BATTERY TEMPERATURE 1 Ambient temperature: 25°C (77°F) [Equivalent to air temperature
cle)
around rear module stack]
20°C - 30°C (68°F - 86°F)
READY (Stop the vehi- [Equivalent to air temperature P
BATTERY TEMPERATURE 2 Ambient temperature: 25°C (77°F)
cle) around front RH module stack
(front side)]
20°C - 30°C (68°F - 86°F)
READY (Stop the vehi- [Equivalent to air temperature
BATTERY TEMPERATURE 4 Ambient temperature: 25°C (77°F)
cle) around front RH module stack (rear
side)]

EV BATTERY SYSTEM
Fail-safe INFOID:0000000010640528
When Li-ion Battery Controller (LBC) detects a malfunction of the Li-ion battery, it enters the control mode that
protects the battery by stopping or restricting the output/charging from/to the battery.
The fail-safe mode differs depending on the contents of the detected malfunction.
FAIL-SAFE PATTERN
• Pattern A: No driving, Charge stop, and EV system warning lamp illuminate
• Pattern B: Driving output power limit, Charge stop, and EV system warning lamp illuminate
• Pattern C: Driving output power limit, Charge limit, and EV system warning lamp illuminate
• Pattern D: EV system warning lamp illuminate
FAIL-SAFE LIST
Pattern
DTC CONSULT screen items
A B C D
P0A0D HV SYSTEM INTERLOCK ERROR ×
P0A1F BATTERY ENERGY CONTROL MODULE × × ×
P3030 CELL CONT LIN ×
P3031 CELL CONT ASIC1 ×
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P303A CELL CONT ASIC10 ×
P303B CELL CONT ASIC11 ×
P303C CELL CONT ASIC12 ×
P303D CELL CONT ASIC13 ×
P303E CELL CONT ASIC14 ×
P303F CELL CONT ASIC15 ×
P3049 CELL CONT ASIC1 VOLT ×
P304A CELL CONT ASIC2 VOLT ×
P304B CELL CONT ASIC3 VOLT ×
P304C CELL CONT ASIC4 VOLT ×
P304D CELL CONT ASIC5 VOLT ×
P304E CELL CONT ASIC6 VOLT ×

EV BATTERY SYSTEM
Pattern
DTC CONSULT screen items A
A B C D
P304F CELL CONT ASIC7 VOLT ×
P3050 CELL CONT ASIC8 VOLT × B
P3053 CELL CONT ASIC11 VOLT × EVB
D
P3058 CELL CONT ASIC16 VOLT × E
P305A CELL CONT ASIC18 VOLT ×
F
P305B CELL CONT ASIC19 VOLT ×
P305C CELL CONT ASIC20 VOLT ×
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P305D CELL CONT ASIC21 VOLT × G
P305E CELL CONT ASIC22 VOLT ×
P305F CELL CONT ASIC23 VOLT ×
H
P3061 CELL BATTERY VOLT ×
P3062 BYPASS SW × I
P3064 CELL CONT ASIC ×
P308B CELL CONT ASIC1 OPEN ×
P308C CELL CONT ASIC2 OPEN ×
J
P308D CELL CONT ASIC3 OPEN ×

P308E CELL CONT ASIC4 OPEN ×
K
P308F CELL CONT ASIC5 OPEN ×
P3090 CELL CONT ASIC6 OPEN ×
P3091 CELL CONT ASIC7 OPEN × L
M
P3096 CELL CONT ASIC12 OPEN × N
O
P309A CELL CONT ASIC16 OPEN ×
P309B CELL CONT ASIC17 OPEN × P
P309C CELL CONT ASIC18 OPEN ×
P309D CELL CONT ASIC19 OPEN ×
P309E CELL CONT ASIC20 OPEN ×
P309F CELL CONT ASIC21 OPEN ×
P30A0 CELL CONT ASIC22 OPEN ×

EV BATTERY SYSTEM
Pattern
A B C D
P30E0 DLC DIAGNOSIS VCM ×
P30E2 DLC DIAGNOSIS HVAC No fail-safe
P30E3 DLC DIAGNOSIS MC No fail-safe
P30E4 DLC DIAGNOSIS PDM (POWER DELIVERY MODULE) No fail-safe
P30FC OVER CURRENT ×
P318D COMMUNICATION ERROR ×
P318E COMMUNICATION ERROR ×
P3191 COMMUNICATION ERROR No fail-safe
P3199 COMMUNICATION ERROR ×
P319C COMMUNICATION ERROR No fail-safe
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P31A4 CAN ERROR VCM ×
P31A7 CAN ERROR INV/MC No fail-safe
P3302 CELL OVER VOLTAGE MODULE1 ×
P330A CELL OVER VOLTAGE MODULE9 ×
P330B CELL OVER VOLTAGE MODULE10 ×
P330C CELL OVER VOLTAGE MODULE11 ×
P330D CELL OVER VOLTAGE MODULE12 ×
P330E CELL OVER VOLTAGE MODULE13 ×
P330F CELL OVER VOLTAGE MODULE14 ×
P331B CELL OVER VOLTAGE MODULE26 ×

EV BATTERY SYSTEM
Pattern
DTC CONSULT screen items A
A B C D
P331E CELL OVER VOLTAGE MODULE29 × B
P3321 CELL OVER VOLTAGE MODULE32 × EVB
D
P3326 CELL OVER VOLTAGE MODULE37 × E
F
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P332B CELL OVER VOLTAGE MODULE42 × G
H
P332E CELL OVER VOLTAGE MODULE45 ×
P3330 CELL OVER VOLTAGE MODULE47 × I
P3375 CELL OVER DISCHARGE MODULE1 ×
J

K
P337A CELL OVER DISCHARGE MODULE6 ×
P337B CELL OVER DISCHARGE MODULE7 × L
P337C CELL OVER DISCHARGE MODULE8 ×
P337D CELL OVER DISCHARGE MODULE9 ×
M
P337E CELL OVER DISCHARGE MODULE10 ×
P337F CELL OVER DISCHARGE MODULE11 ×
P3380 CELL OVER DISCHARGE MODULE12 × N
O
P3385 CELL OVER DISCHARGE MODULE17 × P

EV BATTERY SYSTEM
Pattern
A B C D
P338B CELL OVER DISCHARGE MODULE23 ×
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P339B CELL OVER DISCHARGE MODULE39 ×
P33A0 CELL OVER DISCHARGE MODULE44 ×
P33D4 BATT GRADUAL CAPA LOSS DIAG ×
P33D5 CURRENT SENSOR ×
P33D6 CURRENT SENSOR ×
P33D7 TEMPERATURE SENSOR No fail-safe
P33D9 TEMPERATURE SENSOR No fail-safe
P33DD TEMPERATURE SENSOR No fail-safe
P33DF BATT VOLTAGE ISOLATION SEN
P33E0 BATT VOLTAGE ISOLATION SEN ×
P33E1 BATT VOLTAGE ISOLATION SEN ×
P33E2 BATT PACK OVER TEMP ×
P33E6 CELL VOLTAGE DEVIATION DIAG ×
P33EA BATTERY HEATER RELAY ×
P33EB TEMPERATURE SENSOR No fail-safe
P33ED BATTERY PARALLEL DIAGNOSIS ×
P33EE BATTERY HEATER CONTROL SYSTEM ×
U1000 CAN COMM CIRCUIT × ×

EV BATTERY SYSTEM
DTC Index INFOID:0000000010640529
A
×: Applicable —: Not applicable
EV system
DTC CONSULT screen items warning Trip Reference B
lamp
P0A0D HV SYSTEM INTERLOCK ERROR × 1 EVB-75
P0A1F BATTERY ENERGY CONTROL MODULE × 1 EVB-77 EVB
P3030 CELL CONT LIN × 1 EVB-78
P3031 CELL CONT ASIC1 × 1 EVB-79
D
P3034 CELL CONT ASIC4 × 1 EVB-79 E
F
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P3039 CELL CONT ASIC9 × 1 EVB-79 G
P303A CELL CONT ASIC10 × 1 EVB-79
P303B CELL CONT ASIC11 × 1 EVB-79
P303C CELL CONT ASIC12 × 1 EVB-79
H
P303D CELL CONT ASIC13 × 1 EVB-80
P303E CELL CONT ASIC14 × 1 EVB-80
I
P303F CELL CONT ASIC15 × 1 EVB-80
P3041 CELL CONT ASIC17 × 1 EVB-80 J
K
P3046 CELL CONT ASIC22 × 1 EVB-80 L
M
P3049 CELL CONT ASIC1 VOLT × 1 EVB-81
P304A CELL CONT ASIC2 VOLT × 1 EVB-81
P304B CELL CONT ASIC3 VOLT × 1 EVB-81 N
P304C CELL CONT ASIC4 VOLT × 1 EVB-81
P304D CELL CONT ASIC5 VOLT × 1 EVB-81
P304E CELL CONT ASIC6 VOLT × 1 EVB-81
O
P304F CELL CONT ASIC7 VOLT × 1 EVB-81
P

EV BATTERY SYSTEM
EV system
DTC CONSULT screen items warning Trip Reference
lamp
P305A CELL CONT ASIC18 VOLT × 1 EVB-83
P305B CELL CONT ASIC19 VOLT × 1 EVB-83
P305C CELL CONT ASIC20 VOLT × 1 EVB-83
P305D CELL CONT ASIC21 VOLT × 1 EVB-83
P305E CELL CONT ASIC22 VOLT × 1 EVB-83
P305F CELL CONT ASIC23 VOLT × 1 EVB-83
P3061 CELL BATTERY VOLT × 1 EVB-85
P3062 BYPASS SW × 1 EVB-86
P3064 CELL CONT ASIC × 1 EVB-87
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P308B CELL CONT ASIC1 OPEN × 1 EVB-88
P308C CELL CONT ASIC2 OPEN × 1 EVB-88
P308D CELL CONT ASIC3 OPEN × 1 EVB-88
P308E CELL CONT ASIC4 OPEN × 1 EVB-88
P308F CELL CONT ASIC5 OPEN × 1 EVB-88
P3090 CELL CONT ASIC6 OPEN × 1 EVB-88
P309A CELL CONT ASIC16 OPEN × 1 EVB-91
P309B CELL CONT ASIC17 OPEN × 1 EVB-91
P309C CELL CONT ASIC18 OPEN × 1 EVB-91
P309D CELL CONT ASIC19 OPEN × 1 EVB-91
P309E CELL CONT ASIC20 OPEN × 1 EVB-91
P309F CELL CONT ASIC21 OPEN × 1 EVB-91
P30A0 CELL CONT ASIC22 OPEN × 1 EVB-91
P30E0 DLC DIAGNOSIS VCM × 1 EVB-94
P30E2 DLC DIAGNOSIS HVAC — 1 EVB-95
P30E3 DLC DIAGNOSIS MC — 1 EVB-96
P30E4 DLC DIAGNOSIS PDM (POWER DELIVERY MODULE) — 1 EVB-97
P30FC OVER CURRENT × 1 EVB-98

EV BATTERY SYSTEM
EV system
DTC CONSULT screen items warning Trip Reference A
lamp
P318D COMMUNICATION ERROR × 1 EVB-99
P318E COMMUNICATION ERROR × 1 EVB-100 B
P3191 COMMUNICATION ERROR — 1 EVB-101
EVB
P3199 COMMUNICATION ERROR × 1 EVB-104
P319C COMMUNICATION ERROR — 1 EVB-105 D
P31A4 CAN ERROR VCM × 1 EVB-106
P31A7 CAN ERROR INV/MC — 1 EVB-107
E
P3302 CELL OVER VOLTAGE MODULE1 × 1 EVB-108
P3304 CELL OVER VOLTAGE MODULE3 × 1 EVB-108 F
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G

P3309 CELL OVER VOLTAGE MODULE8 × 1 EVB-108 H
P330A CELL OVER VOLTAGE MODULE9 × 1 EVB-108
P330B CELL OVER VOLTAGE MODULE10 × 1 EVB-108
P330C CELL OVER VOLTAGE MODULE11 × 1 EVB-108 I
P330D CELL OVER VOLTAGE MODULE12 × 1 EVB-108
P330E CELL OVER VOLTAGE MODULE13 × 1 EVB-112
J
P330F CELL OVER VOLTAGE MODULE14 × 1 EVB-112
P3311 CELL OVER VOLTAGE MODULE16 × 1 EVB-112 K
L
P3316 CELL OVER VOLTAGE MODULE21 × 1 EVB-112 M
N
P331B CELL OVER VOLTAGE MODULE26 × 1 EVB-116 O
P331C CELL OVER VOLTAGE MODULE27 × 1 EVB-116
P331E CELL OVER VOLTAGE MODULE29 × 1 EVB-116 P

EV BATTERY SYSTEM
EV system
DTC CONSULT screen items warning Trip Reference
lamp
P332B CELL OVER VOLTAGE MODULE42 × 1 EVB-119
P332C CELL OVER VOLTAGE MODULE43 × 1 EVB-119
P332E CELL OVER VOLTAGE MODULE45 × 1 EVB-119
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P3375 CELL OVER DISCHARGE MODULE1 × 1 EVB-122
P337A CELL OVER DISCHARGE MODULE6 × 1 EVB-122
P337B CELL OVER DISCHARGE MODULE7 × 1 EVB-122
P337C CELL OVER DISCHARGE MODULE8 × 1 EVB-122
P337D CELL OVER DISCHARGE MODULE9 × 1 EVB-122
P337E CELL OVER DISCHARGE MODULE10 × 1 EVB-122
P337F CELL OVER DISCHARGE MODULE11 × 1 EVB-122
P338D CELL OVER DISCHARGE MODULE25 × 1 EVB-130

EV BATTERY SYSTEM
EV system
DTC CONSULT screen items warning Trip Reference A
lamp
P3393 CELL OVER DISCHARGE MODULE31 × 1 EVB-130 B
EVB
P3398 CELL OVER DISCHARGE MODULE36 × 1 EVB-130 D
E
P339D CELL OVER DISCHARGE MODULE41 × 1 EVB-133 F
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P33A0 CELL OVER DISCHARGE MODULE44 × 1 EVB-133
G

P33A2 CELL OVER DISCHARGE MODULE46 × 1 EVB-133 H
P33D4 BATTERY INTERNAL RESISTANCE DIAG × 1 EVB-136 I
P33D5 CURRENT SENSOR × 1 EVB-137
P33D6 CURRENT SENSOR × 1 EVB-139
J
P33D7 TEMPERATURE SENSOR — 1 EVB-141
P33D9 TEMPERATURE SENSOR — 1 EVB-141
P33DD TEMPERATURE SENSOR — 1 EVB-141 K
P33DF BATT VOLTAGE ISOLATION SEN × 1 EVB-143
P33E0 BATT VOLTAGE ISOLATION SEN × 1 EVB-144
L
P33E1 BATT VOLTAGE ISOLATION SEN × 1 EVB-145
P33E2 BATT PACK OVER TEMP × 1 EVB-146
P33E6 CELL CONTROLLER × 2 EVB-147 M
P33EB TEMPERATURE SENSOR — 1 EVB-154
P33EA BATTERY HEATER RELAY × 1 EVB-152
N
P33ED BATTERY PARALLEL DIAGNOSIS × 1 EVB-156
P33EE BATTERY HEATER CONTROL SYSTEM × 1 EVB-158
U1000 CAN COMM CIRCUIT × 1 EVB-160 O

VCM
< WIRING DIAGRAM >
WIRING DIAGRAM
VCM
Wiring Diagram INFOID:0000000010640530
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AACWA0035GB

VCM
< WIRING DIAGRAM >
EVB
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AACWA0036GB

VCM
< WIRING DIAGRAM >
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AACWA0038GB

VCM
< WIRING DIAGRAM >
EVB
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AACWA0037GB

VCM
< WIRING DIAGRAM >
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AACWA0039GB

VCM
< WIRING DIAGRAM >
EVB
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AACIA0149GB

VCM
< WIRING DIAGRAM >
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AACIA0150GB

VCM
< WIRING DIAGRAM >
EVB
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AACIA0151GB

VCM
< WIRING DIAGRAM >
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AACIA0152GB

VCM
< WIRING DIAGRAM >
EVB
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AACIA0153GB

VCM
< WIRING DIAGRAM >
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AACIA0154GB

VCM
< WIRING DIAGRAM >
EVB
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AACIA0155GB

VCM
< WIRING DIAGRAM >
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AACIA0156GB

VCM
< WIRING DIAGRAM >
EVB
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G
AACIA0157GB

VCM
< WIRING DIAGRAM >
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AACIA0158GB

VCM
< WIRING DIAGRAM >
EVB
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AACIA0159GB

VCM
< WIRING DIAGRAM >
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AACIA0160GB

VCM
< WIRING DIAGRAM >
EVB
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AACIA0161GB

VCM
< WIRING DIAGRAM >
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AACIA0162GB

DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION >
BASIC INSPECTION A
Work Flow INFOID:0000000010640531
B
DETAILED FLOW
1.GET INFORMATION FOR SYMPTOM EVB
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the “Question sheet”. (Refer to EVB-70, "Diagnostic Work Sheet".)
D
>> GO TO 2.
2.CHECK DTC IN VCM E
1. Check DTC in VCM.
2. Check related service bulletins for information.
Are any DTCs detected? F
YES >> Check the DTC. Refer to EVC-103, "DTC Index".
NO >> GO TO 3.
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3.CHECK DTC G
1. Check DTC.
2. Perform the following procedure if DTC is displayed.
H
- Record DTC and freeze frame data. (Print them out with CONSULT.)
- Erase DTC.
- Study the relationship between the cause detected by DTC and the symptom described by the customer.
(Symptom Matrix Chart is useful. Refer to EVC-411, "Symptom Index".) I
3. Check related service bulletins for information.
Are any symptoms described and any DTCs detected?
Symptom is described, DTC is detected>>GO TO 4. J
Symptom is described, DTC is not detected>>GO TO 5.
Symptom is not described, DTC is detected>>GO TO 6.
4.CONFIRM THE SYMPTOM K
Try to confirm the symptom described by the customer.
Also study the normal operation and fail-safe related to the symptom. Refer to EVC-411, "Symptom Index" and
EVB-40, "Fail-safe". L
Diagnosis Work Sheet is useful to verify the incident.
Verify relation between the symptom and the condition when the symptom is detected.
M
>> GO TO 6.
5.CONFIRM THE SYMPTOM
N
Try to confirm the symptom described by the customer.
Also study the normal operation and fail-safe related to the symptom. Refer to EVC-411, "Symptom Index" and
EVB-40, "Fail-safe".
Diagnosis Work Sheet is useful to verify the incident. O
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 7. P
6.PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC CONFIRMATION PROCEDURE for the displayed DTC, and then check that DTC is detected
again.
NOTE:
• Freeze frame data is useful if the DTC is not detected.

• Perform Component Function Check if DTC CONFIRMATION PROCEDURE is not included on Service
Manual. This simplified check procedure is an effective alternative though DTC cannot be detected during
this check.
If the result of Component Function Check is NG, it is the same as the detection of DTC by DTC CONFIR-
MATION PROCEDURE.
Is DTC detected?
YES >> GO TO 8.
NO >> Check according to GI-53, "Intermittent Incident".
7.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
Detect malfunctioning system according to EVC-411, "Symptom Index" based on the confirmed symptom in
step 4, and determine the trouble diagnosis order based on possible causes and symptoms.
Is the symptom described?
YES >> GO TO 8.
NO >> Monitor input data from related sensors using CONSULT.
8.DETECT MALFUNCTIONING PART BY DIAGNOSIS PROCEDURE
Inspect according to Diagnosis Procedure of the system.
Is a malfunctioning part detected?
YES >> GO TO 9.
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NO >> Monitor input data from related sensors using CONSULT.
9.REPAIR OR REPLACE THE MALFUNCTIONING PART
1. Repair or replace the malfunctioning part.
2. Reconnect parts or connectors disconnected during Diagnosis Procedure again after repair and replace-
ment.
3. Check DTC. If DTC is displayed, erase it.
>> GO TO 10.
10.FINAL CHECK
When DTC was detected in step 3, perform DTC CONFIRMATION PROCEDURE or Component Function
Check again, and then check that the malfunction have been completely repaired.
When symptom was described from the customer, refer to confirmed symptom in step 4 or 5, and check that
the symptom is not detected.
Is DTC detected and does symptom remain?
YES-1 >> DTC is detected: GO TO 8.
YES-2 >> Symptom remains: GO TO 5.
NO >> Before returning the vehicle to the customer, always erase DTC.
Diagnostic Work Sheet INFOID:0000000010640532
DESCRIPTION
There are many operating conditions that lead to the malfunction of
“EV battery system” components. A good grasp of such conditions
can make troubleshooting faster and more accurate.
In general, each customer feels differently about symptoms. It is
important to fully understand the symptoms or conditions for a cus-
tomer complaint.
Utilize the diagnostic worksheet in order to organize all the informa-
tion for troubleshooting.
NOTE:
Some conditions may cause a DTC to be detected.
JSCIA0412GB
WORKSHEET SAMPLE

Question Sheet A
Incident Date VIN
Customer name
Model & Year In Service Date
MR/MS
Trans. Mileage km/mile
B
Symptoms Power limitation indicator

Does not to READY EV system warning lamp is on
lamp is on
EVB
Water leak* Noise* Vibration* Shock* Gear noise*
Non driving* Poor acceleration* Poor torque* Radio noise*
Does not charge Other* *: If applied, enter in detail D
Detailed symptom
E
Onomatopoeia
Frequency All the time Once Sometimes ( times a day) Other

F
Charging condition Full Medium Low
Weather
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Not affected
conditions G
Weather Fine Clouding Raining Snowing Other ( )
Temp. [Approx. °C
Temp. Hot Warm Cool Cold
( °F)] H
Humidity High Middle Low Humidity (Approx. %)
Road conditions Deplorable
Not affected In town Freeway Off road (Up / Down)
road I
Flat road While turning (Right / Left) Bump
Other
J
Shift position Not affected
P position R position N position D position ECO mode
Driving conditions Not affected K
Power switch ON → OFF Power switch OFF → ON READY (stop the vehicle)
While cruis- While decel- Just before Just after stop-
D position (stop the vehicle) L
ing erating stopping ping
While recharging Other
Vehicle speed [ km/h ( MPH)] Accelerator pedal ( / 8)
M
Battery level (Low / Middle / High)
Moments when mal- Disappears with select oper-
Disappears while driving Disappears when stopped
function disappears ation
N
Disappears when power switch Disappears when battery charge is
Does not disappear
is pushed OFF stopped
Other
O
Other

ADDITIONAL SERVICE WHEN REPLACING LI-ION BATTERY CONTROLLER
ADDITIONAL SERVICE WHEN REPLACING LI-ION BATTERY CONTROL-
LER
Description INFOID:0000000010640533
When only Li-ion Battery Controller (LBC) is replaced, it is necessary to save the battery information stored in
LBC to the new LBC.
Work Procedure INFOID:0000000010640534
1.SAVE THE LI-ION BATTERY CONTROLLER (LBC) INTERNAL INFORMATION

With CONSULT
1. Select “SAVE BATTERY INFORMATION DATA” in “WORK SUPPOTRT” mode.
2. Save the LBC internal information.
>> GO TO 2.
2.REPLACE LBC
Replace LBC. Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal and Installation".
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>> GO TO 3.
3.WRITE THE LBC INTERNAL INFORMATION
With CONSULT
1. Select “WRITE BATTERY INFORMATION DATA” in “WORK SUPPOTRT” mode.
2. Write the information that has been read out before LBC replacement.
>> GO TO 4.
4.WRITE THE LBC INTERNAL INFORMATION TO VCM
Refer to “Li-ion Battery Registration Operation Manual.
>> END

MODULE CHARGE BALANCE
A
If a malfunction (e.g. abnormal voltage) occurs in a Li-ion battery cell, the module which includes the malfunc- B
tioning cell must be replaced. When replacing a module with a new one, its voltage is required to be adjusted
to the adjusting voltage calculated from the maximum cell voltage of normal cells.
Work Procedure INFOID:0000000010640536 EVB
NOTE:
Voltage adjustment under low temperature conditions may require a long time. To prevent this from occurring,
it is advisable to adjust voltage under room temperature conditions [20°C ± 10°C (68°F ±18°F)]. D
1.CHECK ADJUSTMENT VOLTAGE VALUE

With CONSULT E
1. Power switch ON.
2. Select “DATA MONITOR”of “HV BAT”.
3. Check “MAXIMUM CELL VOLTAGE”. F
4. Double the “MAXIMUM CELL VOLTAGE” and use that value as the module adjustment value.
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Adjustment voltage value : MAXIMUM CELL VOLTAGE× 2
G
Example: 3.925 V (MAXIMUM CELL VOLTAGE) × 2 = 7.850 V (Adjustment voltage value)
>> GO TO 2. H
2.CHECK MODULE VOLTAGE
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual. I
1. Set the new module to the module charge balancer.
2. Measure module voltage and compare it with “adjustment voltage value” confirmed in Step1.
J
Module voltage is lower than adjustment voltage value>>GO TO 4.
Module voltage is higher than adjustment voltage value>>GO TO 3.
3.DISCAHRGE OF MODULE VOLTAGE K
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual. L
Discharge the module to 5.0 V using module charge balancer.
Discharge voltage : 5.0 V

M
>> GO TO 4.
4.ADJUST VOLTAGE WITH A MODULE CHARGE BALANCER N
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual.
1. Enter “adjustment voltage value” into module charge balancer. O
Adjustment voltage value : MAXIMUM CELL VOLTAGE× 2

2. Start the voltage adjustment. P
>> After module voltage adjustment, GO TO 5.

1. Remove the module from the module charge balancer.
2. Using a circuit tester, check that the module voltage is within the specified range.

Standard : Adjustment voltage value ± 10 mV
>> GO TO 6.
6.CHECK CELL VOLTAGE
With CONSULT
1. After adjusting the voltage, install the module to the vehicle.
2. Select “DATA MONITOR” of “HV BAT”.
3. Check “CELL VOLTAGE” of install module.
4. Check that the difference from the “MAXIMUM CELL VOLTAGE” confirmed in Step1 is within the specified
range.
Standard : MAXIMUM CELL VOLTAGE ± 33 mV
>> WORK END
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P0A0D HV SYSTEM INTERLOCK ERROR
< DTC/CIRCUIT DIAGNOSIS >
DTC/CIRCUIT DIAGNOSIS A
DTC Logic INFOID:0000000010640537
B
DTC DETECTION LOGIC

EVB
DTC Trouble diagnosis name DTC detecting condition Possible causes
HV SYSTEM INTERLOCK Self diagnosis program of Li-ion battery controller de-
P0A0D Li-ion battery controller
ERROR tects a malfunction in the CPU.
D
DTC CONFIRMATION PROCEDURE
1.PERFORM DTC CONFIRMATION PROCEDURE E
With CONSULT
1. Power switch ON and wait for 10 seconds or more.
2. Select “Self Diagnostic Result” of “HV BAT”. F
3. Check DTC.
Is P0A1F detected?
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YES >> Refer to EVB-75, "Diagnosis Procedure". G
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000010640538
H
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of I
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
J
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in K
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system. L
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
• Refer to EVB-7, "High Voltage Precautions". M
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
instructed in the Service Manual. A malfunction may occur if this is not observed. N
1.PRECONDITIONING
WARNING: O
Disconnect the high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-181, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-191, "BATTERY PACK UPPER CASE : Removal and
Installation". P
>> GO TO 2.
2.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-1
1. Disconnect Li-ion battery controller (LBC) harness connector.
2. Disconnect interlock detecting switch (high voltage harness connector) harness connector.
3. Check the continuity between Li-ion battery controller harness connector and ground.
LBC
— Continuity
Connector Terminal
LB11 8 Ground Not existed
Is the inspection result normal?
YES >> GO TO 3.
NO >> Replace Li-ion battery vehicle communication harness.
3.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-2
1. Disconnect interlock detecting switch (service plug) harness connector.
2. Check the continuity between Li-ion battery controller harness connector and ground.
LBC
— Continuity
Connector Terminal
LB11 6 Ground Not existed
YES >> GO TO 4.
NO >> Replace Li-ion battery vehicle communication harness.
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4.CHECK INTERLOCK DETECTIONG SWITCH (SERVICE PLUG)
Refer to EVB-76, "Component Inspection".
YES >> Replace Li-ion battery controller. Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
NO >> Replace service plug.
Component Inspection INFOID:0000000010640539
1.CHECK INTERLOCK DETECTIONG SWITCH (SERVICE PLUG)

Check the continuity between terminals in the figure.
Value: Approx. 0 Ω
YES >> INSPECTION END
NO >> Replace service plug.
JPCIA0347ZZ

P0A1F BATTERY ENERGY CONTROL MODULE
P0A1F BATTERY ENERGY CONTROL MODULE
A
DTC DETECTION LOGIC B

BATTERY ENERGY CON- Self diagnosis program of Li-ion battery controller de- EVB
P0A1F Li-ion battery controller
TROL MODULE tects a malfunction in the CPU.

D
With CONSULT
1. Power switch ON and wait for 10 seconds or more. E
2. Select “Self Diagnostic Result” of “HV BAT”.
3. Check DTC.
Is P0A1F detected? F
YES >> Refer to EVB-77, "Diagnosis Procedure".
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G
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-201, "LI-ION BATTERY CONTROL-
LER : Removal and Installation". H

P3030 CELL CONTROLLER LIN
P3030 CELL CONTROLLER LIN
DTC DETECTION LOGIC

• Li-ion battery controller
A malfunction occurs with the communication function in
P3030 CELL CONT LIN • Module
Li-ion battery controller.
• Harness or connector

With CONSULT
3. Check DTC.
Is P3030 detected?
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1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER

With CONSULT
2. Check to see if “P3375 - P33A4” is detected simultaneously with “P3030”.
Is P30F3 detected?
YES >> • When “P3375” - “P3380” are detected simultaneously, perform the diagnosis procedure of
“P3375” - “P3380”. Refer to EVB-122, "Diagnosis Procedure".
• When “P3381” - “P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381” - “P338C”. Refer to EVB-126, "Diagnosis Procedure".
• When “P338D” - “P3398” are detected simultaneously, perform the diagnosis procedure of
“P338D” - “P3398”. Refer to EVB-130, "Diagnosis Procedure".
• When “P3399” - “P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399” - “P33A4”. Refer to EVB-133, "Diagnosis Procedure".
NO >> Replace Li-ion battery controller. Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal
and Installation".

P3031-P303C CELL CONTROLLER ASIC
P3031-P303C CELL CONTROLLER ASIC
A

P3031 CELL CONT ASIC1 EVB
P3032 CELL CONT ASIC2
D
P3036 CELL CONT ASIC6 A malfunction occurs with the communication function E
Li-ion battery controller
P3037 CELL CONT ASIC7 in Li-ion battery controller.

F
P303A CELL CONT ASIC10
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P303B CELL CONT ASIC11 G
P303C CELL CONT ASIC12
DTC CONFIRMATION PROCEDURE H

With CONSULT
1. Power switch ON and wait for 10 seconds or more. I
3. Check DTC.
Is any DTC detected? J
K
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER L

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P3031 -P303C”. M
Is P3030 detected?
YES >> Perform diagnosis on the detected P3030. Refer to EVB-78, "Diagnosis Procedure".
NO >> Replace Li-ion battery controller. Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal N
and Installation".

P303D-P3048 CELL CONTROLLER ASIC
P303D-P3048 CELL CONTROLLER ASIC
DTC DETECTION LOGIC

P303D CELL CONT ASIC13
P303E CELL CONT ASIC14
P303F CELL CONT ASIC15
P3042 CELL CONT ASIC18 A malfunction occurs with the communication function
P3043 CELL CONT ASIC19 in Li-ion battery controller.

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With CONSULT
3. Check DTC.
Is any DTC detected?

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P303D” -“P3048”.
Is P3030 detected?
YES >> Perform diagnosis on the detected P3030. Refer to EVB-78, "Diagnosis Procedure".
and Installation".

P3049-P3054 CELL CONTROLLER ASIC VOLTAGE
A

P3049 CELL CONT ASIC1 VOLT EVB
P304A CELL CONT ASIC2 VOLT
P304B CELL CONT ASIC3 VOLT
D
P304C CELL CONT ASIC4 VOLT
P304D CELL CONT ASIC5 VOLT
P304E CELL CONT ASIC6 VOLT • Li-ion battery controller E
The A/D converter in Li-ion battery controller is malfunc-
• Module
P304F CELL CONT ASIC7 VOLT tioning.
P3050 CELL CONT ASIC8 VOLT
F
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P3053 CELL CONT ASIC11 VOLT G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check DTC. M
YES-1 >> “P3302” - “P3331” are detected simultaneously.
• When “P3302” - “P330D” are detected simultaneously, perform the diagnosis procedure of N
“P3302” - “P330D”. Refer to EVB-108, "Diagnosis Procedure".
• When “P330E” - “P3319” are detected simultaneously, perform the diagnosis procedure of
“P330E” - “P3319”. Refer to EVB-112, "Diagnosis Procedure".
• When “P331A” - “P3325” are detected simultaneously, perform the diagnosis procedure of O
“P331A” - “P3325”. Refer to EVB-116, "Diagnosis Procedure".
• When “P3326” - “P3331” are detected simultaneously, perform the diagnosis procedure of
“P3326” - “P3331”. Refer to EVB-119, "Diagnosis Procedure". P
YES-2 >> “P3375” - “P33A4” are detected simultaneously.

NO >> When only “P3049” - “P3054” are detected, replace Li-ion battery controller. Refer to EVB-201,
"LI-ION BATTERY CONTROLLER : Removal and Installation".
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A

P3055 CELL CONT ASIC13 VOLT EVB
D
P305A CELL CONT ASIC18 VOLT • Li-ion battery controller E
The A/D converter in Li-ion battery controller is malfunc-
• Module
P305B CELL CONT ASIC19 VOLT tioning.
P305C CELL CONT ASIC20 VOLT
F
P305D CELL CONT ASIC21 VOLT
P305E CELL CONT ASIC22 VOLT
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P305F CELL CONT ASIC23 VOLT G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check DTC. M
YES-1 >> “P3302” - “P3331” are detected simultaneously.
• When “P3302” - “P330D” are detected simultaneously, perform the diagnosis procedure of N
“P3302” - “P330D”. Refer to EVB-108, "Diagnosis Procedure".
• When “P330E” - “P3319” are detected simultaneously, perform the diagnosis procedure of
“P330E” - “P3319”. Refer to EVB-112, "Diagnosis Procedure".
• When “P331A” - “P3325” are detected simultaneously, perform the diagnosis procedure of O
“P331A” - “P3325”. Refer to EVB-116, "Diagnosis Procedure".
“P3326” - “P3331”. Refer to EVB-119, "Diagnosis Procedure". P
YES-2 >> “P3375” - “P33A4” are detected simultaneously.

NO >> When only “P3055” - “P3060” are detected, replace Li-ion battery controller. Refer to EVB-201,
"LI-ION BATTERY CONTROLLER : Removal and Installation".
cardiagn.com

P3061 CELL BATTERY VOLTAGE
P3061 CELL BATTERY VOLTAGE
A

An open circuit diagnosis detection circuit in Li-ion battery EVB
P3061 CELL BATTERY VOLT Li-ion battery controller
controller is malfunctioning.

D
With CONSULT
3. Check DTC.
Is P3061 detected? F
cardiagn.com
G

P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
DTC DETECTION LOGIC

A malfunction of the bypass switch in Li-ion battery con-
P3062 BYPASS SW • Module
troller is detected.
DTC DETECTION LOGIC

With CONSULT
3. Check DTC.
Is P3062 detected?
cardiagn.com

With CONSULT
2. Check to see if “P3375”-“P33A4” is detected simultaneously with “P3062”.
Is P3375-P33A4 detected?
YES >> • When “P3375” - “P3380” are detected simultaneously, perform the diagnosis procedure of
and Installation".

P3064 CELL CONT ASIC
P3064 CELL CONT ASIC
A

A malfunction occurs with the communication function in Li- EVB
P3064 CELL CONTROLLER ASIC Li-ion battery controller
ion battery controller.

D
With CONSULT
3. Check DTC.
Is P3064 detected? F
cardiagn.com
G

P308B-P3096 CELL CONTROLLER ASIC OPEN
DTC DETECTION LOGIC

P308B CELL CONT ASIC1 OPEN
P308C CELL CONT ASIC2 OPEN
P308D CELL CONT ASIC3 OPEN
P308E CELL CONT ASIC4 OPEN
P308F CELL CONT ASIC5 OPEN
P3090 CELL CONT ASIC6 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller
P3091 CELL CONT ASIC7 OPEN tects an open circuit in the cell voltage detection line. • Harness or connector
P3092 CELL CONT ASIC8 OPEN

cardiagn.com
DTC DETECTION LOGIC

With CONSULT
3. Check DTC.
Is P308B-P3096 detected?
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
maintenance.
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
• Refer to EVB-7, "High Voltage Precautions".
CAUTION:
instructed in the Service Manual. A malfunction may occur if this is not observed.

With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. A
2. Check to see if “P3049”-“P3060” (CELL CONT ASIC VOLT related codes) or “P3375”-“P33A4” (CELL
OVER DISCHARGE related codes) is detected simultaneously with “P308B”-“P3096”.
Is P3049-P3060 or P3375-P33A4 detected? B
YES-1 >> “P3049”-“P3060” are detected simultaneously.
• When “P3049”-“P3054” are detected simultaneously, perform the diagnosis procedure of
“P3049”-“P3054”. Refer to EVB-81, "Diagnosis Procedure". EVB
“P3055”-“P3060”. Refer to EVB-83, "Diagnosis Procedure".
YES-2 >> “P3375”-“P33A4” are detected simultaneously.
• When “P3375”-“P3380” are detected simultaneously, perform the diagnosis procedure of D
• When “P3381”-“P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381”-“P338C”. Refer to EVB-126, "Diagnosis Procedure". E
• When “P338D”-“P3398” are detected simultaneously, perform the diagnosis procedure of
“P338D”-“P3398”. Refer to EVB-130, "Diagnosis Procedure"
• When “P3399”-“P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399”-“P33A4”. Refer to EVB-133, "Diagnosis Procedure". F
NO >> GO TO 2.
2.PRECONDITIONING
cardiagn.com
G
WARNING:
Disconnect high voltage. Refer to GI-33, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-181, "Removal and Installation". H
Installation".
I
>> GO TO 3.
3.CHECK CONNECTION STATUS
1. Power switch OFF. J
2. Check connection status of Li-ion battery controller harness connector and module harness connector.
YES >> GO TO 4. K
NO >> Recover the connection status.
4.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE L
1. Disconnect Li-ion battery controller harness connector and voltage detection terminal of bus bar.
2. Refer to below table and continuity between Li-ion battery controller and voltage detection terminal
of bus bar, according to detected DTC.
M
JSCIA0813ZZ

Module Li-ion battery controller

DTC Continuity
No. Connector Terminal
1 50
P308B LB13 Existed
2 51
3 52
P308C LB13 Existed
4 53
5 54
P308D LB13 Existed
6 55
7 56
P308E LB13 Existed
8 57
9 58
P308F LB13 Existed
10 59
11 Voltage detection terminal of bus 60
P3090 LB13 Existed
12 bar 61
13 62
cardiagn.com
P3091 LB13 Existed
14 63
15 77
P3092 LB14 Existed
16 78
17 80
P3093 LB14 Existed
18 81
19 82
P3094 LB14 Existed
20 83
21 84
P3095 LB14 Existed
22 85
23 86
P3096 LB14 Existed
24 87
and Installation".
NO >> Repair harness or connector.

P3097-P30A2 CELL CONTROLLER ASIC OPEN
A

P3097 CELL CONT ASIC13 OPEN EVB
D
P309A CELL CONT ASIC16 OPEN
P309B CELL CONT ASIC17 OPEN
P309C CELL CONT ASIC18 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller E
P309D CELL CONT ASIC19 OPEN tects an open circuit in the cell voltage detection line. • Harness or connector
P309E CELL CONT ASIC20 OPEN

F
P309F CELL CONT ASIC21 OPEN
P30A0 CELL CONT ASIC22 OPEN
cardiagn.com
P30A1 CELL CONT ASIC23 OPEN G
P30A2 CELL CONT ASIC24 OPEN
DTC DETECTION LOGIC H

With CONSULT
3. Check DTC.
Is P308B-P30A2 detected? J
K
DANGER:
L
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and M
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- N
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses O
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- P
CAUTION:

With CONSULT
1. Select “Self Diagnostic Result” mode of “HV BAT” using CONSULT.
2. Check to see if “P3049”-“P3060” (CELL CONT ASIC VOLT related codes) or “P3375”-“P33A4” (CELL
OVER DISCHARGE related codes) is detected simultaneously with “P3097”-“P30A2”.
Is P3049-P3060 or P3375-P33A4 detected?
YES-1 >> “P3049”-“P3060” are detected simultaneously.
“P3049”-“P3054”. Refer to EVB-81, "Diagnosis Procedure"
“P3055”-“P3060”. Refer to EVB-83, "Diagnosis Procedure"
YES-2 >> “P3375”-“P33A4” are detected simultaneously.
• When “P3381”-“P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381”-“P338C”. Refer to EVB-126, "Diagnosis Procedure".
• When “P338D”-“P3398” are detected simultaneously, perform the diagnosis procedure of
“P338D”-“P3398”. Refer to EVB-130, "Diagnosis Procedure".
• When “P3399”-“P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399”-“P33A4”. Refer to EVB-133, "Diagnosis Procedure"
NO >> GO TO 2.
2.PRECONDITIONING
cardiagn.com
WARNING:
Installation".
>> GO TO 3.
1. Power switch OFF.
2. Check connection status of Li-ion battery controller harness connector and module harness connector.
YES >> GO TO 4.
4.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE
1. Disconnect Li-ion battery controller harness connector and Module harness connector.
2. Refer to below table and continuity between Li-ion battery controller and Module, according to detected
DTC.
Module Module Li-ion battery controller

DTC Continuity
No. Connector Terminal Connector Terminal
25 10 110
P3097 LB8 LB15 Existed
26 12 111
27 28 112
28 26 113
29 23 114
30 19 115
31 3 116
P309A LB8 LB15 Existed
32 18 117
33 2 118
P309B LB8 LB15 Existed
34 6 119

DTC Continuity A
35 22 120
P309C LB8 LB15 Existed
36 7 121 B
37 38 122
P309D LB7 LB15 Existed
38 51 123
39 39 124 EVB
P309E LB7 LB15 Existed
40 43 125
41 55 127
P309F LB7 LB15 Existed D
42 42 128
43 52 130
P30A0 LB7 LB15 Existed
44 50 138 E
45 35 140
46 33 141
F
47 46 142
48 48 143
cardiagn.com
Is the inspection result normal? G
and Installation".
NO >> Repair harness or connector. H

P30E0 DLC DIAGNOSIS VCM
P30E0 DLC DIAGNOSIS VCM
DTC DETECTION LOGIC

• CAN communication line
When no CAN communication signal is received from
P30E0 DLC DIAGNOSIS VCM • Li-ion battery controller
VCM continuously for 2 seconds or more.
• VCM

With CONSULT
3. Check DTC.
Is P30E0 detected?
cardiagn.com
1.PERFORM THE SELF-DIAGNOSIS

With CONSULT
1. Perform "All DTC Reading".
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P30E0” is detected.
Is P30E0 detected?
YES >> Replace VCM. Refer to EVC-425, "Removal and Installation".
NO >> GO TO 2.
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P30E0”.
Is U1000 detected?
and Installation".

P30E2 DLC DIAGNOSIS HVAC
P30E2 DLC DIAGNOSIS HVAC
A

• CAN communication line EVB
When no CAN communication signal is received from A/
P30E2 DLC DIAGNOSIS HVAC • Li-ion battery controller
C auto amp. continuously for 2 seconds or more.
• A/C auto amp.
DTC CONFIRMATION PROCEDURE D

With CONSULT E
3. Check DTC. F
Is P30E2 detected?
cardiagn.com
NO >> INSPECTION END G
1.PERFORM THE SELF-DIAGNOSIS H
With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P30E2” is detected. I
Is P30E2 detected?
YES >> Replace A/C auto amp.. Refer to HAC-187, "Removal and Installation" (With heat pump) or HAC-
J
348, "Removal and Installation" (Without heat pump).
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER K
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P30E2”. L
Is U1000 detected?
and Installation". M

P30E3 DLC DIAGNOSIS MC
P30E3 DLC DIAGNOSIS MC
DTC DETECTION LOGIC

When no CAN communication signal is received from • CAN communication line
P30E3 DLC DIAGNOSIS MC traction motor inverter continuously for 2 seconds or • Li-ion battery controller
more. • Traction motor inverter

With CONSULT
3. Check DTC.
Is P30E3 detected?
cardiagn.com

With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P30E3” is detected.
Is P30E3 detected?
YES >> Replace traction motor inverter. Refer to TMS-103, "Removal and Installation".
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".

P30E4 DLC DIAGNOSIS PDM(POWER DELIVERY MODULE)
P30E4 DLC DIAGNOSIS PDM(POWER DELIVERY MODULE)
A

When no CAN communication signal is received from • CAN communication line EVB
DLC DIAGNOSIS PDM
P30E4 PDM (Power Delivery Module) continuously for 2 sec- • Li-ion battery controller
(Power Delivery Module)
onds or more. • PDM (Power Delivery Module)

With CONSULT E
3. Check DTC. F
Is P30E4 detected?
cardiagn.com
With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P30E4” is detected. I
Is P30E4 detected?
YES >> Replace PDM (Power Delivery Module). Refer to VC-111, "Removal and Installation".
J
NO >> GO TO 2.
With CONSULT K
Is U1000 detected? L
and Installation".
NO >> INSPECTION END M

P30FC OVER CURRENT
P30FC OVER CURRENT
DTC DETECTION LOGIC

When the temperature of the entire battery pack estimat- • Battery current sensor
P30FC OVER CURRENT
ed from the current value is excessively high. • Other systems malfunction

With CONSULT
3. Check DTC.
Is P30FC detected?
cardiagn.com

With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if any DTC is detected.
YES >> After performing trouble diagnosis of detected DTC, GO TO 2.
NO >> GO TO 2.
2.CHECK BATTERY TEMPERATURE SENSOR
With CONSULT
Using FFD, check the values of three temperature sensors when DTC is detected.
Monitor item Condition Limit

Battery temperature sensor 1
Battery temperature sensor 2 Power switch ON 55°C (131°F) or less
Is there temperature increase?
Temperature increase is seen>>Replace Li-ion battery. Refer to EVB-181, "Removal and Installation".
Temperature increase is not seen>>Replace battery junction box. Refer to EVB-201, "LI-ION BATTERY
CONTROLLER : Removal and Installation".

P318D COMMUNICATION ERROR
P318D COMMUNICATION ERROR
A

COMMUNICATION ER- When no CAN communication signal is received contin-
P318D • Li-ion battery controller
ROR uously.
• VCM

With CONSULT E
3. Check DTC. F
Is P318D detected?
cardiagn.com
For the diagnosis procedure, refer to LAN-17, "Trouble Diagnosis Flow Chart". H

P318E COMMUNICATION ERROR
P318E COMMUNICATION ERROR
DTC DETECTION LOGIC

NOTE:
When the 12 V battery is removed within 5 minutes after turning the power switch OFF, “P318E”, “P3191”, and
“P3196” may be simultaneously detected. This is not a malfunction.

• VCM
COMMUNICATION ER- When no CAN communication signal is received from VCM
P318E • Li-ion battery controller
ROR continuously.

With CONSULT
2. After turning the power switch OFF, get out of the vehicle and close all doors (including back door).
3. After turning the power switch OFF, wait for 5 minutes or more to remove the 12 V battery negative termi-
cardiagn.com
nal. Refer to EVB-6, "Precaution for Removing 12V Battery".
4. Connect 12 V battery negative terminal.
7. Check DTC.
Is P318E detected?

With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P318E” is detected.
Is P318E detected?
YES >> Replace VCM. Refer to EVC-425, "Removal and Installation".
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P318E”.
Is U1000 detected?
and Installation".

P3191 COMMUNICATION ERROR
A

NOTE:
When the 12 V battery is removed within 5 minutes after turning the power switch OFF, “P318E”, “P3191” and
“P3196” may be simultaneously detected. This is not a malfunction. EVB

• Traction motor inverter D
When no CAN communication signal is received from traction
P3191 COMMUNICATION ERROR • Li-ion battery controller
motor inverter continuously.
DTC CONFIRMATION PROCEDURE E

With CONSULT
F
cardiagn.com
nal. Refer to EVB-6, "Precaution for Removing 12V Battery". G
6. Select “Self Diagnostic Result” of “HV BAT”. H
7. Check DTC.
Is P3191 detected?
YES >> Refer to EVB-101, "Diagnosis Procedure". I
J
With CONSULT
1. Perform "All DTC Reading". K
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P3191” is detected.
Is P3191 detected?
YES >> Replace traction motor inverter. Refer to TMS-103, "Removal and Installation" L
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER M
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P3191”. N
Is U1000 detected?
and Installation". O

DTC DETECTION LOGIC

NOTE:
When the 12 V battery is removed within 5 minutes after turning the power switch OFF, “P318E”, “P3191” and
“P3196” may be simultaneously detected. This is not a malfunction.

• PDM (Power Delivery
When no CAN communication signal is received from on-board Module)
charger continuously. • Li-ion battery controller

With CONSULT
cardiagn.com
nal. Refer to EVB-6, "Precaution for Removing 12V Battery".
7. Check DTC.
Is P3196 detected?

With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P3196” is detected.
Is P3196 detected?
YES >> Replace PDM (Power Delivery Module). Refer to VC-111, "Removal and Installation"
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P3196”.
Is U1000 detected?
and Installation".

A

COMMUNICATION ER- When no CAN communication signal is received from A/
P3198 • Li-ion battery controller
ROR C auto amp. continuously for 2 seconds or more.
• A/C auto amp.

With CONSULT E
3. Check DTC. F
Is P3198 detected?
cardiagn.com
With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P3198” is detected. I
Is P3198 detected?
YES >> Replace A/C auto amp.. Refer to HAC-187, "Removal and Installation" (With heat pump) or HAC-
J
348, "Removal and Installation" (Without heat pump).
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER K
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P3198”. L
Is U1000 detected?
and Installation". M

DTC DETECTION LOGIC

COMMUNICATION ER- • VCM
P3199 When a CRC error from VCM is detected.
ROR • Li-ion battery controller

With CONSULT
3. Check DTC.
Is P3199 detected?
cardiagn.com
When this DTC is detected, replace VCM. Refer to EVC-425, "Removal and Installation".

P319C COMMUNICATION ERROR
P319C COMMUNICATION ERROR
A

COMMUNICATION ER- • Traction motor inverter EVB
P319C When a CRC error from traction motor inverter is detected.
ROR • Li-ion battery controller

D
With CONSULT
3. Check DTC.
Is P319C detected? F
cardiagn.com
G
When this DTC is detected, replace traction motor inverter. Refer to TMS-103, "Removal and Installation".
H

P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
DTC DETECTION LOGIC

If the CAN data from VCM has not change from the value
P31A4 CAN ERROR VCM VCM
which was previously received.

With CONSULT
3. Check DTC.
Is P31A4 detected?
cardiagn.com
When this DTC is detected, replace VCM. Refer to EVC-425, "Removal and Installation".

P31A7 CAN ERROR INV/MC
P31A7 CAN ERROR INV/MC
A

If the CAN data from traction motor inverter has not EVB
P31A7 CAN ERROR INV/MC Traction motor inverter
change from the value which was previously received.

D
With CONSULT
3. Check DTC.
Is P31A7 detected? F
cardiagn.com
G
When this DTC is detected, replace traction motor inverter. Refer to TMS-103, "Removal and Installation".
H

P3302-P330D CELL OVER VOLTAGE
DTC DETECTION LOGIC

P3302 CELL OVER VOLTAGE MODULE1
• Overcharge caused by traction
P3306 CELL OVER VOLTAGE MODULE5 motor inverter/VCM malfunc-
P3307 CELL OVER VOLTAGE MODULE6 tion
When cell voltage exceeds the allowable
• Module
P3308 CELL OVER VOLTAGE MODULE7 working voltage range.
P3309 CELL OVER VOLTAGE MODULE8 • Bus bar
P330A CELL OVER VOLTAGE MODULE9
P330B CELL OVER VOLTAGE MODULE10
cardiagn.com
P330C CELL OVER VOLTAGE MODULE11
P330D CELL OVER VOLTAGE MODULE12

With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
1. Perform “All DTC Reading” with CONSULT.
2. Check systems other than “HV BAT” if any DTC is detected. A
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Installation". D
>> GO TO 3.
E
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
1. Disconnect voltage detection terminal of bus bar and Li-ion battery controller harness connector.
2. Refer to below table and check the continuity between Li-ion battery controller and corresponding bus F
bar .
cardiagn.com
G
JSCIA0812GB
N


DTC Continuity
33
P3302 1 LB13 50 Existed
34
34
35
35
36
36
37
37
cardiagn.com
38
38
Bus bar
39
39
40
40
42
42
P330A 9 LB13 58 Existed
43
43
P330B 10 LB13 59 Existed
44
44
P330C 11 LB13 60 Existed
45
45
P330D 12 LB13 61 Existed
46
YES >> GO TO 4.
Check voltage of corresponding module. Refer to EVB-111, "Component Inspection".

and Installation". A
NO >> Replace corresponding module. Refer to EVB-248, "REAR MODULE STACK : Disassembly and
Assembly".
Component Inspection INFOID:0000000010640592 B

Check voltage of module. EVB
: Positive terminal (Red)

D
: Negative terminal (Black)
Terminals E
Voltage
(+) (-)
(Approx.)
Module
F
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
cardiagn.com
YES >> INSPECTION END G
NO >> Replace module. Refer to EVB-233, "FRONT MODULE
STACK : Disassembly and Assembly" (Front module
stack) or EVB-248, "REAR MODULE STACK : Disas-
sembly and Assembly" (Rear module stack). H
JSCIA0338ZZ

P330E-P3319 CELL OVER VOLTAGE
DTC DETECTION LOGIC

P330E CELL OVER VOLTAGE MODULE13
P330F CELL OVER VOLTAGE MODULE14
P3312 CELL OVER VOLTAGE MODULE17 motor inverter/VCM malfunc-
P3313 CELL OVER VOLTAGE MODULE18 tion
• Module
cardiagn.com

With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Installation". D
>> GO TO 3.
E
bar .
cardiagn.com
G
JSCIA0812GB
N


DTC Continuity
46
P330E 13 LB13 62 Existed
47
47
P330F 14 LB13 63 Existed
48
LB13 48
P3310 15 77 Existed
LB14
65
65
66
66
cardiagn.com
69
69
Bus bar
70
70
71
71
72
72
73
73
74
74
75
75
76
YES >> GO TO 4.

NO >> Replace corresponding module. Refer to EVB-226, "FRONT MODULE STACK : Removal and
Installation".


D
Terminals E
Voltage
(+) (-)
(Approx.)
Module
F
cardiagn.com
NO >> Replace module. Refer to EVB-248, "REAR MODULE
STACK : Disassembly and Assembly".
H
JSCIA0338ZZ

P331A-P3325 CELL OVER VOLTAGE
DTC DETECTION LOGIC

P331A CELL OVER VOLTAGE MODULE25
P331B CELL OVER VOLTAGE MODULE26
P331C CELL OVER VOLTAGE MODULE27
P331D CELL OVER VOLTAGE MODULE28
P331E CELL OVER VOLTAGE MODULE29 motor inverter/VCM malfunc-
P331F CELL OVER VOLTAGE MODULE30 tion
• Module
cardiagn.com

With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
2. Check “Self Diagnostic Result” of systems other than “HV BAT” if any DTC is detected. A
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Installation". D
>> GO TO 3.
E
With CONSULT
1. Power switch OFF. F
2. Identify the malfunctioning module based on detected DTC.
3. Disconnect module harness connector and Li-ion battery controller harness connector.
cardiagn.com
4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller. G

DTC Continuity
No. Connector Terminal Connector Terminal H
9 89
P331A 25 LB8 10 LB15 110 Existed
I
11 90
11 90
P331B 26 LB8 12 LB15 111 Existed J
13 91
13 91
P331C 27 LB8 28 LB15 112 Existed K
27 92
27 92 L
P331D 28 LB8 26 LB15 113 Existed
25 93
25 93 M
P331E 29 LB8 23 LB15 114 Existed
21 94
N
21 94
P331F 30 LB8 19 LB15 115 Existed
17 95 O
17 95
P3320 31 LB8 3 LB15 116 Existed
P
4 96
4 96
P3321 32 LB8 18 LB15 117 Existed
1 97

DTC Continuity
1 97
P3322 33 LB8 2 LB15 118 Existed
20 99
20 99
P3323 34 LB8 6 LB15 119 Existed
8 100
8 100
P3324 35 LB8 22 LB15 120 Existed
5 101
5 101
P3325 36 LB8 7 LB15 121 Existed
24 102
YES >> GO TO 4.
cardiagn.com
and Installation".
NO >> Replace corresponding module. Refer to EVB-233, "FRONT MODULE STACK : Disassembly and
Assembly".

Check voltage of module.

Terminals
Voltage
(+) (-)
(Approx.)
Module
JSCIA0338ZZ

P3326-P3331 CELL OVER VOLTAGE
A

P3326 CELL OVER VOLTAGE MODULE37 EVB
D
P332A CELL OVER VOLTAGE MODULE41 • Overcharge caused by traction
motor inverter/VCM malfunction
P332B CELL OVER VOLTAGE MODULE42 When cell voltage exceeds the allowable • Module E
P332C CELL OVER VOLTAGE MODULE43 working voltage range. • Li-ion battery controller
• Bus bar
P332D CELL OVER VOLTAGE MODULE44 • Harness or connector
F
P332E CELL OVER VOLTAGE MODULE45
P332F CELL OVER VOLTAGE MODULE46
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P3330 CELL OVER VOLTAGE MODULE47 G

H
With CONSULT
3. Check DTC.
K
DANGER:
L
maintenance.
WARNING:
N
CAUTION:
With CONSULT
2. Check “Self Diagnostic Result” of systems other than “HV BAT” if any DTC is detected.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT
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4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller.

DTC Continuity
LB8 24 102
P3326 37 38 LB15 122 Existed
LB7
40 103
40 103
P3327 38 LB7 51 LB15 123 Existed
37 104
37 104
P3328 39 LB7 39 LB15 124 Existed
53 105
53 105
P3329 40 LB7 43 LB15 125 Existed
44 106
44 106
41 107
41 107
P332B 42 LB7 42 LB15 128 Existed
56 108
56 LB15 108
P332C 43 LB7 54 137 Existed
LB16
52 130
52 130
36 131

DTC Continuity A
36 131
P332E 45 LB7 35 LB16 140 Existed B
47 132
47 132
P332F 46 LB7 33 LB16 141 Existed EVB
45 133
45 133
D
P3330 47 LB7 46 LB16 142 Existed
34 134
34 134 E
P3331 48 LB7 48 LB16 143 Existed
49 135
F
YES >> GO TO 4.
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NO >> Repair harness or connector. G
H
and Installation".
NO >> Replace corresponding module. Refer to EVB-233, "FRONT MODULE STACK : Disassembly and I
Assembly".
J
Check voltage of module. K

: Negative terminal (Black) L
Terminals
Voltage M
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V N
NO >> Replace module. Refer to EVB-233, "FRONT MODULE O
JSCIA0338ZZ

P3375-P3380 CELL OVER DISCHARGE
DTC DETECTION LOGIC

P3375 CELL OVER DISCHARGE MODULE1
P3379 CELL OVER DISCHARGE MODULE5 • Overcharge caused by traction motor
inverter/VCM malfunction
P337A CELL OVER DISCHARGE MODULE6 When cell voltage lowers below the • Module
P337B CELL OVER DISCHARGE MODULE7 allowable working voltage range. • Li-ion battery controller
• Bus bar
P337C CELL OVER DISCHARGE MODULE8 • Harness or connector
P337D CELL OVER DISCHARGE MODULE9
P337E CELL OVER DISCHARGE MODULE10
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P337F CELL OVER DISCHARGE MODULE11

With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Installation". D
>> GO TO 3.
E
bar .
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G
JSCIA0812GB
N


DTC Continuity
33
34
34
35
35
36
36
37
37
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38
38
Bus bar
39
39
40
40
42
42
P337D 9 LB13 58 Existed
43
43
P337E 10 LB13 59 Existed
44
44
P330F 11 LB13 60 Existed
45
45
46
YES >> GO TO 4.

Assembly".


D
Terminals E
Voltage
(+) (-)
(Approx.)
Module
F
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H
JSCIA0338ZZ

P3381-P338C CELL OVER DISCHARGE
DTC DETECTION LOGIC

• Overcharge caused by trac-
P3385 CELL OVER DISCHARGE MODULE17 tion motor inverter/VCM mal-
P3386 CELL OVER DISCHARGE MODULE18 function
When cell voltage lowers below the allowable
• Module
P3387 CELL OVER DISCHARGE MODULE19 working voltage range.
P3388 CELL OVER DISCHARGE MODULE20 • Bus bar
P338A CELL OVER DISCHARGE MODULE22
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P338B CELL OVER DISCHARGE MODULE23
P338C CELL OVER DISCHARGE MODULE24

With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Disconnect high voltage circuit. Refer to GI-33, "How to Disconnect High Voltage".
Installation", D
>> GO TO 3.
E
bar .
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G
JSCIA0812GB
N


DTC Continuity
46
47
47
48
LB13 48
P3383 15 77 Existed
LB14
65
65
66
66
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69
69
Bus bar
70
70
71
71
72
72
73
73
74
74
75
75
76
YES >> GO TO 4.

Assembly".


D
Terminals E
Voltage
(+) (-)
(Approx.)
Module
F
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H
JSCIA0338ZZ

P338D-P3398 CELL OVER DISCHARGE
DTC DETECTION LOGIC

P338D CELL OVER DISCHARGE MODULE25
P338E CELL OVER DISCHARGE MODULE26
P338F CELL OVER DISCHARGE MODULE27
P3391 CELL OVER DISCHARGE MODULE29 tion motor inverter/VCM mal-
P3392 CELL OVER DISCHARGE MODULE30 function
• Module
P3393 CELL OVER DISCHARGE MODULE31 working voltage range.
P3394 CELL OVER DISCHARGE MODULE32 • Bus bar
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With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
2. Check “Self Diagnostic Result” of systems other than “” if any DTC is detected. A
NO >> GO TO 2. B
2.PRECONDITIONING
WARNING: EVB
Installation", D
>> GO TO 3.
E
With CONSULT
1. Select “Self Diagnostic Result” mode of “HV BAT” using CONSULT. F
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4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller. G

DTC Continuity
No. Connector Terminal Connector Terminal H
9 89
I
11 90
11 90
P338E 26 LB8 12 LB15 111 Existed J
13 91
13 91
P338F 27 LB8 28 LB15 112 Existed K
27 92
27 92 L
P3390 28 LB8 26 LB15 113 Existed
25 93
25 93 M
P3391 29 LB8 23 LB15 114 Existed
21 94
N
21 94
P3392 30 LB8 19 LB15 115 Existed
17 95 O
17 95
P3393 31 LB8 3 LB15 116 Existed
P
4 96
4 96
P3394 32 LB8 18 LB15 117 Existed
1 97

DTC Continuity
1 97
P3395 33 LB8 2 LB15 118 Existed
20 99
20 99
P3396 34 LB8 6 LB15 119 Existed
8 100
8 100
P3397 35 LB8 22 LB15 120 Existed
5 101
5 101
P3398 36 LB8 7 LB15 121 Existed
24 102
YES >> GO TO 4.
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NO >> Repair Harness or connector.
and Installation".
NO >> Replace corresponding module. Refer to EVB-233, "FRONT MODULE STACK : Disassembly and
Assembly".

Check voltage of module.

Terminals
Voltage
(+) (-)
(Approx.)
Module
JSCIA0338ZZ

P3399-P33A4 CELL OVER DISCHARGE
A

P3399 CELL OVER DISCHARGE MODULE37 EVB
P339A CELL OVER DISCHARGE MODULE38
P339B CELL OVER DISCHARGE MODULE39
D
P339C CELL OVER DISCHARGE MODULE40
P339D CELL OVER DISCHARGE MODULE41 tion motor inverter/VCM mal-
P339E CELL OVER DISCHARGE MODULE42 function E
• Module
P339F CELL OVER DISCHARGE MODULE43 working voltage range.
P33A0 CELL OVER DISCHARGE MODULE44 • Bus bar
• Harness or connector F
P33A1 CELL OVER DISCHARGE MODULE45
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P33A3 CELL OVER DISCHARGE MODULE47 G

H
With CONSULT
3. Check DTC.
K
DANGER:
L
maintenance.
WARNING:
N
CAUTION:
With CONSULT
2. Check “Self Diagnostic Result” of systems other than “” if any DTC is detected.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation",
>> GO TO 3.
With CONSULT
1. Select “Self Diagnostic Result” mode of “HV BAT” using CONSULT.
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4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller.

DTC Continuity
LB8 24 102
P3399 37 38 LB15 122 Existed
LB7
40 103
40 103
37 104
37 104
P339B 39 LB7 39 LB15 124 Existed
53 105
53 105
P339C 40 LB7 43 LB15 125 Existed
44 106
44 106
41 107
41 107
P339E 42 LB7 42 LB15 128 Existed
56 108
56 LB15 108
P339F 43 LB7 54 137 Existed
LB16
52 130
52 130
P33A0 44 LB7 50 LB16 138 Existed
36 131

DTC Continuity A
36 131
P33A1 45 LB7 35 LB16 140 Existed B
47 132
47 132
P33A2 46 LB7 33 LB16 141 Existed EVB
45 133
45 133
D
34 134
34 134 E
49 135
F
YES >> GO TO 4.
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NO >> Repair Harness or connector. G
H
and Installation".
NO >> Replace corresponding module. Refer to EVB-233, "FRONT MODULE STACK : Disassembly and I
Assembly".
J
Check voltage of module. K

: Negative terminal (Black) L
Terminals
Voltage M
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V N
NO >> Replace module. Refer to EVB-233, "FRONT MODULE O
JSCIA0338ZZ

P33D4 BATTERY DETERIORATION DIAGNOSIS
P33D4 BATTERY DETERIORATION DIAGNOSIS
DTC DETECTION LOGIC

BATTERY INTERNAL RESIS- When the battery charge lowers.
P33D4 Li-ion battery
TANCE DIAG (The internal resistance of the battery increases.)

With CONSULT
3. Check DTC.
Is P33D4 detected?
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When this DTC is detected, replace Li-ion battery. Refer to EVB-181, "Removal and Installation".

P33D5 CURRENT SENSOR
A

Deviation in characteristics of battery current sensor sig- • Li-ion battery controller EVB
nal voltage. • Current sensor
(Battery current sensor signal voltage is too high or too • System main relay
low.) • Harness or connector
D
1.PERFORM DTC CONFIRMATION PROCEDURE E
With CONSULT
2. Select “Self Diagnostic Result” of “HV BAT”. F
3. Check DTC.
Is P33D5 detected?
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YES >> Refer to EVB-137, "Diagnosis Procedure". G
H
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of I
maintenance.
J
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in K
before beginning work on the high voltage system. L
• Refer to EVB-7, "High Voltage Precautions". M
CAUTION:
instructed in the Service Manual. A malfunction may occur if this is not observed. N
1.CHECK SELF-DIAGNOSIS RESULTS OF VCM
With CONSULT
1. Select “Self Diagnostic Result” mode of “EV/HEV” using CONSULT. O
2. Check to see if “P0AA0”, “P0AA1” or “P0AA4” is detected.
YES >> Perform diagnosis on the detected DTC. Refer to EVB-45, "DTC Index". P
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:

Installation".
>> GO TO 3.
Check connection status of Li-ion battery controller harness connector and current sensor harness connector.
YES >> GO TO 4.
4.CHECK HARNESS BETWEEN CURRENT SENSOR AND LI-ION BATTERY CONTROLLER
Check continuity between current sensor harness connector and Li-ion battery controller harness connector.
Current sensor Li-ion battery controller

Continuity
Connector Terminal Connector Terminal
S 10
LB5 V LB11 9 Exited
G 15
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YES >> GO TO 5.
NO >> Repair Harness or connector.
5.CHECK CURRENT SENSOR
Check resistance of current sensor.
Current sensor Resistance val-

Connector Terminal Terminal ue
S G
LB5 1 kΩ–10 MΩ
V G
YES >> GO TO 6.
NO >> Replace current sensor.
6.CHECK LI-ION BATTERY CONTROLLER
Check resistance of Li-ion battery controller.
Li-ion battery controller Resistance val-

Connector Terminal Terminal ue
LB11 10 15 Approx. 4.7 kΩ

YES >> Replace current sensor. Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY HAR-
NESS : Disassembly and Assembly".
and Installation".

A

Deviation from the specified voltage characteristics of EVB
P33D6 CURRENT SENSOR Li-ion battery controller
battery current sensor.

D
With CONSULT
3. Check DTC.
Is P33D6 detected? F
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G
DANGER:
H
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and I
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- J
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses K
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- L
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise M
1.PRECONDITIONING N
WARNING:
1. Remove Li-ion battery. Refer to EVB-181, "Removal and Installation". O
Installation".
P
>> GO TO 2.
2.CHECK CURRENT SENSOR
1. Disconnect Li-ion battery controller harness connector.
2. Check the resistance of current sensor from Li-ion battery controller side.


Resistance value
Connector Terminal
10 9
LB11 1 kΩ–10 MΩ
9 15
and Installation".
NO >> GO TO 3.
3.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND BATTERY JUNCTION BOX (CUR-
RENT SENSOR)
1. Disconnect current sensor harness connector.
2. Check continuity between Li-ion battery controller and current sensor.
Li-ion battery controller Current sensor

Continuity
10 S
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LB11 9 LB5 V Existed
15 G
YES >> Replace current sensor. Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY HAR-
NESS : Disassembly and Assembly".

P33D7, P33D9, P33DD TEMPERATURE SENSOR
A

Battery temperature sensor 1 center signal voltage is EVB
P33D7
too high or too low.
• Battery temperature sensor
Battery temperature sensor 2 signal voltage is too high
P33D9 TEMPERATURE SENSOR • Li-ion battery controller
or too low. D
Battery temperature sensor 4 signal voltage is too high
P33DD
or too low.
DTC CONFIRMATION PROCEDURE E

With CONSULT F
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3. Check DTC. G
NO >> INSPECTION END H
DANGER: I
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are J
maintenance.
WARNING:
K
the tool box during the procedure to prevent the plug from being connected by mistake. L
• Never allow workers other than the responsible person to touch the vehicle containing high voltage M
CAUTION: N
1.PRECONDITIONING O
WARNING:
1. Remove Li-ion battery. Refer to EVB-181, "Removal and Installation". P
Installation".
>> GO TO 2.
2.CHECK HARNESS
2. Check a connection state of harness connector of Li-ion battery controller.
YES >> GO TO 3.
YES >> GO TO 4.
NO >> Replace battery temperature sensor.
4.CHECK HARNESS BETWEEN BATTERY TEMPERATURE SENSOR AND GROUND
2. Check continuity between battery temperature sensor harness connector and ground.
Battery tem-
perature sen- Connector Terminal — Continuity
sor
1 LB9 1
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2 LB10 4 Ground No existed
4 LB10 2
and Installation".

1. Remove battery temperature sensor. Refer to EVB-190, "BATTERY PACK UPPER CASE : Exploded
View".
2. Check resistance between battery temperature sensor terminals.
Battery temperature sensor Terminals Condition Resistance (kΩ)

1 1 5 10 (50) Approx. 7.4
2 4 3 Temperature °C (°F) 25 (77) Approx. 4.0
4 2 1 40 (104) Approx. 2.3

P33DF BAT VOLTAGE ISOLATION SEN
P33DF BAT VOLTAGE ISOLATION SEN
A

BAT VOLTAGE ISOLA- Signal voltage of the on-board isolation resistance moni- EVB
P33DF Li-ion battery controller
TION SEN toring system is too high.

D
With CONSULT
3. Check DTC.
Is P33DF detected? F
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G

P33E0 BAT VOLTAGE ISOLATION SEN
DTC DETECTION LOGIC

BATTERY VOLTAGE ISO- Signal Voltage of the on-board isolation resistance mon-
P33E0 Li-ion battery controller
LATION SENSOR itoring system is too low.

With CONSULT
3. Check DTC.
Is P33E0 detected?
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LER : Removal and Installation".

A

BATTERY VOLTAGE ISO- Signal voltage of the on-board isolation resistance moni- EVB
P33E1 Li-ion battery controller
LATION SENSOR toring system exhibits no amplitude variation.

D
With CONSULT
3. Check DTC.
Is P33E1 detected? F
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G
When this DTC is detected, perform Li-ion battery insulation resistance loss check. Refer to EVB-163, "Com-
ponent Inspection". H

P33E2 BATT PACK OVER TEMP
P33E2 BATT PACK OVER TEMP
DTC DETECTION LOGIC

BATTERY PACK OVER When the battery (battery pack) temperature is excessively Overcharge caused by traction
P33E2
TEMPERATURE high. motor inverter/VCM malfunction

With CONSULT
3. Check DTC.
Is P33E2 detected?
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With CONSULT
2. Check to see if “P33EB” is detected simultaneously with “P33E2”.
Is P33EB detected?
YES >> Perform diagnosis on the detected “P33EB”. Refer to EVB-154, "Diagnosis Procedure".
NO >> GO TO 2.
With CONSULT
Using FREEZE FRAME DATA (FFD), check the values of three temperature sensors when DTC is detected.
Monitor item Condition Limit

Battery temperature sensor 2 Power switch ON 55°C (131°F) or less
Is there temperature increase?
Temperature increase is seen>>Replace Li-ion battery. Refer to EVB-201, "LI-ION BATTERY CONTROL-
LER : Removal and Installation".
Temperature increase is not seen>>Replace battery temperature sensors. Refer to EVB-190, "BATTERY
PACK UPPER CASE : Exploded View".

P33E6 CELL CONTROLLER
A

With the power switch ON and no load condition, the dif- EVB
P33E6 CELL CONTROLLER ference between the maximum voltage and minimum volt-
• Module
age exceeds the allowable range.

With CONSULT E
1. Turn power switch ON and wait for 10 seconds or more.
3. Check DTC. F
Is P33E6 detected?
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DANGER: H
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are I
maintenance.
WARNING:
J
the tool box during the procedure to prevent the plug from being connected by mistake. K
• Never allow workers other than the responsible person to touch the vehicle containing high voltage L
CAUTION: M
1.CHECK SELF-DIAGNOSIS RESULTS OF LI-ION BATTERY CONTROLLER N
With CONSULT
O
2. Check to see if “P0A1F”, “P3062” or “P33ED” is detected simultaneously with “P33E6”.
Is P0A1F, P3062 or P33ED detected?
YES-1 >> When “P0A1F” or “P3062” are detected simultaneously, Replace Li-ion battery controller. Refer to
P
EVB-181, "Removal and Installation".
YES-2 >> When “P33ED” is detected simultaneously, perform the diagnosis procedure of “P33ED”. Refer to
EVB-156, "Diagnosis Procedure".
NO >> GO TO 2.
2.CHECK FREEZE FRAME DATA (FFD)
With CONSULT
1. Check “FFD” when DTC is detected.
2. Calculate the average value of cell voltage by dividing “TOTAL BATTERY VOLTAGE” by 96 (the number
of cells).
Average cell voltage = “TOTAL BETTER VOLTAGE” ÷ 96 (the number of cells)

3. Identify the minimum cell voltage and the maximum cell voltage from 96 cells.
4. Calculate voltage according to the following expressions to compare voltage between A and B.
A = Maximum cell voltage − Average cell voltage

B = Average cell voltage − Minimum cell voltage
Which voltage is larger, A or B?
A >> Replace module including a cell of the maximum cell voltage. Refer to EVB-222, "FRONT MOD-
ULE STACK : Exploded View" (Front module stack) or EVB-238, "REAR MODULE STACK :
Exploded View" (Rear module stack). After replacing module, GO TO 3.
B >> Replace module including a cell of the minimum cell voltage. Refer to EVB-222, "FRONT MOD-
ULE STACK : Exploded View" (Front module stack) or EVB-238, "REAR MODULE STACK :
Exploded View" (Rear module stack). After replacing module, GO TO 3.
3.PERFORM CELL VOLTAGE LOSS INSPECTION
With CONSULT
1. Select “WORK SUPPORT” of “HV BAT.”
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2. Select “CELL VOLTAGE LOSS INSPECTION.” Touch “START.”
3. Check “MINIMUM CELL VOLTAGE.”
Is “MINIMUM CELL VOLTAGE” 3,712 mV or less?
YES >> GO TO 5.
NO >> GO TO 4.
4.DISCHARGE OF LI-ION BATTERY
With CONSULT
1. Set the vehicle to READY.
2. Set the vehicle, according to the following conditions.
A/C set temperature : Full hot

A/C fan speed : Maximum speed
A/C air outlet : Defroster
Headlamp : High beam ON
Door glass : Full open
3. Check “DATA MONITOR” and let the Li-ion battery discharge until the “MINIMUM CELL VOLTAGE”
reaches 3,712 mV or less.
NOTE:
The guide line is to discharge until the Li-ion battery available charge gauge indicates 2 segments or less.
For discharge time, refer to the following table.
Guideline for discharge time
The number of light-

ing segments of Li-
Time to 2 segments
ion battery available
charge gauge
12 Approx. 230 minute
6 Approx. 90 minute

The number of light-
ing segments of Li- A
Time to 2 segments
ion battery available
charge gauge
5 Approx. 70 minute B
4 Approx. 40 minute
3 Approx. 20 minute
EVB
>> GO TO 5.
5.CHECK CELL OF VOLTAGE LOSS D
With CONSULT
1. Check that “MINIMUM CELL VOLTAGE” is 3,712 mV or less. Touch “START.”
2. Check to see if a cell of which voltage is less than or equal to “CELL VOLTAGE LOSS JUDGMENT E
VALUE” is displayed.
Is a cell displayed?
YES >> Record applicable cell No. and then GO TO 6. F
NO >> Check the minimum cell voltage on the data monitor and replace a module which includes the
minimum cell voltage. Refer to EVB-222, "FRONT MODULE STACK : Exploded View" (Front
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module stack) or EVB-238, "REAR MODULE STACK : Exploded View" (Rear module stack).
G
6.PRECONDITIONING
WARNING:
Disconnect high voltage circuit. Refer to GI-33, "How to Disconnect High Voltage". H
2. Remove battery pack upper case. Refer to EVB-190, "BATTERY PACK UPPER CASE : Exploded View".
I
>> GO TO 7.
7.CHECK CONDENSATION J
Check condensation in battery pack.
YES >> GO TO 8. K
NO >> Replace Li-ion battery. Refer to EVB-181, "Removal and Installation".
8.CHECK CONNECTORS AND FIXING BOLTS
L
Check connection state, damage and dust of following;
• Li-ion battery controller (LBC) harness connector
• Module harness connector
• Module terminal fixing bolt M
YES >> GO TO 9
NO >> Repair or replace error-detected parts. N
Check module voltage within determined cell at step 3 and check the divergence of the voltage and cell volt- O
age with “DATA MONITOR”.
DANGER:
When check module voltage, be careful not to short.
P
Is Divergence within 40mV?
YES-1 >> When the determined cell at step 3 is in front module stack.: GO TO 10.
YES-2 >> When the determined cell at step 3 is in rear module stack.: GO TO 12.
and Installation".
10.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE HARNESS CONNEC-
TOR
1. Disconnect Li-ion battery controller harness connector and module harness connector.
2. Check the resistance Li-ion battery controller harness connector and module harness connector of the
determined cell at step 3.
Resistance val-
Terminal
ue
Li-ion battery control- Module harness
Approx. 0 Ω
ler harness connector connector
3. Check the divergence of the resistance and the resistance of other cell harness.
YES >> GO TO 11
NO >> Repair or replace harness or connectors.
11.CHECK HARNESS BETWEEN MODULE HARNESS CONNECTOR AND BUS BAR
1. Check the resistance module harness connector and bus bar of the determined cell at step 3.
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JSCIA0811GB
Resistance val-
Terminal
ue
Module harness con-
Bus bar Approx. 0 Ω
nector
YES >> Replace module within the determined cell at step 5.
12.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND BUS BAR

1. Check the resistance Li-ion battery controller harness connector and bus bar of the determined cell
at step 5. A
EVB
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G
H
JSCIA0812GB
I
Resistance val-
Terminal
ue
Li-ion battery control-
Bus bar Approx. 0 Ω J
ler harness connector
K
YES >> Replace module within the determined cell at step 5.
L

P33EA BATTERY HEATER RELAY
DTC DETECTION LOGIC

Li-ion battery controller judges that the status of a relay control
signal transmitted from Li-ion battery controller and that of a
P33EA BATTERY HEATER RELAY • Heater relay unit
relay status signal transmitted from heater relay unit do not
match.
NOTE:
• The Li-ion battery controller transmits a relay control signal to the heater relay unit and turns ON/OFF the
relay built-in the heater relay unit.
• The heater relay unit turns ON/OFF the built-in relay, according to a relay control signal transmitted from the
Li-ion battery controller, and transmits a relay status signal (the ON/OFF status of the built-in relay) to the Li-
ion battery controller.
1.PERFORM DTC CONFIRMATION PROCEDURE-1
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With CONSULT
1. Select “ACTIVE TEST” of “HV BAT.”
2. Select “HEATER RELAY UNIT.” Touch “START.”
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE-2
With CONSULT
2. Check DTC.
Is P33EE detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Shut off high voltage circuit. Refer to GI-33, "How to Disconnect High Voltage". A
Installation".
B
>> GO TO 2.
2.CHECK CONTINUITY LI-ION BATTERY CONTROLLER AND HEATER RELAY UNIT EVB
1. Remove service plug switch bracket. Refer to EVB-204, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Exploded View".
2. Disconnect Li-ion battery controller harness connector and heater relay unit harness connector. D
3. Check continuity Li-ion battery controller harness connector and heater relay unit harness connector.
Lli-ion battery controller Heater relay unit E

Continuity
20 3
LB11 LB17 Existed F
18 6
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YES >> GO TO 3. G
3.CHECK CONTINUITY LI-ION BATTERY AND HEATER RELAY UNIT
H
Check continuity Li-ion battery harness connector and heater relay unit harness connector.
Lli-ion battery Heater relay unit

Continuity I
LB1 31 LB17 1 Existed
Is the inspection result normal? J
YES >> GO TO 4.
4.CHECK CONTINUITY HEATER RELAY UNIT AND LI-ION BATTERY CONTROLLER K
Check continuity heater relay unit harness connector and Li-ion battery controller harness connector.
L
Heater relay unit Li-ion battery controller
Continuity
4 M
8
8
LB17 LB11 Existed
7 7
N
5 6
YES >> Replace to shown in the below. O
• Li-ion battery controller. Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
• Heater relay unit. Refer to EVB-221, "LI-ION BATTERY HEATER RELAY UNIT : Disassembly
P
and Assembly".

P33EB TEMPERATURE SENSOR
DTC DETECTION LOGIC

Deviation in characteristics of battery temperature sensor
P33EB TEMPERATURE SENSOR Battery temperature sensor
1, 2 or 4.

With CONSULT
3. Check DTC.
Is P33EB detected?
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DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.
YES >> Replace all battery temperature sensor.
NO >> Replace applicable battery temperature sensor.

A
1. Remove battery temperature sensor. Refer to EVB-222, "FRONT MODULE STACK : Exploded View"
(Front module stack) or EVB-238, "REAR MODULE STACK : Exploded View" (Rear module stack). B
2. Check resistance between battery temperature sensor terminals.
Battery temperature sensor Terminals Condition Resistance (kΩ) EVB

1 1 5 10 (50) Approx. 7.4
2 4 3 Temperature °C (°F) 25 (77) Approx. 4.0
D
4 2 1 40 (104) Approx. 2.3
YES >> INSPECTION END E
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G

P33ED BATTERY PARALLEL DIAGNOSIS
DTC DETECTION LOGIC

P33ED BATTERY PARALLEL DIAGNOSIS When a sudden voltage fluctuation is detected in module. Module

1.CHECK LI-ION BATTERY AVAILABLE CHARGE GAUGE
Check the indication of the Li-ion battery available charge gauge.
NOTE:
Check 12 segments for lighting status.
Is the lighting status 1 Segment or none?
YES >> GO TO 3.
NO >> GO TO 2.
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1. Set the vehicle to READY.
A/C set temperature : Full hot

A/C air outlet : Defroster
3. Let the Li-ion battery discharge until the Li-ion battery available charge gauge shows segment 1 or below.
>> GO TO 3.
3.CHARGE OF LI-ION BATTERY
1. Charge the Li-ion battery by normal charge until the level reaches full charge.
2. After the completion of normal charge, check that the indication of the Li-ion battery available charge
gauge shows 12 segments.
>> GO TO 4.
With CONSULT
3. Check DTC.
Is P33ED detected?
1.CHECK DATA MONITOR OR FREEZE FRAME DATA (FFD)

With CONSULT
1. Select “DATA MONITOR” or “FFD”.
2. Check to see if there is a cell voltage which largely differ from the others.
Is there any abnormal cell?
YES >> Replace corresponding Module. Refer to EVB-222, "FRONT MODULE STACK : Exploded View".
NO >> GO TO 2. A
2.DTC CONFIRMATION PROCEDURE OPERATION
1. If abnormal cell is not identified, perform DTC confirmation procedure. Refer to EVB-156, "DTC Logic".
B
2. Check cell voltage again using “DATA MONITOR” or “FFD” to identify malfunctioning cell.
>> Replace corresponding Module. Refer to EVB-222, "FRONT MODULE STACK : Exploded View".
EVB
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G

P33EE BATTERY HEATER CONTROL SYSTEM
DTC DETECTION LOGIC

Under extremely low temperatures that Li-ion battery heater
BATTERY HEATER CON- • Heater relay unit
P33EE activates, Li-ion battery controller judges that the temperature
TROL SYSTEM • Li-ion battery heater
of Li-ion battery is still low after a lapse of specified time.
DANGER:
maintenance.
WARNING:
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CAUTION:
1.PRECONDITIONING
WARNING:
2. Remove battery pack upper case. Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
>> GO TO 2.
2.CHECK INSTALLATION CONDITION OF LI-ION BATTERY HEATER
Check the main body of Li-ion battery heater for installation condition.
YES >> GO TO 3.
NO >> Tighten the mounting nut of the Li-ion battery heater to the specified torque. Refer to EVB-214,
"LI-ION BATTERY HEATER : Exploded view".
3.CHECK CONNECTION STATUS OF LI-ION BATTERY HEATER CONNECTOR
Check the connection status of the Li-ion battery heater connector.
YES >> GO TO 4.
NO >> Restore the connection status of the Li-ion battery heater connector.
4.CHECK RESISTANCE OF LI-ION BATTERY HEATER
Check resistance of Li-ion battery heater.
A
Li-ion battery heater
Resistance
Item Terminal
B
LH 1
LH 2
1 2 Less than 5,269 Ω
RH 1 EVB
RH 2
RR 1
1 2 Less than 1,265 Ω D
RR 2
YES >> GO TO 5. E
NO >> Replace applicable Li-ion battery heater. Refer to EVB-215, "LI-ION BATTERY HEATER : Disas-
sembly and Assembly".
5.CHECK CONTINUITY OF LI-ION BATTERY HEATER AND BATTERY JUNCTION BOX F
1. Disconnect Li-ion battery heater and battery junction box harness connector.
2. Check continuity Li-ion battery heater and battery junction box harness connector.
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G
Li-ion battery heater Battery junction box
Continuity
Item Connector Terminal Connector Terminal
H
LH 1 LB19 2
LH 2 LB20 2
RH 1 LB23 2 I
LB25 15 Existed
RH 2 LB24 2
RR 1 LB21 2
RR 2 LB22 2 J

YES >> GO TO 6 K
6.CHECK CONTINUITY OF LI-ION BATTERY HEATER AND HEATER RELAY UNIT
1. Disconnect Li-ion battery heater and heater relay unit harness connector harness connector. L
2. Check continuity Li-ion battery heater and heater relay unit harness connector harness connector.
Li-ion battery heater Heater relay unit M

Continuity
Item Connector Terminal Connector Terminal
LH 1 LB19 1
N
LH 2 LB20 1
RH 1 LB23 1
LB18 11 Existed
RH 2 LB24 1 O
RR 1 LB21 1
RR 2 LB22 1
P
YES >> Replace heater relay unit. Refer to EVB-221, "LI-ION BATTERY HEATER RELAY UNIT : Disas-
sembly and Assembly".

U1000 CAN COMM CIRCUIT
U1000 CAN COMM CIRCUIT
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul-
tiplexcommunication line with high data communication speed and excellent error detection ability. Modern
vehicle is equipped with many electronic control units, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN-H, CAN-L) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads the required data only.
CAN communication signal chart. Refer to LAN-37, "CAN COMMUNICATION SYSTEM : CAN Communica-
tion Signal Chart".
DTC DETECTION LOGIC

When no CAN communication signal is received continu-
U1000 CAN COMM CIRCUIT CAN communication system
ously for 2 seconds or more.
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For the diagnosis procedure, refer to LAN-17, "Trouble Diagnosis Flow Chart".

HIGH VOLTAGE CIRCUIT
A
DANGER: B
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and EVB
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- D
the tool box during the procedure to prevent the plug from being connected by mistake. E
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- F
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CAUTION: G
1.CHECK HIGH VOLTAGE FUSE H
Check the continuity between and .
I
YES >> GO TO 2
NO >> Replace the service plug (with high voltage fuse) after
repairing the applicable circuit. Refer to EVB-206, "BAT-
TERY JUNCTION BOX AND BATTERY HARNESS : J
Disassembly and Assembly".
K
JSCIA0745ZZ
2.PRECONDITIONING L
WARNING:
1. Remove Li-ion battery. Refer to EVB-181, "Removal and Installation". M
Installation".
N
>> GO TO 3.
Check connection status of each bus bar in high voltage circuit O
YES >> GO TO 4
P
4.CHECK HIGH VOLTAGE HARNESS
CAUTION:
Check that high voltage harness and harness shield have no scratches and cracks. If any damage is
found, replace damaged parts.
1. Remove high voltage harness from battery junction box.

3. Check the continuity between battery junction box and rear module stack.
High voltage harness between battery junction box and rear module stack
High voltage harness — Continuity

Terminal Battery pack ground Existed
High voltage harness between front module stack RH and battery junction box
High voltage harness — Continuity

Terminal Battery pack ground Existed
NO >> Replace high voltage harness connector.
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LI-ION BATTERY INSULATION RESISTANCE LOSS CHECK
A
DANGER: B
maintenance.
WARNING:
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CAUTION: G
The following diagnosis procedure must be performed when “P0AA6 or P33E1” are detected and Li-ion H
battery is judged that its insulation resistance is dropping.
1.CHECK MAXIMUM CELL VOLTAGE
I
With CONSULT
1. Power switch ON.
2. Select “DATA MONITOR” of “HV BAT”.
J
3. Record “MAXIMUM CELL VOLTAGE”.
NOTE:
It is used, when replace a malfunction module.
K
>> GO TO 2
2.CHECK INSULATION OF FRONT MODULE STACK LH-1 L
CAUTION:
Check that high voltage harness and harness shield have no scratches and cracks. If any damage is
found, replace damaged parts. M
2. Remove Li-ion battery controller. Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
3. Remove bus bar that connects front module stack LH and front module stack RH. N
4. Measure voltages between positive terminal of front module stack LH and battery pack ground, and
between positive terminal of front module stack LH and battery pack ground.
O
JSCIA0739ZZ

: Battery pack front
+
Front module stack LH − Voltage
Terminal
, Battery pack ground Approx. 0 V

YES >> GO TO 8.
NO >> GO TO 3.
3.CHECK INSULATION OF FRONT MODULE STACK LH-2
1. Disconnect vehicle communication harness connector of front module stack LH.
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JSCIA0739ZZ
+
Terminal

YES >> Replace vehicle communication harness of front module stack LH and GO TO 8.
NO >> GO TO 4.
4.CHECK INSULATION OF FRONT MODULE STACK LH-3
1. Remove bus bar that connects service plug and front module stack LH.
JSCIA0739ZZ

+ A
Terminal
B

YES >> GO TO 5. EVB
NO >> GO TO 6.
5.CHECK SERVICE PLUG SWITCH INSULATION RESISTANCE D
1. Remove bus bar that connects service plug and front module stack LH from service plug switch bracket.
2. Using insulation resistance tester, measure insulation resistance between service plug switch terminal
and service plug switch bracket.
E
WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used
incorrectly, there is the danger of electric shock. If used in the vehicle 12V system, there is the
danger of damage to electronic devices. Read the insulation resistance tester instruction manual F
carefully and be sure to work safely.
CAUTION:
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Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting G
higher than 500 V can result in damage to the component being inspected.
NOTE:
Check resistance without disassembling service plug switch and service plug switch bracket.
H
+ — Resistance
Service plug switch terminal Service plug switch bracket 1000 MΩ or more
I
YES >> Replace bus bar that connects service plug and front module stack LH and GO TO 8.
NO >> Replace service plug switch (Refer to EVB-204, "BATTERY JUNCTION BOX AND BATTERY J
HARNESS : Exploded View".) and GO TO 8.
6.CHECK MODULE-1
1. Remove front module stack LH. Refer to EVB-226, "FRONT MODULE STACK : Removal and Installa- K
tion".
NOTE:
Do not disassemble module stack. L
2. Measure voltages between terminal / of all modules in front
module stack LH and module body.
M
O
JSCIA0740ZZ
P
+
Module − Voltage
Terminal
Module body Approx. 0 V

YES >> GO TO 7.
NO >> Replace malfunctioning module (Refer to EVB-233, "FRONT MODULE STACK : Disassembly
and Assembly".) and GO TO 8.
7.CHECK MODULE-2
Measure insulation resistance between terminal / of all modules
in front module stack LH and module body.
WARNING:
Unlike the ordinary tester, the insulation resistance tester
applies 500 V when measuring. If used incorrectly, there is the
danger of electric shock. If used in the vehicle 12V system,
there is the danger of damage to electronic devices. Read the
insulation resistance tester instruction manual carefully and be
sure to work safely.
CAUTION:
Be sure to set the insulation resistance tester to 500 V when JSCIA0740ZZ
performing this test. Using a setting higher than 500 V can
result in damage to the component being inspected.
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+
Module − resistance
Terminal
Module body 100 MΩ or more

YES >> Check insulation resistance of front module stack RH, because front module stack LH is normal.
GO TO 8.
8.CHECK INSULATION OF FRONT MODULE STACK RH-1
1. Measure voltages between positive terminal of front module stack RH and battery pack ground, and
JSCIA0741ZZ
+
Front module stack RH − Voltage
Terminal

YES >> GO TO 14.

NO >> GO TO 9.
9.CHECK INSULATION OF FRONT MODULE STACK RH-2 A
1. Disconnect vehicle communication harness connector of front module stack RH.

B
between positive terminal of front module stack RH and battery pack ground.
EVB
E
JSCIA0741ZZ
: Battery pack front F
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+ G
Terminal
H

YES >> Replace vehicle communication harness of front module stack RH and GO TO 14. I
NO >> GO TO 10.
1. Remove bus bar that connects front module stack RH and battery junction box. J
between positive terminal of front module stack RH and battery pack ground.
K
JSCIA0741ZZ N
O
+
P
Terminal

YES >> GO TO 11.
NO >> GO TO 12.

11.CHECK BATTERY JUNCTION BOX INSULATION RESISTANCE
1. Using insulation resistance tester, measure insulation resistance
between high voltage terminal / of battery junction box and
battery pack ground.
WARNING:
applies 500 V when measuring. If used incorrectly, there is
the danger of electric shock. If used in the vehicle 12V sys-
tem, there is the danger of damage to electronic devices.
Read the insulation resistance tester instruction manual JSCIA0453ZZ
carefully and be sure to work safely.

CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting
Battery junction box

— Resistance
Terminal
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Battery pack ground 1000 MΩ or more

YES >> Replace bus bar that connects front module stack RH and battery junction box and GO TO 14.
NO >> Replace battery junction box (Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Disassembly and Assembly") and GO TO 14.
12.CHECK MODULE-3
1. Remove front module stack RH. Refer to EVB-226, "FRONT MODULE STACK : Removal and Installa-
tion".
NOTE:
Do not disassemble module stack.
2. Measure voltages between terminal / of all modules in front
module stack RH and module body.
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 13.

13.CHECK MODULE-4 A
in front module stack RH and module body.
WARNING: B
there is the danger of damage to electronic devices. Read the EVB
CAUTION: D
E
+
Module − resistance F
Terminal
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Module body 100 MΩ or more G

YES >> Check insulation resistance of front module stack RH, because front module stack LH is normal. H
GO TO 14.
and Assembly".) and GO TO 14. I
14.CHECK INSULATION OF REAR MODULE STACK-1
1. Measure voltages between positive terminal of rear module stack and battery pack ground, and
between positive terminal of rear module stack and battery pack ground. J
M
JSCIA0744ZZ
+ N
Rear module stack − Voltage
Terminal
O

YES-1 >> Replace or repair of malfunctioning part is not-yet performed: Replace Li-ion battery controller. P
Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal and Installation".
YES-2 >> Replace or repair of malfunctioning part is complete: INSPECTION END.
NO >> GO TO 15.
15.CHECK INSULATION OF REAR MODULE STACK-2

1. Disconnect vehicle communication harness connector of rear
module stack.
JSCIA0146ZZ
between positive terminal of rear module stack and battery pack ground.
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JSCIA0744ZZ
+
Terminal

YES >> Replace vehicle communication harness of rear module stack.
NO >> GO TO 16.
1. Remove mounting nuts / and remove high voltage harness from rear module stack.
JSCIA0743ZZ
between positive terminal of rear module stack and battery pack ground.

EVB
JSCIA0744ZZ
D
+
Rear module stack − Voltage
E
Terminal
Is the inspection result normal? F

YES >> .Replace high voltage harness.
NO >> GO TO 17.
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17.CHECK MODULE-5 G
1. Remove rear module stack. Refer to EVB-248, "REAR MODULE STACK : Disassembly and Assembly".
NOTE:
Do not disassemble module stack. H
2. Measure voltages between terminal / of all modules in rear
module stack and module body.
I
K
JSCIA0740ZZ
L
+
Module − Voltage
M
Terminal

N

YES >> GO TO 18. O
NO >> Replace malfunctioning module. Refer to EVB-248, "REAR MODULE STACK : Disassembly and
Assembly".
18.CHECK MODULE-6 P

in rear module stack and module body.
WARNING:
there is the danger of damage to electronic devices. Read the
CAUTION:
+
Module − resistance
Terminal
Module body 100 MΩ or more
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YES-1 >> Replace or repair of malfunctioning part is not-yet performed: Replace Li-ion battery controller.
Refer to EVB-201, "LI-ION BATTERY CONTROLLER : Removal and Installation".
YES-2 >> Replace or repair of malfunctioning part is complete: INSPECTION END.
NO >> Replace malfunctioning module. Refer to EVB-248, "REAR MODULE STACK : Disassembly and
Assembly".

LI-ION BATTERY HEATER SYSTEM INSULATION RESISTANCE CHECK
A
DANGER: B
maintenance.
WARNING:
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CAUTION: G
1.PRECONDITIONING H
WARNING:
1. Remove Li-ion battery. Refer to EVB-181, "Removal and Installation". I
Installation".
J
>> GO TO 2.
2.CHECK HIGH VOLTAGE HARNESS K
Check the harness shield between the heater relay unit and the Li-ion battery heater for scratches and cracks.
YES >> GO TO 3. L
NO >> Repair or replace error-detected parts and Li-ion battery controller.
3.CHECK HEATER RELAY UNIT INSULATION RESISTANCE
M
WARNING:
incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the danger
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully N
and be sure to work safely.
1. Disconnect high voltage harness connector from heater relay unit.
NOTE: O
Check the heater relay with it installed on the battery pack.
2. Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until
the value becomes stable.
CAUTION: P

Heater relay unit

Ground Resistance
Terminal
10
Battery pack lower case 1000 MΩ or more
11
YES >> GO TO 4.
NO >> Replace heater relay unit and Li-ion battery controller.
4.CHECK LI-ION BATTERY HEATER
WARNING:
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully
1. Disconnect high voltage harness connector from Li-ion battery heater.
NOTE:
Check the heater relay with it installed on the battery pack.
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CAUTION:
Li-ion battery heater

Ground Resistance
Item Connector Terminal
1
LH1 LB19 1000 MΩ or more
2
1
LH2 LB20 1000 MΩ or more
2
1
RH1 LB23 1000 MΩ or more
2
Battery pack lower case
1
RH2 LB24 1000 MΩ or more
2
1
RR1 LB21 1000 MΩ or more
2
1
RR2 LB22 1000 MΩ or more
2
YES >> GO TO 5.
NO >> Replace corresponding Li-ion battery heater and Li-ion battery controller.
5.CHECK HIGH VOLTAGE HARNESS INSULATION RESISTANCE
WARNING:
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully
CAUTION:
Be sure to set the insulation resistance tester to 500V when performing this test. Using a setting

High voltage harness A

Ground Resistance
Connector Terminal
LB18 11 Battery pack lower case 1000 MΩ or more
B
YES >> INSPECTION END.
NO >> Replace high voltage harness. EVB
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G

POWER SUPPLY AND GROUND CIRCUIT
DANGER:
maintenance.
WARNING:
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CAUTION:
1.CHECK FUSE
Check that the following fuse is not fusing.
Power supply Fuse No.

Battery 79
57
Power switch ON
74
Is the fuse fusing?
YES >> Replace the fuse after repairing the applicable circuit.
NO >> GO TO 2.
2.CHECK LI-ION BATTERY CONTROLLER GROUND CIRCUIT
1. Turn power switch OFF.
2. Disconnect Li-ion battery vehicle communication harness connector.
3. Check the continuity between Li-ion battery vehicle communication harness connector and ground.
+
Li-ion battery − Continuity
Connector Terminal
6
B24 7 Ground Existed
8
YES >> GO TO 3.
NO >> Repair or replace error-detected parts.
3.CHECK BATTERY POWER SUPPLY
Check the voltage between Li-ion battery vehicle communication harness connector and ground.

+ A
Li-ion battery − Voltage
Connector Terminal
B
12V battery power
B24 5 Ground
supply
Is the inspection result normal? EVB
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK BATTERY POWER SUPPLY CIRCUIT D
1. Check the continuity between Li-ion battery vehicle communication harness connector and fuse terminal.
E
+
Li-ion battery − Continuity
Connector Terminal F
No.79 fuse ter-
B24 5 Existed
minal
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2. Also check harness for short to ground. G
YES >> Check power supply circuit for battery power supply.
NO >> Repair or replace error-detected parts. H
5.CHECK POWER SWITCH ON POWER SUPPLY
1. Turn power switch ON. I
2. Check the voltage between Li-ion battery vehicle communication harness and ground.
+
J
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4 K
B24 Ground 11 – 14 V
31
Is the inspection result normal? L
YES >> GO TO 8.
NO >> GO TO 6.
6.CHECK POWER SWITCH ON POWER SUPPLY CIRCUIT-1 M
1. Turn power switch OFF.
2. Disconnect IPDM E/R harness connector.
3. Check the continuity between Li-ion battery vehicle communication harness and IPDM E/R harness con- N
nector.
Li-ion battery IPDM E/R O

Continuity
B24 4 E15 59 Existed
P
4. Also check harness for short to ground.
YES >> GO TO 7.
7.CHECK POWER SWITCH ON POWER SUPPLY CIRCUIT-2
1. Check the continuity between Li-ion battery vehicle communication harness and fuse terminal.

Li-ion battery
— Continuity
Connector Terminal
No.74 fuse ter-
B24 31 Existed
minal
YES >> Check power supply circuit for battery power supply.
8.PRECONDITIONING
WARNING:
Shut off high voltage circuit. Refer to GI-33, "How to Disconnect High Voltage".
Installation".
>> GO TO 9.
9.CHECK HARNESS BETWEEN LI-ION BATTERY AND LI-ION BATTERY CONTROLLER
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1. Check the continuity between Li-ion battery vehicle communication harness connector and Li-ion battery
controller harness connector.
LBC Li-ion battery

Continuity
5 31
7 4
12 5
LB11 LB1 Existed
2 8
3 7
14 6

REDUCTION IN THE DRIVING RANGE
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
REDUCTION IN THE DRIVING RANGE
B
• The driving range is shorter than before.
• Sudden change (decrease/increase) in possible travel distance indicated on the combination meter.
EVB
1.CHECK LI-ION BATTERY AVAILABLE CHARGE GAUGE D

Check the indication of the Li-ion battery available charge gauge.
NOTE:
Check 12 segments for lighting status. E
Is the lighting status 1 Segment or none?

YES >> GO TO 3. F
NO >> GO TO 2.
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1. Set the vehicle to READY. G
A/C set temperature : Full hot H

A/C air outlet : Defroster I
J
3. Let the Li-ion battery discharge until the Li-ion battery available charge gauge shows Segment 1 or below.
>> GO TO 3.
K
3.CHARGE OF LI-ION BATTERY
1. Charge the Li-ion battery by normal charge until the level reaches full charge.
2. After the completion of normal charge, check that the indication of the Li-ion battery available charge L
gauge shows 12 segments.
>> GO TO 4. M
With CONSULT N
3. Check DTC.
O
YES >> Perform diagnosis on the detected DTC. Refer to EVB-45, "DTC Index".
P

EV BATTERY USAGE REPORT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
EV BATTERY USAGE REPORT
Inspection INFOID:0000000010640651
Generation of the EV battery usage report is one of the maintenance items.

This maintenance item generates a report that will help the customer understand the vehicle operating condi-
tions needed to keep the Li-ion battery in the best possible condition.
For details about how to generate this report, please refer to EV battery usage report in the CONSULT opera-
tion manual.
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LI-ION BATTERY
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION A
LI-ION BATTERY
Exploded View INFOID:0000000010640652
B
EVB
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G
N
JSCIA0554GB
Li-ion battery Bonding plate (stamped No. 4.) Li-ion battery undercover (front)
O
Li-ion battery undercover (center) Li-ion battery undercover (rear) Clip
Battery mounting bracket (left) Battery mounting bracket (right)
: N-m (kg-m ft-lb) P
: N·m (kg-m, in-lb)
Removal and Installation INFOID:0000000010640653
DANGER:

LI-ION BATTERY
Because hybrid vehicles and electric vehicles contain a high voltage battery, there is a risk of
electric shock, electric leakage, or similar accidents if the vehicle is handled incorrectly. Be sure to fol-
low the correct work procedures when performing inspection and maintenance.
WARNING:
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
REMOVAL
WARNING:
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Prepare for work on the high-voltage system. Refer to GI-33, "How to Disconnect High Voltage".
1. Lift up the vehicle and remove the Li-ion battery undercover. EVB-181, "Exploded View".
2. Remove the harness clamp and disconnect the Li-ion battery
high-voltage harness connector .
DANGER:
• There is the danger of electric shock caused by

contact with the terminals. Be sure to wear insulated pro-
tective gear.
JSCIA0555ZZ
• Because there is the danger of electric shock, imme-

diately insulate disconnected high voltage connectors and terminals with insulating tape.
• Follow the procedure below to disconnect the high-voltage harness connector.
JPCIA0035ZZ
3. Disconnect the Li-ion battery heater harness connector .

DANGER:

tective gear.
JSCIA0556ZZ

LI-ION BATTERY
• Because there is the danger of electric shock, immediately insulate disconnected high volt- A
age connectors and terminals with insulating tape.
• Follow the procedure below to disconnect the PTC heater harness connector. B
EVB
JSCIA0557ZZ
E
4. Disconnect the Li-ion battery vehicle communications connector
while rotating it in the counterclockwise direction.
WARNING: F
To prevent electric shock, wear insulated protective
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gear.
G
H
JSCIA0558ZZ
5. Remove bonding plate . I

WARNING:

gear. J
JSCIA0559ZZ
L
6. Remove Li-ion battery mounting bolts .
WARNING:
M
gear.
N
CAUTION:
O
Do not remove the 4 bolts shown by in the figure.
JSCIA0560ZZ
7. Set the pallet [SST: — (J-50583)] onto the lift table. P

LI-ION BATTERY
• Align the pallet center mark and the lift table center
mark .
Front
Side
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JSCIA0178ZZ
8. Set the pallet onto the Li-ion battery.

CAUTION:
For preventing the battery from falling, fasten the pallet and
battery with transport fastening bolts.
JSCIA0179ZZ
9. Remove the Li-ion battery mounting bolts (4 bolts) .
JSCIA0561ZZ
WARNING:
To prevent electric shock, wear insulated protective gear.

LI-ION BATTERY
10. Lower the pallet, and remove the Li-ion battery from the vehi-
cle. A
WARNING:
To prevent electric shock, wear insulated protective B

gear.
EVB
JSCIA0181ZZ
D
11. Lower the Li-ion battery from the lift table together with the pallet.
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JPCIA0196ZZ
1. Lift up the Li-ion battery.

H
2. Move the lift table.
3. Lower the Li-ion battery.
4. Operate the stacker and move the Li-ion battery.
I
CAUTION:
Because there is the danger of tipping over, do not move the stacker while the Li-ion battery is J
lifted up.
INSTALLATION
1. When replacing the Li-ion battery with a new battery, perform the work listed below. K
a. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
together with the new part.
b. Cut the EV battery tracking identification seal into 2 pieces and apply them to the body of the replaced L
(old) Li-ion battery and to the “Li-ion battery replacement history record”.
c. Enter the necessary information in the “Li-ion battery replacement history record”.
2. Install the locating pin [SST: KV99111300 (J-50306)] in the position on the body as shown in the figure. M
JSCIA0182ZZ

LI-ION BATTERY
: Vehicle front
3. Install the Li-ion battery onto the vehicle body.

• Align the Li-ion battery and the locating pin .
WARNING:

gear.
JSCIA0183ZZ
4. Tighten the Li-ion battery mounting bolts (4 bolts) , then remove the pallet.
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JSCIA0561ZZ
WARNING:
5. Remove the locating pin from the body.

• If the locating pin is stuck and cannot be removed, remove
it using a wrench.
WARNING:

gear.
JSCIA0185ZZ
6. Install the Li-ion battery mounting bolts .

WARNING:

gear.
JSCIA0560ZZ

LI-ION BATTERY
7. Install the bonding plate .
WARNING: A

gear. B
EVB
JSCIA0559ZZ
D
8. After installing the bonding plate, perform an electric equipotential test. EVB-188, "Inspection".
9. Rotate the vehicle communications connector clockwise to
connect it. E
WARNING:

F
gear.
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G
JSCIA0562ZZ
H
10. Install the Li-ion battery heater harness connector .
DANGER:
I
tective gear.
J
K
JSCIA0556ZZ
• Follow the procedure below to connect the heater harness connector. L
JSCIA0563ZZ
O

LI-ION BATTERY
11. Install the high-voltage harness connector and install the har-
ness clamp .
WARNING:

gear.
JSCIA0555ZZ
• Connect the high-voltage harness connector by the following procedure.
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JPCIA0036ZZ
12. Install the Li-ion battery undercover.

13. Install the service plug GI-33, "How to Disconnect High Voltage".
ELECTRIC EQUIPOTENTIAL TEST

After installing the Li-ion battery, measure the resistance between the battery pack ground bolt and the body
ground.
JSCIA0707ZZ
WARNING:
Standard : Less than 0.1Ω

If the result deviates from the standard value, check the following and correct the malfunction location.

LI-ION BATTERY
• Conditions of bonding plate connection
• Corrosion on bonding plate mounting surface A
• Presence of paint, oil, dirt, or other substance on the bonding plate mounting surface
EVB
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G

LI-ION BATTERY
< UNIT DISASSEMBLY AND ASSEMBLY >
UNIT DISASSEMBLY AND ASSEMBLY
LI-ION BATTERY
BATTERY PACK UPPER CASE
BATTERY PACK UPPER CASE : Exploded View INFOID:0000000010640655
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JSCIA0565GB

LI-ION BATTERY
Service plug Service plug retainer Battery pack upper case A

Seal Plug Plug washer
Breather
B
Battery pack case side
: Always replace after every disas-
sembly.
EVB
: N·m (kg-m, ft-lb)

D
BATTERY PACK UPPER CASE : Removal and Installation INFOID:0000000010640656
DANGER: E
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and F
maintenance.
WARNING:
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• Be sure to remove the service plug in order to shut off the high voltage circuits before performing G
tainer so that another person does not accidentally connect it while work is in progress. H
or similar item to prevent contact with other persons. I
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent-
ing electric shock, fire, and damage to parts. J
CAUTION:
K
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment. L
• The environment must utilize a shutter or other means to shut out the outside environment and prevent
rain, snow, dust, or other substances from entering.
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur
M
due to high temperature or humidity.
2. Metal powder, grease, and other foreign substances must not enter.
• The indoor environment must also prevent metal powder, grease, and other foreign substances from
entering due to maintenance performed on other vehicles and other sources during disassembly work. N
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a
vinyl curtain or an equivalent to shut out the outside environment.
3. The floor must be dry. O
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow.
4. Work space
• The work space must be approximately the size of one entire vehicle. P
• Take appropriate countermeasures so that persons other than the operator do not enter the work space,
such as by placing signs indicating that disassembly work is in progress.
5. Standard fire fighting equipment
• Always place a standard fire fighting equipment in the disassembly work area.
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin-
guisher).
REMOVAL
LI-ION BATTERY
1. Clean any dust or dirt adhered to the battery pack.
2. Remove the service plug retainer .
WARNING:

gear and use insulated tools.
JSCIA0143ZZ
3. Remove the battery pack upper case mounting bolts and ground bolts .
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JSCIA0571GB
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
4. Cut the battery pack upper case adhesive according to the following procedure.
WARNING:
a. Prepare a windshield cutter.

NOTE:
• Sharpen the blade of the windshield cutter .
• Apply a tape for preventing damage to the battery pack.
: 38 mm (1.50 in)
JSCIA0572ZZ

LI-ION BATTERY
b. Use the windshield cutter and cut the adhesive in the order from 1 to 4 as shown in the figure.
A
EVB
JSCIA0655ZZ F
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I
JSCIA0699ZZ
Battery pack upper case Battery pack lower case

J
Paint sealant Adhesive
: Paint sealant mark
: Battery front K
CAUTION:
• When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi- L
mum extent possible.
• The paint sealant is set between the paint sealant marks stamped on the battery pack upper case
(between to ). Therefore be careful not to damage the paint sealant when cutting the adhe-
sive. M
• Because the paint sealant functions to release pressure from inside the battery pack, if the paint
sealant is damaged beyond the limit, the battery pack lower case must be replaced. If the paint
sealant damage is less than the limit, repair by applying primer (adhesive primer: 999MP- N
43533PP).
Paint sealant damage limit: O

Continuous length of undamaged section: : 210 mm (8.27 in) or more
NOTE:
• Because there is no clearance at the embossed part, cut the adhesive there last. P

LI-ION BATTERY
• Set the windshield cutter (A) at an angle of 90° to the surface of the battery case.
JSCIA0678ZZ
• Hold the windshield cutter facing toward the grip, and cut the adhesive while holding the blade level.
c. Use piano wire (A) to cut the adhesive at the battery pack cor-
ners.
CAUTION:
When cutting the adhesive, be careful to avoid scratching
the battery pack coating and paint sealant to the maximum
extent possible.
NOTE:
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Press the piano wire against the adhesive at the battery pack
corner, and pull it in alternate directions for cutting of adhesive.
JSCIA0574ZZ
d. Use the windshield cutter (A) for cutting adhesive at the embossed locations.
JSCIA0679ZZ
i. Insert a plastic remover tool (B) into the embossed locations to open a clearance.
CAUTION:
Do not press the remover tool farther in than necessary. Doing so may deform the battery pack
upper case.
ii. Tilt the windshield cutter blade at an angle and cut the adhesive at the embossed locations.
CAUTION:
When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi-
mum extent possible.
5. Remove the battery pack upper case.
WARNING:
CAUTION:
• Check that the adhesive is fully cut before removing. Use of excessive force during removal may
deform the battery pack upper case.
• When removing the battery pack upper case, be careful that cutting particles do not enter the
battery pack.

LI-ION BATTERY
• If adhesive cutting particles enter the battery pack, clean (use of air blow is prohibited) when
assembling so that no particles remain on the battery module, bus bar, and high-voltage har- A
ness.
• Operation must be performed by 2 persons. Be careful that the battery pack upper case does not
contact the battery module.
B
INSTALLATION
1. To remove remaining adhesive on the battery pack upper case and battery pack lower case , use a
scraper (B), and cut so that the surface is smooth, leaving approximately 1 – 2 mm (0.04 – 0.08 in) of EVB
adhesive behind.
F
JSCIA0576ZZ
CAUTION:
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• Because airtightness leakage is likely to occur, cut the seal in such a way that burrs are not pro-
G
duced.
• Be careful not to damage the paint sealant.
- If the paint sealant on a straight section is damaged in excess of the limit, the battery pack lower
case must be replaced. If the paint sealant damage is less than the limit, repair by applying H
primer (adhesive primer: 999MP-43533PP).
Paint sealant damage limit: I

Continuous length of undamaged section: : 210 mm (8.27 in) or more
- If the paint sealant damage on a corner is damaged, repair by applying primer (adhesive primer:
999MP-43533PP). J
NOTE:
• Leave 1 – 2 mm (0.04 – 0.08 in) of adhesive so that the battery pack coating surface and paint sealant
are not damaged. K
• Sharpen the blade of the scraper.
2. Repair scratches to the battery pack upper case by the following procedure.
a. Protect the seal with masking tape . L
NOTE:
If primer surfacer (anti-corrosion primer) contacts the seal, the
adhesive strength is reduced.
M
b. Spray primer surfacer (anti-corrosion primer) (B) into the cracks
in the battery pack upper case.
N
JSCIA0577ZZ O

LI-ION BATTERY
3. Install a carabiner (A) onto the bracket of the battery pack upper
case.
NOTE:
This is to provide a handle for use after the adhesive is applied
and prevent adhesive from adhering to the operator's hands.
JSCIA0634ZZ
4. Apply dam rubber (KA390-0059U) on the inside of the old adhesive on the battery pack lower case.
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JSCIA0578ZZ
C : 10 mm (0.39 in)
WARNING:
CAUTION:
If dam rubber is already applied there, replace it with new dam rubber.
NOTE:
Apply the dam rubber so that adhesive does not enter the inner side. If the adhesive enters the inner side,
then the next time the battery pack is disassembled, the windshield cutter may not be able to reach the
adhesive and removing the battery pack upper case may be difficult.
5. Apply adhesive (999MP-57302NP) to the battery pack lower case as shown in the figure.
WARNING:

LI-ION BATTERY
EVB
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G
L
JSCIA0580ZZ
A : 5 mm (0.20 in) B : 10 mm (0.39 in) M

: Old adhesive : Dam rubber
E : 50 mm (1.97 in) or more
N
CAUTION:
• Because there is a risk of airtightness leakage, apply the adhesive so that there are no seams or
overlaps.
• Complete installation of the battery pack upper case before the adhesive surface hardens. The O
adhesive begins to harden in as little as 12 minutes. [Humidity: 80%, Temperature: 35°C (95°F)]
• Before installing the battery pack upper case, check that there are no locations of insufficient
adhesive. If there is insufficient adhesive, correct the location. (If the adhesive height is lower P
than the height of the dam rubber, then the amount of adhesive is insufficient.)
• Do not apply too much adhesive as doing so may make work difficult the next time the battery
pack upper case is removed.
NOTE:

LI-ION BATTERY
• For applying the adhesive in a triangle, cut the end of the nozzle as shown in the figure.
JSCIA0642ZZ
Nozzle inner diameter (A) : Approx. 5 mm (0.20 in)

6. Grasp the carabiner installed in Step 3, and install the battery pack upper case while visually aligning the
alignment holes on the battery pack upper case and battery pack lower case .
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JSCIA0680ZZ
WARNING:
CAUTION:
• Operation must be performed by 2 persons. Be careful
that the battery pack upper case does not contact the bat-
tery module.
• Moving the upper case after it is installed makes airtight-
ness leakage more likely. Therefore, position the upper
case carefully.
JSCIA0581ZZ

LI-ION BATTERY
7. Tighten the mounting bolts in the order from 1 to 6 as shown in the figure.
A
EVB
JSCIA0582ZZ F
WARNING:
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To prevent electric shock, wear insulated protective gear and use insulated tools. G
H
8. Install the ground bolt .
M
JSCIA0583ZZ
WARNING:
N

LI-ION BATTERY
9. Install the service plug retainer .
WARNING:

JSCIA0143ZZ
10. Perform a battery pack air leak inspection. Refer to EVB-256, "Inspection".
CAUTION:
If air leakage occurs, remove the battery pack upper case and wipe off the adhesive, then apply
new dam rubber and apply adhesive again. (Proceed to Step 4.)
11. Spray primer surfacer (anti-corrosion primer) (A) into cracks in
the periphery of the battery pack adhesive.
WARNING:
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gear.
JSCIA0584ZZ
CAUTION:
• After the battery pack is assembled, it can be installed into the vehicle. However the battery pack
must not be subjected to any external force (such as high-pressure washing or parking in a location
which strains the vehicle body) for approximately 3 hours after installation.
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged,
replace it with a new clip before installing.
• After assembling the battery pack, perform an electric equipotential test.
• Check the following items after installing battery pack: Refer to EVB-256, "Inspection".
AIR LEAK INSPECTION
LI-ION BATTERY CONTROLLER

LI-ION BATTERY
LI-ION BATTERY CONTROLLER : Exploded View INFOID:0000000010640657
EVB
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G
JSCIA0760GB
I
Li-ion battery controller Controller bracket

J
LI-ION BATTERY CONTROLLER : Removal and Installation INFOID:0000000010640658
DANGER: K
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are L
maintenance.
WARNING: M
tainer so that another person does not accidentally connect it while work is in progress. N
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet O
ing electric shock, fire, and damage to parts. P
CAUTION:
1. Must be an indoor environment.

LI-ION BATTERY
entering due to maintenance performed on other vehicles and other sources during disassembly work.
3. The floor must be dry.
4. Work space
• The work space must be approximately the size of one entire vehicle.
guisher).
REMOVAL
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1. Remove the battery pack upper case. EVB-191, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
2. Disconnect the low-voltage harness connector of the Li-ion
battery controller.
WARNING:

gear.
JSCIA0145ZZ
3. Remove the Li-ion battery controller mounting nuts , then

remove the mounting bolts .
WARNING:

JPCIA0192ZZ
4. Disconnect the high-voltage harness connector , then remove

the Li-ion battery controller.
: Low-voltage harness connector

: Battery front
WARNING:
• To prevent electric shock, wear insulated protective

gear.
JPCIA0204ZZ

LI-ION BATTERY
• Because there is a risk of electric shock, immediately protect the terminals of the discon-
B
nected high-voltage harness connector with insulating tape so that they are not exposed.
INSTALLATION
EVB
1. Install the Li-ion battery controller.
WARNING:
• To prevent electric shock, wear insulated protective gear and use insulated tools. D
E
• The Li-ion battery controller includes 2 harness connec-
tors: a high-voltage connector and a low-voltage con-
nector . If the high-voltage harness connector is F
inserted at the low-voltage point, smoking and compo-
nent damage may occur. Be very careful not to insert the
connectors at the wrong points.
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G
: Battery front
H
JPCIA0204ZZ
2. Install the battery pack upper case. EVB-191, "BATTERY PACK UPPER CASE : Removal and Installa-
tion". I
CAUTION:
replace it with a new clip before installing. J
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST K
BATTERY JUNCTION BOX AND BATTERY HARNESS
L

LI-ION BATTERY
BATTERY JUNCTION BOX AND BATTERY HARNESS : Exploded View INFOID:0000000010640659
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JSCIA0761GB
Service plug switch Service plug switch bracket High-voltage battery harness
Bus bar nut cap Bus bar Bus bar nut cap
Bus bar (integrated with noise filter) Battery junction box Harness bracket
Vehicle communications harness Snap ring PTC heater harness connector

LI-ION BATTERY
High-voltage harness connector Connector flange Seal
Voltage detection harness Bus bar Battery current sensor (integrated
A
with bus bar)
High-voltage battery harness
: Always replace after every disas-
B
sembly.
EVB
Bus bar Layout
DANGER:
D
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G

LI-ION BATTERY
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal.
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JSCIA0874ZZ
: Battery front
BATTERY JUNCTION BOX AND BATTERY HARNESS : Disassembly and Assembly

INFOID:0000000010640660
DANGER:

LI-ION BATTERY
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of A
maintenance.
B
WARNING:
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con- EVB
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not D
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent- E
ing electric shock, fire, and damage to parts.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the F
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ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK G
rain, snow, dust, or other substances from entering. H
2. Metal powder, grease, and other foreign substances must not enter. I
vinyl curtain or an equivalent to shut out the outside environment. J
4. Work space K
such as by placing signs indicating that disassembly work is in progress. L
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin- M
guisher).
DISASSEMBLY
1. Remove the battery pack upper case. EVB-191, "BATTERY PACK UPPER CASE : Removal and Installa- N
tion".
Installation". O

LI-ION BATTERY
3. Disconnect the high-voltage harness engagement detection
switch harness connector .
WARNING:

gear.
JSCIA0708ZZ
4. Open the bus bar cover and remove the high-voltage harness
connector terminal mounting bolt .
DANGER:

tective gear and use insulated tools.
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JSCIA0709ZZ
• Because of the danger of electric shock, be sure to
close the bus bar cover after removing the bus bar.
5. Remove the mounting bolt and disconnect the high-voltage

harness connector from the connector flange.
WARNING:

JSCIA0590ZZ
6. Disconnect the PTC heater harness connector .

WARNING:

gear.
JSCIA0710ZZ

LI-ION BATTERY
7. Remove the mounting bolts and remove the PTC heater har-
ness connector from the connector flange. A
WARNING:

EVB
JSCIA0592ZZ
D
8. Disconnect the vehicle communications harness connector ,
connector clips , and Li-ion battery heater harness connector
. E
WARNING:

F
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G
JSCIA0762ZZ
9. Remove the bus bar nut caps . H

WARNING:

gear and use insulated tools. I
JSCIA0727ZZ
K
10. Remove the bus bar mounting nuts and , and remove the
bus bar (integrated with noise filter) .
L
WARNING:

gear and use insulated tools. M
N
JSCIA0728ZZ
11. Remove the harness clips, then remove the battery member O
pipe .
WARNING:
P
NOTE:
JSCIA0715ZZ

LI-ION BATTERY
The right-side mounting hole is larger for facilitating removal of the battery member pipe. Lifting up the left
side first makes removal easier.
12. Remove the bus bar nut cap and remove the high-voltage
harness nut cap , then open the bus bar cover .
WARNING:

gear.
JSCIA0712ZZ
13. Remove the mounting nuts , and remove the bus bar and
high-voltage harness .
DANGER:

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JSCIA0713ZZ
• Because there is a risk of electric shock, immedi-

ately protect the terminals of the disconnected high-voltage harness connector (high-voltage
terminals) with insulating tape so that they are not exposed.
• Because of the danger of electric shock, be sure to close the bus bar cover after removing
the bus bar.
14. Remove the mounting nuts and remove the junction box .
WARNING:

JSCIA0595ZZ
15. Disconnect the current sensor harness connector .

WARNING:

JSCIA0657ZZ

LI-ION BATTERY
16. Remove the bus bar mounting nut which connects the current
sensor and left front module stack . A
DANGER:
• There is the danger of electric shock caused by B

EVB
JSCIA0596ZZ
• Because of the danger of electric shock, be sure to D
close the bus bar cover after removing the bus bar.
17. Remove the service plug switch bracket mounting bolts .

E
WARNING:

gear and use insulated tools. F
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G
JSCIA0597ZZ
H
18. Invert the service plug switch bracket and remove the high-volt-
age harness mounting bolt , current sensor mounting bolt ,
and the connector , then remove the service plug switch I
bracket .
DANGER:
J
K
JSCIA0598ZZ
L
• Because there is a risk of electric shock, immediately protect the terminals of the discon-
nected high-voltage harness connector (high-voltage terminals) with insulating tape so that they
are not exposed. M
19. Remove the mounting nuts , then remove high-voltage harness and .
N

LI-ION BATTERY
JSCIA0764ZZ
: Harness clip
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DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear and use insulated tools.
• Because of the danger of electric shock, be sure to close the bus bar cover after removing
the bus bar.
20. Remove the vehicle communications harness and voltage detection harness.
JSCIA0765ZZ
Vehicle communications harness Voltage detection harness Snap ring

: Harness clip
WARNING:

LI-ION BATTERY
ASSEMBLY B
Note the following items, and disassembly in the reverse order of disassembly.
DANGER:
EVB
D
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter- E
minal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.
- Since the correct installation position for the bus bar connected to both front module stacks is com- F
monly-confused with the wrong position , install the bus bar to the correct position with extreme
caution.
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G
L
JSCIA0873ZZ
Correct position Wrong position

M
: Battery front
WARNING:
Install the Li-ion battery controller immediately before installing the battery pack upper case. Refer to N
EVB-201, "LI-ION BATTERY CONTROLLER : Removal and Installation".
CAUTION:
• Perform the “LI-ION BATTERY JUNCTION BOX DATA CLEAR” when battery junction box is replaced. O
Refer to EVC-137, "Work Procedure".
• Check the following items after installing battery pack: Refer to EVB-256, "Inspection". P
AIR LEAK INSPECTION
LI-ION BATTERY HEATER

LI-ION BATTERY
LI-ION BATTERY HEATER : Exploded view INFOID:0000000010640661
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JSCIA0750GB
Li-ion battery heater RR2 Li-ion battery heater RH2 Li-ion battery heater RH1
Li-ion battery heater LH1 Li-ion battery heater LH2 Li-ion battery heater relay unit

LI-ION BATTERY
Li-ion battery heater harness Li-ion battery heater RR1
A
LI-ION BATTERY HEATER : Disassembly and Assembly INFOID:0000000010640662

B
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of EVB
maintenance. D
WARNING:
E
before beginning work on the high voltage system. F
• To prevent electric shock hazards, ignition, and damage to parts, always remove Li-ion battery con-
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troller before disassembling battery pack. G
CAUTION:
so in the Service Manual. H
WORK ENVIRONMENT FOR DISASSEMBLY OF LI-ION BATTERY

1. Must be an indoor environment. I
• The work environment must be able to be isolated from the outside by shutters or other means to pre-
vent the intrusion of rain, snow, sand, and other substances.
• The environment must prevent the entry of sweat during work, and also prevent condensation from
occurring as a result of high temperature and humidity. J
2. No entry of foreign materials.
• In addition to being indoors, the environment must not permit the entry during disassembly work of
metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles. K
• If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take
other necessary steps.
3. The floor must be dry. L
• The floor must not become wet as a result of causes such as vehicles entering when it is raining or
snowing.
4. Work space M
• Space approximately the size of one vehicle must be secured as the disassembly space.
• A sign indicating that disassembly is in progress or other measures must be taken so that persons other
than the workers do not enter the work space.
5. Standard fire fighting equipment N
guisher). O
REMOVAL
Li-Ion Battery Heater RR1 & RR2 P
Installation".
Installation".

LI-ION BATTERY
3. Disconnect the harness connectors .
JSCIA0751ZZ
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools.
4. Remove mounting nuts and then remove Li-ion battery heaters.
cardiagn.com
JSCIA0752ZZ
Li-ion battery heater RR1 Li-ion battery heater RR2

: Battery front
WARNING:
lated tools.
Li-Ion Battery Heater LH1

Installation".
Installation".
3. Remove vehicle communication harness. Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Disassembly and Assembly".

LI-ION BATTERY
4. Disconnect Li-ion battery heater LH1 harness connector .
A
: Battery front
WARNING:
B
To prevent electric shock hazards, be sure to put on
EVB
JSCIA0753ZZ
5. Remove mounting nuts and then remove Li-ion battery heater D
LH1 .
WARNING:
E
lated tools.
Li-Ion Battery Heater RH1
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G
Installation".
Installation". H
3. Disconnect Li-ion battery heater RH1 harness connector .
: Battery front I
WARNING:
J
K
JSCIA0755ZZ
4. Remove mounting nuts and then remove Li-ion battery heater
RH1 . L
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu- M
lated tools.
Li-Ion Battery Heater LH2

1. Remove battery pack upper case. Refer to EVB-191, "BATTERY PACK UPPER CASE : Removal and O
Installation".
Installation".
P
3. Remove the following parts; Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
• Vehicle communication harness
• Battery current sensor (integrated with bus bar)

LI-ION BATTERY
4. Remove the battery member pipe .
WARNING:

NOTE:
The right-side mounting hole is larger for facilitating removal of
the battery member pipe. Lifting up the left side first makes JSCIA0715ZZ
removal easier.
5. Disconnect Li-ion battery heater LH2 harness connector .
: Battery front
WARNING:

cardiagn.com
JSCIA0754ZZ
6. Remove mounting nuts and then remove Li-ion battery heater
LH2 .
WARNING:
lated tools.
Li-Ion Battery Heater RH2

1. Remove battery pack upper case. Refer to EVB-190, "BATTERY PACK UPPER CASE : Exploded View".
Installation".
3. Remove the following parts; Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
• Vehicle communication harness
• Bus bar [Battery junction box – Front module stack (RH)]

WARNING:

NOTE:
removal easier.

LI-ION BATTERY
5. Disconnect Li-ion battery heater RH2 harness connector .
A
: Battery front
WARNING:
B
EVB
JSCIA0756ZZ
6. Remove mounting nuts and then remove Li-ion battery heater D
RH2 .
WARNING:
E
lated tools.
Li-ion battery heater harness
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Remove Li-ion battery heater harness after front module stack is removed. Refer to EVB-226, "FRONT MOD- G
ULE STACK : Removal and Installation".
INSTALLATION
H
Note the following, and install in the reverse order of removal.
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated I
tools.
CAUTION:
• Install Li-ion battery controller immediately before installing battery pack upper case. Refer to EVB-
201, "LI-ION BATTERY CONTROLLER : Removal and Installation". K
• Check the following items after installing battery pack: Refer to EVB-256, "Inspection". L
AIR LEAK INSPECTION
LI-ION BATTERY HEATER RELAY UNIT M

LI-ION BATTERY
LI-ION BATTERY HEATER RELAY UNIT : Exploded view INFOID:0000000010640663
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JSCIA0750GB
Li-ion battery heater RR2 Li-ion battery heater RH2 Li-ion battery heater RH1
Li-ion battery heater LH1 Li-ion battery heater LH2 Li-ion battery heater relay unit

LI-ION BATTERY
Li-ion battery heater harness Li-ion battery heater RR1
A
LI-ION BATTERY HEATER RELAY UNIT : Disassembly and Assembly INFOID:0000000010640664

B
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of EVB
maintenance. D
WARNING:
E
before beginning work on the high voltage system. F
• To prevent electric shock hazards, ignition, and damage to parts, always remove Li-ion battery con-
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troller before disassembling battery pack. G
CAUTION:
so in the Service Manual. H
WORK ENVIRONMENT FOR DISASSEMBLY OF LI-ION BATTERY

1. Must be an indoor environment. I
• The work environment must be able to be isolated from the outside by shutters or other means to pre-
vent the intrusion of rain, snow, sand, and other substances.
• The environment must prevent the entry of sweat during work, and also prevent condensation from
occurring as a result of high temperature and humidity. J
2. No entry of foreign materials.
• In addition to being indoors, the environment must not permit the entry during disassembly work of
metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles. K
• If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take
other necessary steps.
3. The floor must be dry. L
• The floor must not become wet as a result of causes such as vehicles entering when it is raining or
snowing.
4. Work space M
• Space approximately the size of one vehicle must be secured as the disassembly space.
• A sign indicating that disassembly is in progress or other measures must be taken so that persons other
than the workers do not enter the work space.
5. Standard fire fighting equipment N
guisher). O
DISASSEMBLY
P
Installation".
Installation".
3. Remove the following; Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY HARNESS : Dis-
assembly and Assembly".
• Battery current sensor (integrated with bus bar)
• Service plug switch bracket

LI-ION BATTERY
4. Disconnect harness connector and heater harness connector
.
WARNING:

5. Remove mounting nuts and then remove the Li-ion battery

heater relay unit . JSCIA0757ZZ
ASSEMBLY
Assemble in the reverse order of disassembly.
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated
tools.
cardiagn.com
CAUTION:
AIR LEAK INSPECTION
• Install Li-ion battery controller immediately before installing battery pack upper case.
FRONT MODULE STACK
FRONT MODULE STACK : Exploded View INFOID:0000000010640665
REMOVAL AND INSTALLATION

LI-ION BATTERY
EVB
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G
JSCIA0568GB
P
Rear module stack Battery member pipe Front module stack RH
Battery pack lower case Front module stack LH

LI-ION BATTERY
DISASSEMBLY AND ASSEMBLY
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JSCIA0569GB
Battery temperature sensor harness End plate Module

(front)
Sub frame Bus bar cover Bus bar module

LI-ION BATTERY
NOTE:
The figure shows the right front. A
Module layout
EVB
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JSCIA0704GB
G
Left front module stack Right front module stack
Module No. Module name Cell No. Module No. Module name Cell No.
H
MD25 Module A 49 & 50 MD37 Module A 73 & 74
MD27 Module A 53 & 54 MD39 Module A 77 & 78 I
J

K
MD35 Module A 69 & 70 MD47 Module A 93 & 94 L
Bus bar Layout M

DANGER:

LI-ION BATTERY
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal.
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JSCIA0874ZZ
: Battery front
FRONT MODULE STACK : Removal and Installation INFOID:0000000010640666
DANGER:

LI-ION BATTERY
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of A
maintenance.
B
WARNING:
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con- EVB
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not D
• If the battery pack is to be disassembled, be sure to remove the Li-ion battery controller for prevent- E
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the F
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ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK G
rain, snow, dust, or other substances from entering. H
2. Metal powder, grease, and other foreign substances must not enter. I
vinyl curtain or an equivalent to shut out the outside environment. J
4. Work space K
such as by placing signs indicating that disassembly work is in progress. L
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin- M
guisher).
REMOVAL
1. Remove the battery pack upper case. EVB-191, "BATTERY PACK UPPER CASE : Removal and Installa- N
tion".
Installation". O
3. Remove the following parts. Refer to EVB-206, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
• Battery junction box P
• Service plug switch bracket
• High-voltage battery harnesses
• Vehicle communications harness
• Voltage detection harness
• Harness brackets

LI-ION BATTERY
4. Disconnect the harness connector between the battery tem-
perature sensor harness (front) and the battery temperature
sensor harness (rear).
WARNING:

gear.
JSCIA0658ZZ
5. Remove the battery temperature sensor harness (front) from the front module stack RH.
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JSCIA0631ZZ
: Harness clip
WARNING:

WARNING:

NOTE:
removal easier.
7. Remove the mounting nuts , then remove the bus bar

which connects the left and right front module stacks.
: Battery front
DANGER:

JSCIA0766ZZ

LI-ION BATTERY
• Because there is a danger of electric shock, be sure to close the bus bar cover after remov- A
ing the bus bar.
8. Remove the following parts. Refer to EVB-215, "LI-ION BATTERY HEATER : Disassembly and Assem-
bly". B
• Li-ion battery heater RH1
• Li-ion battery heater RH2
• Li-ion battery heater LH1 EVB
• Li-ion battery heater LH2
9. Remove the Li-ion battery heater relay unit. Refer to EVB-221, "LI-ION BATTERY HEATER RELAY UNIT
: Disassembly and Assembly". D
10. Disconnect the Li-ion battery heater harness connector . And then remove the harness clips and move
them to a location where they do not inhibit with work.
E
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G
J
JSCIA0781ZZ
: Harness clip
K
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools. L
M
11.

LI-ION BATTERY
12. Remove the front module stack mounting nuts .
JSCIA0716ZZ
Front module stack LH Front module stack RH
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WARNING:
13. Follow the procedure below and remove the front module stack from the battery pack.
a. Attach a carabiner at position as shown in the figure, and attach a sling belt to it.
JSCIA0722ZZ
WARNING:
b. Use the engine frame (A) and lift up the front module stack.
WARNING:

gear.
CAUTION:
Do not move the engine crane when the front module stack
is lifted up. JSCIA0718ZZ

LI-ION BATTERY
c. Move the battery pack and place the workbench below the front module stack.
WARNING: A

B
CAUTION:
Place the removed battery pack upper case onto the battery pack for storage. EVB
d. Place the front module stack onto the workbench.

WARNING: D
• To prevent electric shock, wear insulated protective

gear.
E
F
• Because there is a risk of electric shock, lay an anti-
static rubber sheet on the workbench. JSCIA0719ZZ
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NOTE: G
The figure shows the front module stack RH.
14. Remove the Li-ion battery heater harness .

H
JSCIA0782ZZ K
: Harness clip
L
WARNING:
M
N
INSTALLATION
Note the following items, and disassembly in the reverse order of disassembly.
DANGER: O
P
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter-
minal.
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.

LI-ION BATTERY
- Since the correct installation position for the bus bar connected to both front module stacks is com-
monly-confused with the wrong position , install the bus bar to the correct position with extreme
caution.
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JSCIA0873ZZ
Correct position Wrong position

: Battery front
WARNING:
Install the Li-ion battery controller immediately before installing the battery pack upper case. Refer to
EVB-201, "LI-ION BATTERY CONTROLLER : Removal and Installation".
EV Battery Tracking Identification Seal
When replacing the Li-ion battery with a new battery, perform the following operation.
1. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
2. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
(old) LI-ion battery and to the “Li-ion battery replacement history record”.
3. Enter the necessary information in the “Li-ion battery replacement history record”.
Battery Temperature Sensor Harness (Front)

Install the battery temperature sensor harness (front) onto the front module stack RH.
JSCIA0659ZZ
CAUTION:

LI-ION BATTERY
replace it with a new clip before installing. A
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST B
NOTE:
Install the battery temperature sensor onto module No. MD39 and MD46.
FRONT MODULE STACK : Disassembly and Assembly INFOID:0000000010640667 EVB
DANGER:
D
maintenance. E
WARNING:
inspection or maintenance of high voltage system harnesses and parts. F
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G
• Refer to EVB-7, "High Voltage Precautions". H
CAUTION: I
J
• The environment must utilize a shutter or other means to shut out the outside environment and prevent K
L
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a M
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow. N
4. Work space
• Take appropriate countermeasures so that persons other than the operator do not enter the work space, O
P
guisher).
DISASSEMBLY
1. Follow the procedure below and remove the bus bar module from the front module stack.

LI-ION BATTERY
a. Remove the bus bar cover, then remove the module terminal mounting bolts .
JSCIA0720ZZ
DANGER:
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.
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b. Remove the voltage detection terminal mounting screws , then remove the bus bar module from the
front module stack.
JSCIA0721ZZ
DANGER:
c. Install a module terminal cover [SST: KV99111500 ( — )] onto all module terminals.
JPCIA0123ZZ
WARNING:

LI-ION BATTERY
2. Remove the end plate and disassemble the front module stack.
WARNING: B
EVB
ASSEMBLY D
1. When replacing the Li-ion battery with a new battery, perform the following operation.
together with the new part. E
b. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
c. Enter the necessary information in the “Li-ion battery replacement history record”. F
2. Follow the procedure below to assemble the front module stack.
DANGER:
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G
There is the danger of electric shock caused by contact with the terminals. Be sure to wear
H
a. Assemble the module so that the module terminals are arranged as shown in the figure.
I
JSCIA0681ZZ
Right module stack Left module stack

: Battery front
WARNING:

LI-ION BATTERY
Be careful of the directions of the + terminal and – terminal when assembling the module. If
the polarity is incorrect, there is a risk of electric shock, fire, and component damage.
NOTE:
• To identify the module + terminal and − terminal, refer to the
figure.
+ terminal identification color : Red

− terminal identification color : Black
JSCIA0682ZZ
• Install the module while aligning the position of the module col-
lar .
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JSCIA0733ZZ
b. Install so that the end plate carabiner installation holes are in the positions shown in the figure.
JSCIA0722ZZ
NOTE:
There are 2 end plates, each with different carabiner installation hole positions. If they are installed
reversed, the carabiner installation hole is positioned on the inside and lifting up is not possible.
c. Install the mounting bolts at opposite corners for each module, then insert φ7 mm (0.28 in) metal bars
(B) into the empty bolt holes and perform centering of the module collar position.

LI-ION BATTERY
EVB
JSCIA0734ZZ F
CAUTION:
If the collar position is incorrect, there is a risk of the bolts loosening because they are not sup-
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ported by the collar between the modules.
G
d. Tighten the mounting bolt to the specified torque.
3. Follow the following procedure and install the bus bar module onto the front module stack.
a. Install the bus bar module , then use an insulated torque driver to tighten the voltage detection terminal H
mounting screws .
K
JSCIA0721ZZ
DANGER:
L
• This work must not be performed by multiple operators because there is a risk of electric N
b. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
O

LI-ION BATTERY
JPCIA0150ZZ
Right module stack Left module stack

: Battery front
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DANGER:
c. Install the bus bar cover.
REAR MODULE STACK
REAR MODULE STACK : Exploded View INFOID:0000000010640668
REMOVAL AND INSTALLATION

LI-ION BATTERY
EVB
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G
JSCIA0568GB
P
Rear module stack Battery member pipe Front module stack RH
Battery pack lower case Front module stack LH

LI-ION BATTERY
DISASSEMBLY AND ASSEMBLY
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JSCIA0570GB
Battery temperature sensor harness Right end plate Harness bracket

(rear)
Harness bracket Front stack member Harness bracket
Bus bar cover Bus bar module Through-bolt
Left end plate Module Rear stack member

LI-ION BATTERY
Module layout
A
EVB
JSCIA0704GB F
Rear module stack
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Module No. Module name Cell No. Module No. Module name Cell No. G
MD1 Module A 1&2 MD13 Module A 25 & 26
MD2 Module B 3&4 MD14 Module B 27 & 28
H
MD3 Module A 5&6 MD15 Module A 29 & 30
MD4 Module B 7&8 MD16 Module B 31 & 32
MD5 Module A 9 & 10 MD17 Module A 33 & 34 I
MD6 Module B 11 & 12 MD18 Module B 35 & 36
J
MD10 Module B 19 & 20 MD22 Module B 43 & 44 K
L
NOTE:
• Module A: No bracket
• Module B: With bracket
M
REAR MODULE STACK : Removal and Installation INFOID:0000000010640669
DANGER:
N
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and O
maintenance.
WARNING:
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing P
LI-ION BATTERY
CAUTION:
4. Work space
cardiagn.com
guisher).
REMOVAL
1. Remove the battery pack upper case. EVB-191, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
Installation".
3. Remove Li-ion battery heater RR1 and RR2. Refer to EVB-215, "LI-ION BATTERY HEATER : Disassem-
bly and Assembly".
4. Disconnect the harness connector between the battery tem-
perature sensor harness (front) and the battery temperature
sensor harness (rear).
WARNING:

gear.
JSCIA0658ZZ

LI-ION BATTERY
5. Disconnect the connector, and then remove the battery temperature sensor harness (rear).
A
EVB
JSCIA0647ZZ F
WARNING:
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To prevent electric shock, wear insulated protective gear and use insulated tools. G
H
6. Remove the harness clips of the voltage detection harness and the Li-ion battery heater harness
from the harness bracket, and move them to a location where they do not inhibit with work.
I
N
JSCIA0769ZZ
: Harness clip
O
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools. P
7. Remove the mounting nuts and remove the high-voltage harness , from the rear module stack.

LI-ION BATTERY
JSCIA0770ZZ
: Harness clip
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DANGER:
• Because there is a risk of electric shock, immediately protect the disconnected high-volt-
age terminals with insulating tape so that they are not exposed.
8. Remove the rear module stack mounting bolts .
WARNING:

JPCIA0129ZZ
9. Follow the procedure below and remove the rear module stack from the battery pack.
a. Attach a carabiner to position (A) as shown in the figure and
connect a lashing belt to it.
WARNING:

gear.
JSCIA0251ZZ

LI-ION BATTERY
b. Use the engine frame (A) and lift up the rear module stack .
WARNING: A

gear. B
CAUTION: EVB
Do not move the engine crane when the rear module stack
is lifted up. JPCIA0130ZZ
D
c. Move the battery pack and place the workbench below the rear module stack.
WARNING:
E
F
CAUTION:
Place the removed battery pack upper case onto the battery pack for storage.
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G
d. Place the rear module stack onto the workbench.
WARNING:
H
• To prevent electric shock, wear insulated protective gear.
I
• Because there is a risk of electric shock, lay an anti-static rubber sheet on the workbench.
INSTALLATION J
together with the new part. K
c. Enter the necessary information in the “Li-ion battery replacement history record”. L
2. Follow the following procedure and install the rear module stack onto the battery pack.
a. Use the engine frame (A) and lift up the rear module stack .
M
WARNING:

gear. N
O
CAUTION:
Do not move the engine crane when the rear module stack
is lifted up. JPCIA0130ZZ
P
b. Move the workbench and place the battery pack below the rear module stack.
c. Mount the rear module stack onto the battery pack.
WARNING:

LI-ION BATTERY
CAUTION:
Be sure to align the locating pin position.
3. Tighten the rear module stack mounting bolts .

WARNING:

JPCIA0129ZZ
4. Tighten the mounting nuts , and then install the high-voltage harness , onto the rear module stack.
cardiagn.com
JSCIA0770ZZ
: Harness clip
DANGER:
• Because there is a risk of electric shock, immediately protect the disconnected high-volt-
age terminals with insulating tape so that they are not exposed.
5. Install the voltage detection harness and the Li-ion battery heater harness .

LI-ION BATTERY
EVB
JSCIA0769ZZ F
: Harness clip
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WARNING: G

H
6. Install the battery temperature sensor harness (rear). I
N
JSCIA0647ZZ
WARNING:
O
NOTE:
Install the battery temperature sensor onto module No. MD12.

LI-ION BATTERY
7. Connect the harness connector between the battery tempera-
ture sensor harness (front) and battery temperature sensor har-
ness (rear).
WARNING:

gear.
JSCIA0658ZZ
8. Install the Li-ion battery heater RR1 and RR2. Refer to EVB-215, "LI-ION BATTERY HEATER : Disassem-
bly and Assembly".
9. Install the Li-ion battery controller. EVB-201, "LI-ION BATTERY CONTROLLER : Removal and Installa-
tion".
10. Install the battery pack upper case. EVB-191, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
CAUTION:
cardiagn.com
AIR LEAK INSPECTION
REAR MODULE STACK : Disassembly and Assembly INFOID:0000000010640670
DANGER:
maintenance.
WARNING:
• Be sure to remove the service plug for shutting off high voltage circuits before performing inspec-
tion or maintenance of high voltage system harnesses and parts.
CAUTION:

LI-ION BATTERY
vinyl curtain or an equivalent to shut out the outside environment. A
4. Work space B
EVB
guisher). D
DISASSEMBLY
1. Remove harness bracket , and from the rear module stack. E
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G
JSCIA0635ZZ H
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools. I
J
2. Follow the following procedure and remove the bus bar from the rear module stack.
a. Remove the center bus bar cover, then remove the module ter-
minal mounting bolts . K
DANGER:
• There is the danger of electric shock caused by L

M
JSCIA0154ZZ
• This work must not be performed by multiple opera- N
tors because there is a risk of electric shock if the operators contact one another.
CAUTION:
Do not remove all bus bar covers and all module terminal mounting bolts at the same time.
O

LI-ION BATTERY
b. Remove the left-side bus bar cover, then remove the module ter-
minal mounting bolts .
DANGER:

JSCIA0148ZZ
• This work must not be performed by multiple opera-
c. Remove the right-side bus bar cover, then remove the module
terminal mounting bolts .
DANGER:

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JSCIA0155ZZ
d. Remove the voltage detection terminal mounting screws ,

then remove the bus bar from the rear module stack.
DANGER:

JSCIA0191ZZ
e. Install a module terminal cover [SST: KV99111500 ( — )] (A)

onto all module terminals.
WARNING:

gear.
NOTE:
• Because “module B” interferes with the bracket and cover, cut JSCIA0192ZZ
the module terminal cover at the position shown in the figure.

LI-ION BATTERY
EVB
JSCIA0729ZZ
D
A : 7 mm (0.28 in) B : 5 mm (0.20 in)
3. Remove the front stack member .

E
WARNING:

gear and use insulated tools. F
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G
JPCIA0126ZZ
H
4. Remove the rear stack member .
WARNING:
I
J
K
JSCIA0723ZZ
5. Fasten the rear module stack with a lashing belt . L

WARNING:
To prevent electric shock, wear insulated protective M

gear.
JSCIA0240ZZ O

LI-ION BATTERY
6. Remove the through bolt mounting nut, then disassemble the
rear module stack .
WARNING:

JPCIA0131ZZ
ASSEMBLY
c. Enter the necessary information in the “Li-ion battery replacement history record”.
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2. Follow the procedure below to assemble the rear module.
WARNING:
a. Assemble the rear module so that the module terminals are arranged as shown in the figure.
JSCIA0683ZZ
WARNING:
Be careful of the directions of the + terminal and − terminal when assembling the module. If
the polarity is incorrect, there is a risk of electric shock, fire, and component damage.
NOTE:
• To identify the module + terminal and − terminal, refer to the
figure.
+ terminal identification color : Red

− terminal identification color : Black
JSCIA0682ZZ

LI-ION BATTERY
b. Use a lashing belt and apply pressure to the rear module
stack . A
WARNING:

gear.
EVB
JSCIA0240ZZ
D
c. Inspect the module installation condition, and correct it if it is skewed or a large distortion is found.
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G
JSCIA0313ZZ
WARNING:
H
I
d. Install the 2 through-bolts at opposite corners of the module, then insert φ7 mm (0.28 in) metal bars (A)
into the bolt holes and tighten the mounting nuts to the prescribed torque.
J
JSCIA0717ZZ O
CAUTION:
If the collar position is incorrect, there is a risk of the bolts loosening because they are not sup-
ported by the collar between the modules.
P
e. Install the remaining 2 through-bolts, and tighten the mounting nuts to the prescribed torque.

LI-ION BATTERY
• When installing, hold the end of the through bolt stationary and
tighten the installation nut.
JSCIA0347ZZ
3. Install the rear stack member .

WARNING:

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JSCIA0723ZZ
4. Install the front stack member .

WARNING:

JPCIA0126ZZ
5. Remove the module terminal cover [SST: KV99111500 ( — )]

(A).
WARNING:

gear.
6. Follow the procedure below and install the bus bar module onto
the rear module stack. JSCIA0192ZZ
a. Install the bus bar module onto the rear module stack.
WARNING:

LI-ION BATTERY
b. Use an insulated torque driver (A) and tighten the voltage detec-
tion terminal mounting screws to the prescribed torque. A
DANGER:
• There is the danger of electric shock caused by B

EVB
JPCIA0135ZZ
• This work must not be performed by multiple opera- D
c. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
• When tightening of 1 – 16 is completed, install the left-side bus bar cover. E
• When tightening of 17 – 32 is completed, install the right-side bus bar cover.
• When tightening of 33 – 48 is completed, install the center bus bar cover.
F
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G
JPCIA0136ZZ
DANGER: I
J
K
d. Install the bus bar cover . L
JPCIA0137ZZ
O
WARNING:

P
CAUTION:
• Be careful not to install with the top and bottom facing in the wrong directions.
• After installation, check that the mating is not skewed.

LI-ION BATTERY
7. Install the harness bracket , and to the rear module stack.
JSCIA0635ZZ
WARNING:
CAUTION:
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AIR LEAK INSPECTION
AIR LEAK INSPECTION

1. Remove the plug and install the adapter (A) of the air leak tester
[SST: KV99111400 ( — )].
WARNING:

gear.
JSCIA0645ZZ
2. Install the gauge (A) of the air leak tester [SST: KV99111400
( — )].
WARNING:

gear.
CAUTION:
The gauge is a precision instrument. Be careful not to drop JSCIA0646ZZ
it when handling it.
3. Install the service plug.

DANGER:
There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear.

LI-ION BATTERY
NOTE:
Because the service plug location is open, install the service plug for sealing the case.
B
4. Use vinyl tape or similar means (A) for preventing air leakage
from the PTC harness connector.
• Use wide vinyl tape that is capable of covering all of the PTC
harness connector with one strip. EVB
• Apply carefully so that no wrinkles in the tape occur.
WARNING:
D
gear.
E
JSCIA0686ZZ
5. Use vinyl tape or similar means (A) to prevent air leakage from F
the breather.
• Use wide vinyl tape that is capable of covering all of the
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breather with one strip. G
• Apply carefully so that no wrinkles in the tape occur.
WARNING:
H
gear.
JPCIA0128ZZ
I
6. Follow the procedure below to check the battery case pressure. J

WARNING:

K
a. Open the cock on the air leak tester. L

CAUTION:
Do not operate the pump before opening the cock on the air
leak tester. Doing so may damage the gauge. If the pump is M
operated before the cock is opened, first disconnect the air
pump hose to release the pressure.
N
JSCIA0638ZZ
O
b. Operate the air pump slowly and apply the specified inspection pressure inside the battery pack. If the
gauge pressure does not rise, or if the gauge reading fluctuates, check for the location of air leakage. P
Specified inspection pressure : 1.6 kPa (0.016 bar, 0.0163 kg/cm2, 0.232 psi)
CAUTION:
• Operate the air pump carefully when applying pressure. If pressure is applied suddenly to the
gauge, the gauge may be damaged.
• Do not apply pressure of 2.0 kPa (0.0204 kg/cm2) or more to the battery case or air leak tester.

LI-ION BATTERY
c. Close the cock and wait for 1 minute.
d. Check that the air leak tester reading remains at or above the limit value.
Repair limit : 1.4 kPa (0.014 bar, 0.0142 kg/cm2, 0.203 psi)
e. If the pressure is below the limit value, check for the locations of air leakage.
NOTE:
Check for air leakage from the sound of air escaping when pressure is applied.
After assembling the Li-ion battery pack, remove the battery pack upper case ground bolt , then measure
the resistance between the high-voltage harness connector flange ground bolts and the ground bolt seat
(location of coating peeling) .
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JSCIA0747ZZ
WARNING:
Standard : Less than 0.1Ω

If the result deviates from the standard value, check the following and correct the malfunction location.
• Ground bolt connection condition
• Corrosion on ground bolt mounting surface
• Presence of paint, oil, dirt, or other substance on ground bolt mounting surface

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Li-ion Battery INFOID:0000000010640672
B
Items Specification
EVB
Type Li-ion battery
Structure 48 modules (192 cells)
Rated voltage (V) Approx. 360 D
Battery capacity (kWh) Approx. 24
Weight [kg (lb)] Approx. 275 (606)
E
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G
JSCIA0644ZZ
External dimension “a” [mm (in)] 1188 (46.77) M

“b” [mm (in)] 1007 (39.65)
“c” [mm (in)] 264 (10.39)
N
“d” [mm (in)] 1547 (60.90)

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ELECTRIC POWER TRAIN

Revision: June 2014 EVB-1 2015 Leaf NAM

P3030 CELL CONTROLLER LIN ...................... 78 P30FC OVER CURRENT .................................. 98

P3031-P303C CELL CONTROLLER ASIC ....... 79 P318D COMMUNICATION ERROR .................. 99

P3049-P3054 CELL CONTROLLER ASIC P3191 COMMUNICATION ERROR ................. 101

Revision: June 2014 EVB-2 2015 Leaf NAM

Revision: June 2014 EVB-3 2015 Leaf NAM

LI-ION BATTERY CONTROLLER ...........................200 FRONT MODULE STACK ....................................... 222

Revision: June 2014 EVB-4 2015 Leaf NAM

Precaution for Removing 12V Battery INFOID:0000000010640506

1. Check that EVSE is not connected.

Revision: June 2014 EVB-6 2015 Leaf NAM

Revision: June 2014 EVB-7 2015 Leaf NAM

Revision: June 2014 EVB-8 2015 Leaf NAM

KV99111400 When checking air leaks after disassem-

KV99111500 Protect module terminals (for LEAF) K

— Module voltage adjustment

Revision: June 2014 EVB-9 2015 Leaf NAM

Tool name Description

Removing and installing high voltage components

• Removing and installing high voltage compo-

• Removing and installing high voltage compo-

• Removing and installing high voltage compo-

Insulated helmet Removing and installing high voltage components

Revision: June 2014 EVB-10 2015 Leaf NAM

Insulated cover sheet Removing and installing high voltage components

Insulation resistance tester Measuring insulation resistance, voltage, and re-

Insulated hand tools Removing and installing high voltage components N

Revision: June 2014 EVB-11 2015 Leaf NAM

• Removing and installing battery module stack

Removing and installing battery module stack

Removing and installing battery module stack

Mobile floor crane Removing and installing battery module stack

Lashing belt Removing and installing battery rear module stack

Removing battery pack upper case

Installing battery pack upper case

Revision: June 2014 EVB-12 2015 Leaf NAM

Installing battery pack upper case B

Assembling battery module stack

Revision: June 2014 EVB-13 2015 Leaf NAM

Revision: June 2014 EVB-14 2015 Leaf NAM

Front of battery pack Back of battery pack A

Service plug EVB-20, "Service Plug" EVB

Battery junction box EVB-20, "Battery Junction Box" D

Front module stack LH EVB-17, "Module"

Rear module stack EVB-17, "Module"

Battery temperature sensor 1 EVB-19, "Battery Temperature Sensor"

Battery temperature sensor 4 EVB-19, "Battery Temperature Sensor"

Li-ion battery heater RH 2 EVB-18, "Li-ion Battery Heater"

Li-ion battery heater RR 2 EVB-18, "Li-ion Battery Heater"

Li-ion battery heater LH 1 EVB-18, "Li-ion Battery Heater"

Revision: June 2014 EVB-15 2015 Leaf NAM

Heater relay unit EVB-18, "Heater Relay Unit"

Li-ion battery heater RR 1 EVB-18, "Li-ion Battery Heater"

Li-ion Battery INFOID:0000000010640512

• A Li-ion battery with flat construction is placed under floor.

Li-ion Battery Controller INFOID:0000000010640513

• Li-ion battery controller (LBC) is included in the battery pack and