Inspection Procedure

CAUTION:

Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

HINT:

Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
After completing repairs, restart the system (turn the power switch on (READY)) and recheck for DTCs (See DTC CHECK / CLEAR ).

CHECK AUXILIARY BATTERY

Turn the power switch off.

Measure the voltage between the terminals of the auxiliary battery.

Standard voltage

VOLTAGE SPECIFICATION

Tester Connection	Condition	Specified Condition
Auxiliary battery positive terminal (+) - Auxiliary battery negative terminal (-)	Battery electrolyte temperature: 20°C (68°F)	11 to 14 V

NG: CHARGE OR REPLACE AUXILIARY BATTERY (See BATTERY )

OK: Go to next step

CHECK HARNESS AND CONNECTOR (IGCT VOLTAGE)

Turn the power switch on (IG)

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

Standard voltage

VOLTAGE SPECIFICATION

Tester Connection	Switch Condition	Specified Condition
zR2-1 (IGCT) - zR2-20 (GND)	Power switch on (IG)	8.6 V or higher

HINT.

For the removal and installation procedures related to the battery pack wire inspection, (See HV BATTERY ).
Perform this inspection with the battery pack wire connected.

NG: Go to step 4

Fig 1: Identifying ZR2 Connector Terminal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR - BATTERY SMART UNIT)

Turn the power switch off
Disconnect the battery pack wire connector
Disconnect connector z36 from the battery smart unit.

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

Standard resistance

RESISTANCE REFERENCE

Tester Connection	Switch Condition	Specified Condition
zR2-1 (IGCT) - z36-1 (IGCT)	Power switch off	Below 1 Ω

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

Fig 2: Identifying ZR2 Connector Terminal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: REPLACE BATTERY SMART UNIT (See REMOVAL )

CHECK FUSE (IGCT3)

Remove the IGCT3 fuse from the luggage room junction block

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

Standard resistance

RESISTANCE REFERENCE

Tester Connection	Condition	Specified Condition
IGCT3 fuse	Always	Below 1 Ω

NG: REPLACE FUSE

Fig 3: Identifying ZR2 Connector Terminal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK FUSE (IGCT2 NO. 2)

Remove the IGCT2 NO 2 fuse from the engine room No. 3 relay block

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

Standard resistance

RESISTANCE REFERENCE

Tester Connection	Condition	Specified Condition
IGCT2 NO. 2 fuse	Always	Below 1 Ω

NG: REPLACE FUSE

Fig 4: Identifying Engine Room No.3 Relay Block

OK: Go to next step

CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR - IGCT2 RELAY)

CAUTION: Be sure to wear insulated gloves.

Disconnect the battery pack wire connector.
Install the IGCT3 fuse to the luggage room junction block
Install the IGCT2 NO 2 fuse to the engine room No. 3 relay block
Remove the IGCT2 relay from the engine room No. 2 relay block
Disconnect connector z36 from the battery smart unit

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

Fig 5: Identifying Battery Pack Wire Connector & Engine Room No. 2 Relay Block

Standard resistance

RESISTANCE REFERENCE

Tester Connection	Switch Condition	Specified Condition
zR2-1 (IGCT) - IGCT2 relay terminal 3	Power switch off	Below 1 Ω

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: CHECK AND REPAIR POWER SOURCE CIRCUIT (IGCT2 RELAY POWER SOURCE)