ENV200 Workshop Manual

QUICK REFERENCE INDEX
Publication Number:
A
A GENERAL INFORMATION GI General Information
SM14E00-1ME0E E
B ELECTRIC POWER TRAIN TMS Traction Motor System
HCO High Voltage Cooling System
B
EVC EV Control System
EVB EV Battery System
VC Vehicle Charging System
ACC Accelerator Control System
D TRANSMISSION
& DRIVELINE
TM
FAX
Transaxle & Transmission
Front Axle C
RAX Rear Axle
E SUSPENSION FSU
RSU
Front Suspension
Rear Suspension
D
WT Road Wheels & Tires
F BRAKES BR
PB
Brake System
Parking Brake System E
BRC Brake Control System
G STEERING ST
STC
SB
Steering System
Steering Control System
Seat Belt
F
H RESTRAINTS
I VENTILATION, HEATER
SR
SRC
VTL
SRS Airbag
SRS Airbag Control System
Ventilation System
G
H
& AIR CONDITIONER HA Heater & Air Conditioning System
MODEL ME0 SERIES HAC Heater & Air Conditioning Control System
J BODY INTERIOR INT Interior
I
IP Instrument Panel
SE Seat
K BODY EXTERIOR, DOOR, DLK Door & Lock
ROOF & VEHICLE SECURITY
J
SEC Security Control System
GW Glass & Window System
PWC Power Window Control System
K
BRM Body Repair
EXT Exterior
L DRIVER CONTROLS MIR Mirrors
L
EXL Exterior Lighting System
INL Interior Lighting System
WW Wiper & Washer
DEF Defogger
HRN
VSP
Horn
Approaching Vehicle Sound for Pedestrians (VSP) M
M ELECTRICAL & PWO Power Outlet
POWER CONTROL BCS
LAN
PCS
Body Control System
LAN System
Power Control System
N
N DRIVER INFORMATION
& MULTIMEDIA
PG
MWI
WCS
Power Supply, Ground & Circuit Elements
Meter, Warning Lanp & Indicator
Warning Chime System
O
O CRUISE CONTROL
P MAINTENANCE
AV
CCS
MA
Audio, Visual & Navigation System
Cruise Control System
Maintenance
P
© 2014 NISSAN INTERNATIONAL SA
All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form,
or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan International
SA, Switzerland.
FOREWORD
This manual contains maintenance and repair procedures for the NISSAN
, model series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
fications and methods at any time without notice.
IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by NISSAN must
first be completely satisfied that neither personal safety nor the vehicle’s
safety will be jeopardized by the service method selected.
NISSAN INTERNATIONAL SA
Service Engineering Section
Paris, France
GENERAL INFORMATION
GI
GENERAL INFORMATION
SECTION GI B
E
CONTENTS
HOW TO USE THIS MANUAL ...................... 3 Precaution for Procedure without Cowl Top Cover....23 F
Precautions for Removing Battery Terminal ............23
HOW TO USE THIS MANUAL ............................ 3 General Precautions ................................................23
Description ................................................................ 3 Hoses ......................................................................25 G
Terms ........................................................................ 3 Air Conditioning .......................................................26
Units .......................................................................... 3
Contents .................................................................... 4 CAUTIONS AS TO HIGH VOLTAGE ................ 27
How to Disconnect High Voltage .............................27 H
Relation between Illustrations and Descriptions ...... 4
Components .............................................................. 4 High Voltage Precautions ........................................29
Check Voltage in High Voltage Circuit .....................31
HOW TO FOLLOW TROUBLE DIAGNOSES ..... 6 High Voltage Warning Label ....................................34 I
Description ................................................................ 6 Insulated Protective Wear and Insulating Tools ......35
How to Follow Test Groups in Trouble Diagnosis...... 6 Cautions for Scrapping Vehicles .............................35
Key to Symbols Signifying Measurements or Pro- Handling of a Vehicle with a Dead Battery ..............35 J
cedures ..................................................................... 7
LIFTING POINT ................................................. 36
HOW TO READ WIRING DIAGRAMS ................ 9 Commercial Service Tools .......................................36
Connector Symbols ................................................... 9 Garage Jack and Safety Stand and 2-Pole Lift .......36 K
Sample/Wiring Diagram -Example- ......................... 10 Board-On Lift ...........................................................37
Connector Information ............................................. 12
TOW TRUCK TOWING ..................................... 38
L
ABBREVIATIONS ..............................................14 Tow Truck Towing ...................................................38
Abbreviation List ...................................................... 14 Vehicle Recovery (Freeing a Stuck Vehicle) ...........38
TIGHTENING TORQUE OF STANDARD PROCEDURE FOR PARK LOCK / STEERING M
BOLTS ................................................................19 LOCK RELEASE ............................................... 40
Description .............................................................. 19 PROCEDURE FOR PARK LOCK/STEERING
Tightening Torque Table (New Standard Includ- LOCK RELEASE .....................................................40 N
ed) ........................................................................... 19
VEHICLE INFORMATION ........................... 42
PRECAUTION .............................................. 21
IDENTIFICATION INFORMATION .................... 42 O
PRECAUTIONS ..................................................21 Model Variation ........................................................42
Description .............................................................. 21 Information About Identification or Model Code ......42
Precaution for Technicians Using Medical Electric.... 21 Dimensions ..............................................................45 P
Point to Be Checked Before Starting Maintenance Wheels & Tires ........................................................45
Work ........................................................................ 21
Precaution for Supplemental Restraint System BASIC INSPECTION ................................... 46
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................. 21 SERVICE INFORMATION FOR ELECTRICAL
Precaution Necessary for Steering Wheel Rota- INCIDENT .......................................................... 46
tion after 12V Battery Disconnect ............................ 22 Work Flow ................................................................46
GI-1
Control Units and Electrical Parts ........................... 46 Wiring Diagram - CONSULT/GST CHECKING
Intermittent Incident ................................................ 47 SYSTEM - ............................................................... 57
Circuit Inspection .................................................... 49
INSPECTION AND ADJUSTMENT ................... 63
CONSULT/GST CHECKING SYSTEM .............. 55
Description .............................................................. 55 ADDITIONAL SERVICE WHEN REMOVING BAT-
CONSULT Function and System Application*1 ...... 55 TERY NEGATIVE TERMINAL .................................. 63
CONSULT/GST Data Link Connector (DLC) Cir- ADDITIONAL SERVICE WHEN REMOVING
cuit .......................................................................... 56 BATTERY NEGATIVE TERMINAL : Required
Procedure After Battery Disconnection ................... 63
GI-2
HOW TO USE THIS MANUAL
< HOW TO USE THIS MANUAL >
HOW TO USE THIS MANUAL GI
Description INFOID:0000000010411390
B
This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diag-
noses”.
C
Terms INFOID:0000000010411391
D
Item Description
To be used to inform an operation which will cause a death or serious personal injury if instructions
are not following.
DANGER E
Example: Touching high voltage components without using the appropriate protective equipment
will cause electrocution.
To be used to inform an operation which may cause a death or serious personal injury if instructions
WARNING
are not following. F
To be used to inform an operation which may cause personal injury or component damage if instruc-
CAUTION
tions are not following.
NOTE To be used to inform you helpful information. G
Give you helpful information.
BOLD STATEMENTS except • Standard value: Tolerance at inspection and adjustment.
DANGER, WARNING and NOTE • Limit value: The maximum or minimum limit value that should not be exceeded at inspection and H
adjustment.
Symbol Description I
It may cause an electric shock if instructions are not following to be used in caution for an operation.
Electric shock symbol To be used to describe the removal of component, connector, etc. where high voltage is/might be
present.
J
Insulated gloves Always wear when inspecting or performing service operation of high voltage components.
K
Insulated safety
Always wear when inspecting or performing service operation of high voltage components on lift-up
shoes/Insulated rub-
vehicle.
ber sheet
L
Always wear during under the circumstances
Face shield / • During removal/installation or check operation of high voltage terminals and harnessed where
Safety glasses spark might terminal appear by short circuit.
• Operation inside battery pack. M
Always use when performing high voltage presents operation such as operation inside high voltage
Insulated hand tools
battery pack.
N
Units INFOID:0000000010411392
O
• The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and
alternatively expressed in the metric system and in the yard/pound system.
Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the
standard tightening torque. P
“Example”
Range
Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
GI-3
Standard
Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)
Contents INFOID:0000000010411393
• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the
first page of each section by matching it to the section's black tab.
• THE CONTENTS are listed on the first page of each section.
• THE TITLE is indicated on the upper portion of each page and shows the part or system.
• THE PAGE NUMBER of each section consists of two or three letters which designate the particular section
and a number (e.g. “BR-5”).
• THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of
work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle
or transmission, etc. are presented in a step-by-step format where necessary.
Relation between Illustrations and Descriptions INFOID:0000000010411394
The following sample explains the relationship between the part description in an illustration, the part name in
the text and the service procedures.
JSAIA2307GB
Components INFOID:0000000010411395
• THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubri-
cation points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to
perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the appro-
priate PARTS CATALOG.
Components shown in an illustration may be identified by a circled number. When this style of illustration is
used, the text description of the components will follow the illustration.
GI-4
GI
JPFIA0511GB F
Cap Bleeder valve Cylinder body

Piston seal Piston Piston boot G
Sliding pin Sliding pin boot Bushing
Torque member
H
: Apply rubber grease.
: Apply brake fluid.
: N·m (kg-m, in-lb) I
: Always replace after every disassembly
SYMBOLS J
SAIA0749E
GI-5
HOW TO FOLLOW TROUBLE DIAGNOSES
NOTICE:
Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following
instructions before diagnosing.
• Before performing trouble diagnoses, read the “Work Flow” in each section.
• After repairs, re-check that the problem has been completely eliminated.
• Refer to Component Parts and Harness Connector Location for the Systems described in each section for
identification/location of components and harness connectors.
• When checking circuit continuity, ignition switch should be OFF.
• Refer to the Circuit Diagram for quick pinpoint check.
If you need to check circuit continuity between harness connectors in more detail, such as when a sub-har-
ness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identi-
fication of harness connectors.
• Before checking voltage at connectors, check battery voltage.
• After accomplishing the Diagnosis Procedures and Electrical Components Inspection, check that all harness
connectors are reconnected as they were.
How to Follow Test Groups in Trouble Diagnosis INFOID:0000000010411397
JPAIA0021GB
1. Test group number and test group title

• Test group number and test group title are shown in the upper portion of each test group.
2. Work and diagnosis procedure
• Start to diagnose a problem using procedures indicated in enclosed test groups.
3. Questions and results
• Questions and required results are indicated in test group.
4. Action
• Next action for each test group is indicated based on result of each question.
GI-6
Key to Symbols Signifying Measurements or Procedures INFOID:0000000010411398
GI
H
JPAIA0982GB
GI-7
JSAIA1461GB
GI-8
HOW TO READ WIRING DIAGRAMS
GI
Connector Symbols INFOID:0000000010957614
Most of connector symbols in wiring diagrams are shown from the terminal side. B
• Connector symbols shown from the terminal side are enclosed by
a single line and followed by the direction mark.
• Connector symbols shown from the harness side are enclosed by
a double line and followed by the direction mark. C
• Certain systems and components, especially those related to
OBD, may use a new style slide-locking type harness connector.
For description and how to disconnect, refer to PG section, D
“Description”, “HARNESS CONNECTOR”.
SAIA0257E
I
• Male and female terminals
Connector guides for male terminals are shown in black and
female terminals in white in wiring diagrams. J
SGI363
P
GI-9
Sample/Wiring Diagram -Example- INFOID:0000000010957615
Each section includes wiring diagrams.
JCAWA0150GB
Description
Number Item Description
Power supply • This means the power supply of fusible link or fuse.
Fuse • “/” means the fuse.

Current rating of fusible
• This means the current rating of the fusible link or fuse.
link/fuse
Number of fusible link/
• This means the number of fusible link or fuse location.
fuse
Fusible link • “X” means the fusible link.
• Alphabetic characters show to which harness the connector is placed.
Connector number
• Numeric characters show the identification number of connectors.
• This shows that continuity exists between terminals 1 and 2 when the switch is in the A posi-
Switch
tion. Continuity exists between terminals 1 and 3 when the switch is in the B position.
Circuit (Wiring) • This means the wiring.
GI-10
Number Item Description
GI
Shielded line • The line enclosed by broken line circle shows shield wire.
Connectors • This means that a transmission line bypasses two connectors or more.
Option abbreviation • This means the vehicle specifications which layouts the circuit between “ ”.
B
Relay • This shows an internal representation of the relay.
Optional splice • The open circle shows that the splice is optional depending on vehicle application. C
Splice • The shaded circle “ ” means the splice.
System branch • This shows that the circuit is branched to other systems.
D
Page crossing • This circuit continues to an adjacent page.
Component name • This shows the name of a component.

E
Terminal number • This means the terminal number of a connector.
Ground (GND) • This shows the ground connection.

Explation of option de- F
• This shows a description of the option abbreviation used on the page.
scription
SWITCH POSITIONS
G
Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition.
A vehicle is in the “normal” condition when:
• ignition switch is “OFF”
• doors, hood and trunk lid/back door are closed H
• pedals are not depressed
• parking brake is released
I
N
SGI860
MULTIPLE SWITCH
The continuity of multiple switch is described in two ways as shown below. O
• The switch chart is used in schematic diagrams.
GI-11
• The switch diagram is used in wiring diagrams.
JSAIA0017GB
Connector Information INFOID:0000000010957616
HOW TO USE CONNECTOR INFORMATION
JCAWA0152GB
GI-12
Description
Number Item Description GI
• Alphabetic characters show to which harness the connector is placed.
Connector number
• Numeric characters show the identification number of connectors.
B
: Connector model C
: Cavity
Connector type : Male (M) and female (F) terminals
: Connector color
D
: Special type
JPMIA0113GB
E
Terminal number • This means the terminal number of a connector.
• This shows a code for the color of the wire.
F
B = Black BR = Brown
W = White OR or O = Orange
R = Red P = Pink
G = Green PU or V (Violet) = Purple G
L = Blue GY or GR = Gray
Wire color Y = Yellow SB = Sky Blue
LG = Light Green CH = Dark Brown
H
BG or BE = Beige DG = Dark Green
LA = Lavender
• When the wire color is striped, the base color is given first, followed by the stripe color as
shown below: I
Example: L/W = Blue with White Stripe
• This means the connector information.
Connector
• This unit-side is described by the connector symbols. J
GI-13
ABBREVIATIONS
ABBREVIATIONS
Abbreviation List INFOID:0000000010411402
The following ABBREVIATIONS are used:

A
ABBREVIATION DESCRIPTION
A/C Air conditioner
A/C Air conditioning
A/F sensor Air fuel ratio sensor
A/T Automatic transaxle/transmission
ABS Anti-lock braking system
ACCS Advance climate control system
ACL Air cleaner
AP Accelerator pedal
APP Accelerator pedal position
ATF Automatic transmission fluid
AV Audio visual
AWD All wheel drive
B
BARO Barometric pressure
BCI Back-up collision intervention
BCM Body control module
BLSD Brake limited slip differential
BPP Brake pedal position
BSW Blind spot warning
C
CKP Crankshaft position
CL Closed loop
CMP Camshaft position
CPP Clutch pedal position
CTP Closed throttle position
CVT Continuously variable transaxle/transmission
D
D1 Drive range first gear
D2 Drive range second gear
D3 Drive range third gear
D4 Drive range fourth gear
DCA Distance control assist
DDS Downhill drive support
DFI Direct fuel injection system
DLC Data link connector
DTC Diagnostic trouble code
GI-14
ABBREVIATIONS
E
ABBREVIATION DESCRIPTION GI
E/T Exhaust temperature
EBD Electric brake force distribution
EC Engine control
B
ECL Engine coolant level

ECM Engine control module C
ECT Engine coolant temperature
ECV Electrical control valve
EEPROM Electrically erasable programmable read only memory D
EFT Engine fuel temperature
EGR Exhaust gas recirculation
E
EGRT Exhaust gas recirculation temperature
EGT Exhaust gas temperature
EOP Engine oil pressure F
EP Exhaust pressure
EPR Exhaust pressure regulator
G
EPS Electronically controlled power steering
ESP Electronic stability program system
EVAP canister Evaporative emission canister H
EVSE Electric vehicle supply equipment
EXC Exhaust control
I
F
FC Fan control
J
FCW Forward collision warning
FEB Forward emergency braking
FIC Fuel injector control K
FP Fuel pump
FR Front
L
FRP Fuel rail pressure
FRT Fuel rail temperature
FTP Fuel tank pressure M
FTT Fuel tank temperature
G
N
GND Ground
GPS Global positioning system O
GST Generic scan tool
H
ABBREVIATION DESCRIPTION P
HBMC Hydraulic body-motion control system
HDD Hard disk drive
HO2S Heated oxygen sensor
HOC Heated oxidation catalyst
HPCM Hybrid power train control module
GI-15
ABBREVIATIONS
I
I/M Inspection and maintenance
IA Intake air
IAC Idle air control
IAT Intake air temperature
IBA Intelligent brake assist
IC Ignition control
ICC Intelligent cruise control
ICM Ignition control module
IPDM E/R Intelligent power distribution module engine room
ISC Idle speed control
ISS Input shaft speed
K
KS Knock sensor
L
LBC Li-ion battery controller
LCD Liquid crystal display
LCU Local control unit
LDP Lane departure prevention
LDW Lane departure warning
LED Light emitting diode
LH Left-hand
LIN Local interconnect network
M
M/T Manual transaxle/transmission
MAF Mass airflow
MAP Manifold absolute pressure
MDU Multi display unit
MI Malfunction indicator
MIL Malfunction indicator lamp
N
NOX Nitrogen oxides
O
O2 Oxygen
O2S Oxygen sensor
OBD On board diagnostic
OC Oxidation catalytic converter
OD Overdrive
OL Open loop
OSS Output shaft speed
GI-16
ABBREVIATIONS
P
ABBREVIATION DESCRIPTION GI
P/S Power steering
PBR Potentio balance resistor
PCV Positive crankcase ventilation
B
PFCW Predictive forward collision warning

PNP Park/Neutral position C
PSP Power steering pressure
PTC Positive temperature coefficient
PTO Power takeoff D
PWM Pulse width modulation
R E
RAM Random access memory
RAS Rear active steer F
RH Right-hand
ROM Read only memory
G
RPM Engine speed
RR Rear
S H
SAE Society of Automotive Engineers, Inc.
SCK Serial clock I
SDS Service Data and Specifications
SRT System readiness test
J
SST Special Service Tools
T
ABBREVIATION DESCRIPTION K
TC Turbocharger
TCM Transmission control module
L
TCS Traction control system
TCU Telematics communication unit
TP Throttle position M
TPMS Tire pressure monitoring system
TSS Turbine shaft speed
TWC Three way catalytic converter N
U
O
USS Uphill start support
V
ABBREVIATION DESCRIPTION P
VCM Vehicle control module
VDC Vehicle dynamics control system
VIN Vehicle identification number
VSS Vehicle speed sensor
GI-17
ABBREVIATIONS
W
WOT Wide open throttle
1
11 1st range first gear
12 1st range second gear
1GR First gear
2
21 2nd range first gear
22 2nd range second gear
2GR Second gear
2WD 2-wheel drive
3
3GR Third gear
4
4GR Fourth gear
4WAS Four wheel active steer
4WD Four wheel drive
5
5GR Fifth gear
6
6GR Sixth gear
7
7GR Seventh gear
GI-18
TIGHTENING TORQUE OF STANDARD BOLTS
GI
This vehicle has both new standard based on ISO* and previous standard bolts/nuts. There are some differ- B
ences between these two types of bolts/ nuts; shape of the head, grade of strength, hexagonal width across
flats and the standard tightening torque.
• For guidance in discriminating, refer to GI-19, "Tightening Torque Table (New Standard Included)".
• The new standard machine screws and tapping screws have a head of ISO standard torx recess. C
• If the tightening torque is not described in the description or figure, refer to GI-19, "Tightening Torque Table
(New Standard Included)".
*ISO: International Organization for Standardization D
Tightening Torque Table (New Standard Included) INFOID:0000000010411404
CAUTION: E
• The special parts are excluded.
• The bolts/nuts in these tables have a strength (discrimination) number/symbol assigned to the head
or the like. As to the relation between the strength grade in these tables and the strength (discrimi-
F
nation) number/symbol, refer to “DISCRIMINATION OF BOLTS AND NUTS”.
PREVIOUS STANDARD
G
Hexagonal Tightening torque (Without lubricant)
Grade Bolt di-
Bolt width Pitch
(Strength ameter Hexagon head bolt Hexagon flange bolt H
size across flats mm
grade) mm
mm N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb
M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62
1.25 13.5 1.4 10 — 17 1.7 13 — I
M8 8.0 12
1.0 13.5 1.4 10 — 17 1.7 13 —
1.5 28 2.9 21 — 35 3.6 26 —
4T M10 10.0 14 J
1.25 28 2.9 21 — 35 3.6 26 —
1.75 45 4.6 33 — 55 5.6 41 —
M12 12.0 17
1.25 45 4.6 33 — 65 6.6 48 — K
M14 14.0 19 1.5 80 8.2 59 — 100 10 74 —
M6 6.0 10 1.0 9 0.92 7 80 11 1.1 8 97
L
1.25 22 2.2 16 — 28 2.9 21 —
M8 8.0 12
1.0 22 2.2 16 — 28 2.9 21 —
1.5 45 4.6 33 — 55 5.6 41 — M
7T M10 10.0 14
1.25 45 4.6 33 — 55 5.6 41 —
1.75 80 8.2 59 — 100 10 74 —
M12 12.0 17 N
1.25 80 8.2 59 — 100 10 74 —
M14 14.0 19 1.5 130 13 96 — 170 17 125 —
M6 6.0 10 1.0 11 1.1 8 — 13.5 1.4 10 — O
1.25 28 2.9 21 — 35 3.6 26 —
M8 8.0 12
1.0 28 2.9 21 — 35 3.6 26 —
1.5 55 5.6 41 — 80 8.2 59 — P
9T M10 10.0 14
1.25 55 5.6 41 — 80 8.2 59 —
1.75 100 10 74 — 130 13 96 —
M12 12.0 17
1.25 100 10 74 — 130 13 96 —
M14 14.0 19 1.5 170 17 125 — 210 21 155 —
CAUTION:
GI-19
The parts with aluminum or the cast iron washer surface/thread surface are excluded.
NEW STANDARD BASED ON ISO
Hexagonal Tightening torque

Grade Bolt di-
Bolt width Pitch
(Strength ameter Hexagon head bolt Hexagon flange bolt
size across flats mm
grade) mm
mm N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb
M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62
1.25 13.5 1.4 10 — 17 1.7 13 —
M8 8.0 13
1.0 13.5 1.4 10 — 17 1.7 13 —
4.8 1.5 28 2.9 21 — 35 3.6 26 —
(Without M10 10.0 16
lubricant) 1.25 28 2.9 21 — 35 3.6 26 —
1.75 45 4.6 33 — 55 5.6 41 —
M12 12.0 18
1.25 45 4.6 33 — 65 6.6 48 —
M14 14.0 21 1.5 80 8.2 59 — 100 10 74 —
M6 6.0 10 1.0 4 0.41 3 35 5.5 0.56 4 49
1.25 11 1.1 8 — 13.5 1.4 10 —
M8 8.0 13
1.0 11 1.1 8 — 13.5 1.4 10 —
4.8 1.5 22 2.2 16 — 28 2.9 21 —
(With lu- M10 10.0 16
bricant) 1.25 22 2.2 16 — 28 2.9 21 —
1.75 35 3.6 26 — 45 4.6 33 —
M12 12.0 18
1.25 35 3.6 26 — 45 4.6 33 —
M14 14.0 21 1.5 65 6.6 48 — 80 8.2 59 —
M6 6.0 10 1.0 8 0.82 6 71 10 1.0 7 89
1.25 21 2.1 15 — 25 2.6 18 —
M8 8.0 13
1.0 21 2.1 15 — 25 2.6 18 —
8.8 1.5 40 4.1 30 — 50 5.1 37 —
(With lu- M10 10.0 16
bricant) 1.25 40 4.1 30 — 50 5.1 37 —
1.75 70 7.1 52 — 85 8.7 63 —
M12 12.0 18
1.25 70 7.1 52 — 85 8.7 63 —
M14 14.0 21 1.5 120 12 89 — 140 14 103 —
M6 6.0 10 1.0 10 1.0 7 89 12 1.2 9 106
1.25 27 2.8 20 — 32 3.3 24 —
M8 8.0 13
1.0 27 2.8 20 — 32 3.3 24 —
10.9 1.5 55 5.6 41 — 65 6.6 48 —
(With lu- M10 10.0 16
bricant) 1.25 55 5.6 41 — 65 6.6 48 —
1.75 95 9.7 70 — 110 11 81 —
M12 12.0 18
1.25 95 9.7 70 — 110 11 81 —
M14 14.0 21 1.5 160 16 118 — 180 18 133 —
CAUTION:
1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. Friction coeffi-
cient stabilizer is applied to the new standard bolts/nuts.
2. However, use tightening torque without lubricant for the following cases. Friction coefficient stabi-
lizer is not applied to the following bolts/nuts.
- Grade 4.8, M6 size bolt, Conical spring washer installed
- Paint removing nut (Size M6 and M8) for fixing with weld bolt
GI-20
PRECAUTIONS
< PRECAUTION >
PRECAUTION GI
PRECAUTIONS
B
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
C
Precaution for Technicians Using Medical Electric INFOID:0000000010411416
OPERATION PROHIBITION D
WARNING:
• Parts with strong magnet is used in this vehicle.
• Technicians using a medical electric device such as pacemaker must never perform operation on the E
vehicle, as magnetic field can affect the device function by approaching to such parts.
NORMAL CHARGE PRECAUTION
WARNING: F
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an
implantable cardioverter defibrillator, the possible effects on the devices must be checked with the
device manufacturer before starting the charge operation. G
• As radiated electromagnetic wave generated by PDM (Power Delivery Module) at normal charge
operation may affect medical electric devices, a technician using a medical electric device such as
implantable cardiac pacemaker or an implantable cardioverter defibrillator must not approach motor
room [PDM (Power Delivery Module)] at the hood-opened condition during normal charge operation. H
PRECAUTION AT TELEMATICS SYSTEM OPERATION

WARNING: I
• 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.
• The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or J
the implantable cardioverter defibrillator (ICD), when using the service, etc.
• 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 K
device. The possible effects on the devices must be checked with the device manufacturer before
TCU use.
PRECAUTION AT INTELLIGENT KEY SYSTEM OPERATION L
WARNING:
avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from inte- M
• 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
N
switch operation, or at engine starting.
able cardioverter defibrillator (ICD), the electromagnetic wave of Intelligent Key might affect the
function of the device. The possible effects on the devices must be checked with the device manu- O
facturer before Intelligent Key use.
Point to Be Checked Before Starting Maintenance Work INFOID:0000000010411417
P
The high voltage system may starts automatically. It is required to check that the timer air conditioner
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
automatically even when the power switch is in OFF state.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
GI-21
PRECAUTIONS
< PRECAUTION >
PRE-TENSIONER" INFOID:0000000011002883
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. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• 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 “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
power switch ON, never 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.
• When using air or electric power tools or hammers, always switch the power switch OFF, disconnect
the 12V battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation after 12V Battery Disconnect
INFOID:0000000010411419
For vehicle with steering lock unit, if the 12V battery is disconnected or discharged, the steering wheel will lock
and cannot be turned.
If turning the steering wheel is required with the 12V battery disconnected or discharged, follow the operation
procedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both 12V battery cables.
NOTE:
Supply power using jumper cables if 12V battery is discharged.
2. Turn the power switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both 12V battery cables. The steering lock will remain released with both 12V battery cables
disconnected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both 12V battery cables. With the brake pedal released,
turn the power switch from ACC position to ON position, then to LOCK position. (The steering wheel will
lock when the power switch is turned to LOCK position.)
6. Perform All DTC Reading using CONSULT and delete DTC.
NOTE:
Multiple DTCs are detected when 12V battery cable is disconnected while power switch is in ACC posi-
tion.
GI-22
PRECAUTIONS
< PRECAUTION >
Precaution for Procedure without Cowl Top Cover INFOID:0000000010411420
GI
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. B
D
PIIB3706J
Precautions for Removing Battery Terminal INFOID:0000000010411421

E
• When removing the 12V battery terminal, turn OFF the power
switch and wait at least 5 minutes.
NOTE: F
ECU may be active for several minutes after the power switch is
turned OFF. If the battery terminal is removed before ECU stops,
then a DTC detection error or ECU data corruption may occur.
• Always disconnect the battery terminal within 60 minutes after G
turning OFF the power switch. Even when the power switch is
OFF, the 12V battery automatic charge control may automatically
start after a lapse of 60 minutes from power switch OFF. H
• Disconnect 12V battery terminal according to the following steps.
SEF289H
WORK PROCEDURE
I
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-
J
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.
K
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 terminal within 60 minutes after turning the power switch OFF → ON → OFF. L
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. M
• 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.
NOTE:
Once the power switch is turned ON → OFF, the 12V battery automatic charge control does not start for N
approximately 1 hour.
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the power switch. O
NOTE:
If the power switch is turned ON with any one of the terminals of main battery and sub battery disconnected,
then DTC may be detected. P
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
General Precautions INFOID:0000000010411429
• Keep the work area well ventilated and free of any inflammable materials. Special care should be taken
when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When work-
GI-23
PRECAUTIONS
< PRECAUTION >
ing in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous
materials.
Do not smoke while working on the vehicle.
• Before jacking up the vehicle, apply wheel chocks or other tire

blocks to the wheels to prevent the vehicle from moving. After jack-
ing up the vehicle, support the vehicle weight with safety stands at
the points designated for proper lifting before working on the vehi-
cle.
These operations should be done on a level surface.
• When removing a heavy component such as the motor or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
SGI231
• Before starting repairs which do not require battery power:

Turn off power switch.
Disconnect the negative battery terminal.
• If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
• For vehicles with two batteries, be sure to remove both batteries
when instructed to remove 12V battery in the service manual. If
specified as main battery or sub battery, then do as instructed.
SEF289H
• To prevent serious burns:

Avoid contact with hot metal parts.
Do not remove the radiator cap when the motor is hot.
• Dispose of drained oil or the solvent used for cleaning parts in an
appropriate manner.
• Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
• Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
• Replace inner and outer races of tapered roller bearings and nee-
dle bearings as a set.
SGI233
• Arrange the disassembled parts in accordance with their assem-
bled locations and sequence.
• Do not touch the terminals of electrical components which use microcomputers (such as VCM).
Static electricity may damage internal electronic components.
• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents when required.
• Use hand tools, power tools (disassembly only) and recommended
special tools where specified for safe and efficient service repairs.
• When repairing the water, check all affected lines for leakage.
JPAIA0335ZZ
GI-24
PRECAUTIONS
< PRECAUTION >
• Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate covers. GI
Take caution that keys, buckles or buttons do not scratch paint.
SGI234
D
WARNING:
To prevent VCM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module) E
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EVC and TM sections.
Hoses INFOID:0000000010411430 F
HOSE REMOVAL AND INSTALLATION

• To prevent damage to rubber hose, do not pry off rubber hose with G
tapered tool or screwdriver.
SMA019D
J
• To reinstall the rubber hose securely, check that hose insertion

length and orientation is correct. (If tube is equipped with hose K
stopper, insert rubber hose into tube until it butts up against hose
stopper.)
L
SMA020D
N
HOSE CLAMPING
• If old rubber hose is re-used, install hose clamp in its original posi-
tion (at the indentation where the old clamp was). If there is a trace
of tube bulging left on the old rubber hose, align rubber hose at O
that position.
• Discard old clamps; replace with new ones.
P
SMA021D
GI-25
PRECAUTIONS
< PRECAUTION >
• After installing plate clamps, apply force to them in the direction of
the arrow, tightening rubber hose equally all around.
SMA022D
Air Conditioning INFOID:0000000010411431
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
HA section “REFRIGERANT” for specific instructions.
GI-26
CAUTIONS AS TO HIGH VOLTAGE
< PRECAUTION >
GI
How to Disconnect High Voltage INFOID:0000000011061786
PROCEDURE FOR DISCONNECTING HIGH VOLTAGE B

Be sure to follow the procedure below and disconnect the high voltage before performing inspection or servic-
ing of the high voltage system.
1. Turn power switch OFF. C
CAUTION:
The worker must keep the intelligent key on his/her person.
2. Disconnect 12V battery negative terminal. D
3. Remove console mask cover.
a. Apply protective tape (A) on console body assembly to protect it
from damage. E
JMJIB0266ZZ
H
b. Disengage fixing pawls using a remover tool (A), and then
remove console mask cover.
I
: Pawl
K
JMJIB0267ZZ
4. Remove fixing screw and disengage fixing metal clips, and

then remove front console assembly. L
: Metal clip
M
JMJIB0268ZZ
O
GI-27
< PRECAUTION >
5. Remove the access cover bolts and remove the cover .
:Vehicle front
JSCIA1194ZZ
6. Remove service plug as follows.
ALAIA0088ZZ
DANGER:
Touching high voltage components without using the appropriate protective equipment will
cause electrocution.
WARNING:
• Immediately insulate removed high voltage connectors and terminals with insulating tape.
• Be sure to put the removed service plug in your pocket and carry it with you so that another per-
son does not accidentally connect it while work is in progress.
7. After removing the service plug, immediately wind the insulation tape around the terminal on the Li-ion
battery side.
• If available, install service lockout plug [SST:NI-4031( — )]
and lock it with the key.
DANGER:
Touching high voltage components without using the

appropriate protective equipment will cause electrocution.
JSCIA1303ZZ
8. Wait for a minimum of approximately 10 minutes after the service plug is removed.
PROCEDURE FOR CONNECTING HIGH VOLTAGE
1. Check that 12V battery negative terminal is disconnected.
GI-28
< PRECAUTION >
2. Install service plug as per the following steps.
GI
ALAIA0089ZZ
DANGER: D
E
WARNING: F
son does not accidentally connect it while work is in progress. G
3. Connect 12V battery negative terminal.
High Voltage Precautions INFOID:0000000010957968
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.
K
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
the tool box during the procedure to prevent the plug from being connected by mistake.
• Be sure to wear insulated protective equipment before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage L
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu-
lating sheet except when using them.
CAUTION: M
• Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace
it with a new clip before installing.
• Take care that coolant does not contact the high voltage harness connectors. If coolant contacts a
high voltage harness connector, immediately dry the high voltage connector completely with an air N
blow gun.
• 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. O
POINT TO BE CHECKED BEFORE STARTING MAINTENANCE WORK
The high voltage system may starts automatically. It is required to check that the EVSE is not con-
nected to charge port before starting maintenance work. P
NOTE:
If the timer air conditioner or timer charge is set when the EVSE is connected, the high voltage system starts
HIGH VOLTAGE HARNESS AND EQUIPMENT IDENTIFICATION
All the high voltage harnesses and connectors are orange. The Li-ion battery and other high voltage devices
include an orange high voltage label. Never touch these harnesses and high voltage parts.
GI-29
< PRECAUTION >
HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS
Immediately insulate disconnected high voltage connectors and terminals with insulating tape.
REGULATIONS ON WORKERS WITH MEDICAL ELECTRONICS
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-
nets. Such persons must not perform work on the vehicle.
PROHIBITED ITEMS TO CARRY DURING THE WORK
Hybrid vehicles and electric vehicles contain parts with high voltage and intense magnetic force. Never carry
metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage
parts. If this is not observed, the metal products may create a risk of short circuit and the magnetic recording
media may lose their magnetic recording.
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT”
GI-30
< PRECAUTION >
Indicate "HIGH VOLTAGE. DO NOT TOUCH" on the vehicle under repair/inspection to call attention to other
workers. GI
JSAIA1600GB P
Check Voltage in High Voltage Circuit INFOID:0000000011061787
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
GI-31
< PRECAUTION >
maintenance.
WARNING:
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
• Refer to EVB-569, "High Voltage Precautions".
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.
INSPECTION
WARNING:
Disconnect high voltage. Refer to EVB-567, "How to Disconnect High Voltage".
1. Lift up the vehicle and remove the Li-ion battery under cover (front). Refer to EVB-786, "Removal and
Installation".
2. 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.
• Because there is the danger of electric shock, imme- JSCIA1070ZZ

diately insulate disconnected high voltage connectors
and terminals with insulating tape.
• Follow the procedure below to disconnect the high-voltage harness connector.
JSCIA1328ZZ
3. Disconnect the Li-ion battery heater harness connector .

DANGER:

tective gear.
JSCIA1071ZZ
GI-32
< PRECAUTION >
• Because there is the danger of electric shock, immediately insulate disconnected high volt- GI
age connectors and terminals with insulating tape.
• Follow the procedure below to disconnect the PTC heater harness connector. B
JSCIA1329ZZ
E
4. Measure voltage between high voltage harness connector terminals and high voltage harness connector
terminals for PTC heater.
DANGER: F
G
JSCIA1195ZZ
K
Standard : 5 V or less
CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher. L
GI-33
< PRECAUTION >
High Voltage Warning Label INFOID:0000000010411434
LOCATION TO APPLY HIGH VOLTAGE WARNING LABEL
JSAIA3647ZZ
No. Position to apply Refer to

FOR EUROPE HA-18, "High Voltage Warning Label"
PTC elements heater
EXCEPT FOR EUROPE HA-85, "High Voltage Warning Label"
Electric compressor
Traction motor TMS-15, "High Voltage Warning Label"
WITHOUT BATTERY COOLER EVB-33, "High Voltage Warning Label"
WITH BATTERY COOLER EVB-303, "High Voltage Warning Label"
Li-ion battery
WITH BATTERY HEATER &
EVB-589, "High Voltage Warning Label"
COOLER
PDM (Power Delivery Module) VC-17, "High Voltage Warning Label"
Service plug
COOLER
Li-ion battery controller
COOLER
CAUTION:
At times such as when a part was replaced, or when a label had become peeled, be sure to apply the new product label in the
same position and facing in the same direction.
GI-34
< PRECAUTION >
Insulated Protective Wear and Insulating Tools INFOID:0000000010411435
GI
PROTECTIVE WEAR CONTROL
• Perform an inspection before beginning work, and do not use any items where abnormalities are found.
B
DAILY INSPECTION
This inspection is performed before and after use, the worker in responsible who will directly use the items
inspects them and checks for deterioration and damage.
• Insulated gloves C
Inspect the insulated gloves for scratches, holes, and tears. (Visual check and air leakage test)
JPCIA0061ZZ H
: Hold glove and fold as shown in the figure.

: Fold three or four more times, preventing air from escaping from the glove. I
: Squeeze glove to check that the glove has no holes.
• Insulated safety shoes J

Inspect the insulated safety boots for holes, damage, nails, metal pieces, wear or other problems on the
soles. (Visual check)
• Insulated rubber sheet
Inspect the insulated rubber sheet for tears. (Visual inspection) K
INSULATING TOOLS
When performing work at locations where high voltage is applied (such as terminals), use insulated tools.
L
HANDLING OF INSULATION RESISTANCE TESTER
CAUTION:
Unlike the ordinary tester, the insulation resistance tester applies 500V when measuring. If used incor- M
rectly, 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.
N
Cautions for Scrapping Vehicles INFOID:0000000010411436
The Li-ion battery must be removed from the vehicle before the vehicle is scrapped.
CAUTION: O
Insulate the terminals of the removed Li-ion battery with insulating tape.
Handling of a Vehicle with a Dead Battery INFOID:0000000010411437
P
For the handling of a vehicle when the battery is dead, refer to GI-38, "Tow Truck Towing".
GI-35
LIFTING POINT
< PRECAUTION >
LIFTING POINT
Commercial Service Tools INFOID:0000000010411438
Tool name Description
Board on attachment
S-NT001
Safety stand attachment
S-NT002
CAUTION:
• Every time the vehicle is lifted up, maintain the complete vehicle curb condition.
• Since the vehicle's center of gravity changes when removing main parts on the front side (engine,
transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission
jack or equivalent.
• Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle,
suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equiv-
alent.
• Be careful not to smash or never do anything that would affect piping parts.
Garage Jack and Safety Stand and 2-Pole Lift INFOID:0000000010411439
WARNING:
• Park the vehicle on a level surface when using the jack. Check to avoid damaging pipes, tubes, etc.
under the vehicle.
• Never get under the vehicle while it is supported only by the jack. Always use safety stands when
you have to get under the vehicle.
• Place wheel chocks at both front and back of the wheels on the ground.
• When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of
the vehicle are well balanced.
• When setting the lift arm, never allow the arm to contact the brake tubes, brake cable, fuel lines and
sill spoiler.
GI-36
LIFTING POINT
< PRECAUTION >
GI
JMAIA1223ZZ F
Safety stand point and lift up point (front) Safety stand point and lift up point Garage jack point (front)
(rear)
G
Garage jack point (rear)
Board-On Lift INFOID:0000000010411440

H
CAUTION:
Check vehicle is empty when lifting.
• The board-on lift attachment (A) set at front end of vehicle I
should be set on the front of the sill under the front door
opening.
• Position attachments at front and rear ends of board-on lift.
J
: Vehicle front
JMAIA0004ZZ L
GI-37
TOW TRUCK TOWING
< PRECAUTION >
TOW TRUCK TOWING
Tow Truck Towing INFOID:0000000010411441
CAUTION:
• All applicable state or Provincial laws and local laws regarding the towing operation must be
obeyed.
• It is necessary to use proper towing equipment to avoid possible damage to the vehicle during tow-
ing operation. Towing instructions are available from a NISSAN certified e–NV200 dealer.
• Always attach safety chains before towing.
• When towing, make sure that the axles, steering system and powertrain are in working condition. If
any unit is damaged, a flatbed must be used.
JMAIA1225ZZ
• NISSAN recommends that the vehicle be towed with the driving (front) wheels off the ground or that
the vehicle be placed on a flatbed truck as illustrated.
Vehicle Recovery (Freeing a Stuck Vehicle) INFOID:0000000010411442
FRONT
Securely install the vehicle recovery hook stored with jacking tools.
Check that the hook is properly secured in the stored place after use.
WARNING:
• Stand clear of a stuck vehicle.
• Never spin your tires at high speed. This could cause them to
explode and result in serious injury. Parts of your vehicle
could also overheat and be damaged.
CAUTION:
• Tow chains or cables must be attached only to the vehicle
recovery hooks or main structural members of the vehicle.
Otherwise, the vehicle body will be damaged. JMAIA1221ZZ
• Never use the vehicle tie downs to free a vehicle stuck in
sand, snow, mud, etc. Never tow the vehicle using the vehicle tie downs or recovery hooks.
• Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle.
• Pulling devices should be routed so they never touch any part of the suspension, steering, brake or
cooling systems.
• Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or
recovery.
REAR
Rrcovery Hook
GI-38
TOW TRUCK TOWING
< PRECAUTION >
Securely install the vehicle recovery hook stored with jacking tools.
Check that the hook is properly secured in the stored place after use. GI
WARNING:
• Stand clear of a stuck vehicle.
• Never spin your tires at high speed. This could cause them to B
explode and result in serious injury. Parts of your vehicle
could also overheat and be damaged.
CAUTION:
• Tow chains or cables must be attached only to the vehicle C
recovery hooks or main structural members of the vehicle.
Otherwise, the vehicle body will be damaged. JMAIA1224ZZ
• Never use the vehicle tie downs to free a vehicle stuck in D
sand, snow, mud, etc. Never tow the vehicle using the vehicle tie downs or recovery hooks.
• Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle.
• Pulling devices should be routed so they never touch any part of the suspension, steering, brake or
cooling systems. E
• Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or
recovery.
F
Rear Hook
WARNING:
• Rear hook is not available. G
JMAIA1222ZZ
J
GI-39
PROCEDURE FOR PARK LOCK / STEERING LOCK RELEASE
< PRECAUTION >
PROCEDURE FOR PARK LOCK/STEERING LOCK RELEASE INFOID:0000000010411443
CAUTION:
If the vehicle must be unavoidably moved with front wheel on the ground or four wheel on the ground,
release the park lock and hold the park lock in the released status (N position). The park lock is acti-
vated when power switch is OFF. Always perform the following work so that the N position status is
maintained. If the vehicle is moved without performing the following work, serious accident may be
caused. Steering lock does not operate after performing this work. Be careful that the brake effective-
ness is reduced and steering operation becomes heavy.
1. Turn power switch ON (Press power switch twice without depressing brake pedal). At this moment, check
that electric parking brake is operated.
2. Shift selector lever from the P position to the N position (Depress brake pedal while all doors are closed,
and then release the P position).
3. Remove the following fuse.
• PBW MTR
JMAIA1139GB
PBW MTR
GI-40
< PRECAUTION >
• METER 1
GI
H
JMAIA1125ZZ
Fuse block METER 1 fuse

I
4. Release electric parking brake.
5. Turn power switch OFF. (Release brake pedal)
6. Move the vehicle while power switch is OFF. J
7. Fix the vehicle after moving. (Using electric parking brake or tire stopper)
8. Install fuse that is removed.
K
9. Turn power switch ON (Press switch twice without depressing brake pedal) and wait for 5 seconds at this
moment, maintain the shift position to the N position. (Charge 12V battery if its voltage is low)
10. Turn power switch OFF. (Wait for 5 seconds)
L
GI-41
IDENTIFICATION INFORMATION
< VEHICLE INFORMATION >
VEHICLE INFORMATION
Model Variation INFOID:0000000010411405
Destination Body Motor Axle Handle Transmission Grade Model

V YSDARD9-BQA
5-door Van
A YSDARG9-BQA
RHD V TSDARD9-BQA
5-door Wagon A TSDARG9-BQA
Ludoup TSDARQ9-BQA
V YSDALD9-BQA
Europe 5-door Van
A YSDALG9-BQA
EM57 2WD Reduction gear V TSDALD9-BQA
5-door Wagon LHD A TSDALG9-BQA
Ludoup TSDALQ9-BQA
V HSDALD9-BQA
4-door Van
A HSDALG9-BQA
Australia 5-door Van V YSDARD9-BWA
RHD Ludoup TSDARQ9-BWK
Hong kong 5-door Wagon
Ludost TSDARP9-BWK
Model variation code (Prefix and suffix designations)
JSAIA3598GB
Information About Identification or Model Code INFOID:0000000010411406
IDENTIFICATION NUMBER
GI-42
GI
JSAIA3599ZZ F
Vehicle identification number plate Vehicle identification label Tire placard

(Driver side)
G
Vehicle identification number Air conditioner specification label
(Chassis number)
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT H
M
JSAIA3648GB
IDENTIFICATION PLATE
N
For Europe
JSAIA3600ZZ
GI-43
Type approval number Vehicle identification number Maximum vehicle weight

Maximum train weight Maximum front axle load Maximum rear axle load
Type
For Australia
JSAIA3600ZZ
Built date Vehicle identification number Maximum vehicle weight

Maximum train weight Maximum front axle load Maximum rear axle load
Type
For Hong Kong
JSAIA3601ZZ
Vehicle identification number Maximum vehicle weight Maximum train weight

Maximum front axle load Maximum rear axle load Type
MOTOR SERIAL NUMBER
JSCIA1111ZZ
GI-44
Dimensions INFOID:0000000010411407
GI
Unit: mm (in)
Overall length 4,560 (179.5)

Overall width 1,755 (69.1)
B
1,850 (72.8)*1
Overall height
1,855 (73.0)*2
C
Front tread 1,530 (60.2)
Rear tread 1,530 (60.2)
Wheelbase 2,725 (107.3) D
*1: Wagon models
*2: Van models
E
Wheels & Tires INFOID:0000000010411408
F
Tire 185/65R15 92H XL
Road wheel Size 15 × 6J

(Steel) Inset 45 mm (1.77in) G
Conventional
Tire 185/65R15 92H XL
Road wheel Size 15 × 6J

(Aluminum) H
Inset 45 mm (1.77in)
GI-45
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
< BASIC INSPECTION >
BASIC INSPECTION
Work Flow INFOID:0000000010411444
WORK FLOW
SGI838
STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHAT Vehicle Model, Motor, Transmission/Transaxle and the System (i.e. Radio).
STEP 1 WHEN Date, Time of Day, Weather Conditions, Frequency.
WHERE Road Conditions, Altitude and Traffic Situation.
System Symptoms, Operating Conditions (Other Components Interaction).
HOW
Service History and if any After Market Accessories have been installed.
Operate the system, road test if necessary.
STEP 2 Verify the parameter of the incident.
If the problem cannot be duplicated, refer to “Incident Simulation Tests”.
Get the proper diagnosis materials together including:
• Power Supply Routing
• System Operation Descriptions
STEP 3
• Applicable Service Manual Sections
• Check for any Service Bulletins
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
Inspect the system for mechanical binding, loose connectors or wiring damage.
STEP 4 Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Lay-
outs.
STEP 5 Repair or replace the incident circuit or component.
Operate the system in all modes. Verify the system works properly under all conditions. Check you have not inadvert-
STEP 6
ently created a new incident during your diagnosis or repair steps.
Control Units and Electrical Parts INFOID:0000000010411445
PRECAUTIONS
• Never reverse polarity of battery terminals.
• Install only parts specified for a vehicle.
• Before replacing the control unit, check the input and output and functions of the component parts.
• Do not apply excessive force when disconnecting a connector.
GI-46
• Do not apply excessive shock to the control unit by dropping or hit-
ting it. GI
• Be careful to prevent condensation in the control unit due to rapid
temperature changes and do not let water or rain get on it. If water
is found in the control unit, dry it fully and then install it in the vehi-
B
cle.
• Be careful not to let oil to get on the control unit connector.
• Avoid cleaning the control unit with volatile oil.
• Do not disassemble the control unit, and do not remove the upper C
and lower covers.
SAIA0255E
D
• When using a DMM, be careful not to let test probes get close to
each other to prevent the power transistor in the control unit from
damaging battery voltage because of short circuiting. E
• When checking input and output signals of the control unit, use the
specified check adapter.
F
JMCIA0152GB
K
Intermittent Incident INFOID:0000000010411446
DESCRIPTION L
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The fol-
lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an M
electrical incident.
The section is broken into the six following topics:
• Vehicle vibration N
• Heat sensitive
• Freezing
• Water intrusion O
• Electrical load
• Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem. P
VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when motor is vibrating (idle with A/
C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration.
Connector & Harness
GI-47
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-
mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
Sensor & Relay
Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
SGI839
Motor Compartment
There are several reasons a vehicle or motor vibration could cause an electrical complaint. Some of the things
to check for are:
• Connectors not fully seated.
• Wiring harness not long enough and is being stressed due to motor vibrations or rocking.
• Wires laying across brackets or moving components.
• Loose, dirty or corroded ground wires.
• Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the
wiring for continuity.
Behind the Instrument Panel
An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehi-
cle vibration can aggravate a harness which is routed along a bracket or near a screw.
Under Seating Areas
An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)
during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or
pinching.
HEAT SENSITIVE
• The customer's concern may occur during hot weather or after car
has sat for a short time. In such cases you will want to check for a
heat sensitive condition.
• To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
CAUTION:
Never heat components above 60°C (140°F).
• If incident occurs while heating the unit, either replace or properly
insulate the component.
SGI842
FREEZING
GI-48
• The customer may indicate the incident goes away after the car
warms up (winter time). The cause could be related to water freez- GI
ing somewhere in the wiring/electrical system.
• There are two methods to check for this. The first is to arrange for
the owner to leave his car overnight. Check it will get cold enough
B
to demonstrate his complaint. Leave the car parked outside over-
night. In the morning, do a quick and thorough diagnosis of those
electrical components which could be affected.
• The second method is to put the suspect component into a freezer C
long enough for any water to freeze. Reinstall the part into the car
and check for the reoccurrence of the incident. If it occurs, repair or
SGI843
replace the component. D
WATER INTRUSION
The incident may occur only during high humidity or in rainy/snowy
weather. In such cases the incident could be caused by water intru- E
sion on an electrical part. This can be simulated by soaking the car
or running it through a car wash.
CAUTION:
Never spray water directly on any electrical components. F
SGI844
H
ELECTRICAL LOAD
The incident may be electrical load sensitive. Perform diagnosis with
all accessories (including A/C, rear window defogger, radio, fog
lamps) turned on. I
K
SGI845
COLD OR HOT START UP L

On some occasions an electrical incident may occur only when the car is started cold, or it may occur when
the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to
make a proper diagnosis.
M
Circuit Inspection INFOID:0000000010411447
DESCRIPTION N
• In general, testing electrical circuits is an easy task if it is approached in a logical and organized method.
Before beginning it is important to have all available information on the system to be tested. Also, get a thor-
ough understanding of system operation. Then you will be able to use the appropriate equipment and follow O
the correct test procedure.
• You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring
harness or electrical component to do this.
P
OPEN A circuit is open when there is no continuity through a section of the circuit.
There are two types of shorts.
When a circuit contacts another circuit and causes the normal resistance to
SHORT • SHORT CIRCUIT
change.
• SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit.
GI-49
TESTING FOR “OPENS” IN THE CIRCUIT
Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This
will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your work-
ing knowledge of the system.
SGI846-A
Continuity Check Method

The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance
function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Check to always start with
the DMM at the highest resistance level.
To help in understanding the diagnosis of open circuits, please refer to the previous schematic.
• Disconnect the battery negative cable.
• Start at one end of the circuit and work your way to the other end. (At the fuse block in this example)
• Connect one probe of the DMM to the fuse block terminal on the load side.
• Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that por-
tion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over
limit or infinite resistance condition. (point A)
• Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit
has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resis-
tance condition. (point B)
• Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the
circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infi-
nite resistance condition. (point C)
Any circuit can be diagnosed using the approach in the previous example.
Voltage Check Method
To help in understanding the diagnosis of open circuits please refer to the previous schematic.
In any powered circuit, an open can be found by methodically checking the system for the presence of voltage.
This is done by switching the DMM to the voltage function.
• Connect one probe of the DMM to a known good ground.
• Begin probing at one end of the circuit and work your way to the other end.
• With SW1 open, probe at SW1 to check for voltage.
voltage: open is further down the circuit than SW1.
no voltage: open is between fuse block and SW1 (point A).
• Close SW1 and probe at relay.
voltage: open is further down the circuit than the relay.
no voltage: open is between SW1 and relay (point B).
• Close the relay and probe at the solenoid.
voltage: open is further down the circuit than the solenoid.
no voltage: open is between relay and solenoid (point C).
Any powered circuit can be diagnosed using the approach in the previous example.
TESTING FOR “SHORTS” IN THE CIRCUIT
GI-50
To simplify the discussion of shorts in the system, please refer to the following schematic.
GI
SGI847-A
Resistance Check Method D

• Disconnect the battery negative cable and remove the blown fuse.
• Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.
• Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known E
good ground.
• With SW1 open, check for continuity.
continuity: short is between fuse terminal and SW1 (point A).
F
no continuity: short is further down the circuit than SW1.
• Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground.
Then, check for continuity.
continuity: short is between SW1 and the relay (point B). G
no continuity: short is further down the circuit than the relay.
• Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a
known good ground. Then, check for continuity. H
continuity: short is between relay and solenoid (point C).
no continuity: check solenoid, retrace steps.
Voltage Check Method I
• Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid discon-
nected) powered through the fuse.
• Turn the power switch to the ON or START position. Verify battery voltage at the battery + side of the fuse
terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). J
• With SW1 open and the DMM leads across both fuse terminals, check for voltage.
voltage: short is between fuse block and SW1 (point A).
no voltage: short is further down the circuit than SW1. K
• With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for
voltage.
voltage: short is between SW1 and the relay (point B).
no voltage: short is further down the circuit than the relay. L
• With SW1 closed, relay contacts jumped with fused jumper wire check for voltage.
voltage: short is down the circuit of the relay or between the relay and the disconnected solenoid (point C).
no voltage: retrace steps and check power to fuse block. M
GROUND INSPECTION
• Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can N
become an unwanted resistance. This unwanted resistance can change the way a circuit works.
• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can
drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. O
Even when the ground connection looks clean, there can be a thin film of rust on the surface.
• When inspecting a ground connection follow these rules:
- Remove the ground bolt or screw.
- Inspect all mating surfaces for tarnish, dirt, rust, etc. P
- Clean as required to assure good contact.
- Reinstall bolt or screw securely.
- Inspect for “add-on” accessories which may be interfering with the ground circuit.
- If several wires are crimped into one ground eyelet terminal, check for proper crimps. Check all of the wires
are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet
check no ground wires have excess wire insulation.
GI-51
• For detailed ground distribution information, refer to “Ground Distribution” in PG section.
SGI853
VOLTAGE DROP TESTS

• Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage
drop in a circuit is caused by a resistance when the circuit is in operation.
• Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire
will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand
of wire is not able to carry the current. The single strand will have a high resistance to the current. This will
be picked up as a slight voltage drop.
• Unwanted resistance can be caused by many situations as follows:
- Undersized wiring (single strand example)
- Corrosion on switch contacts
- Loose wire connections or splices.
• If repairs are needed always use wire that is of the same or larger gauge.
Measuring Voltage Drop — Accumulated Method
• Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the
DMM should be closer to power and the negative lead closer to ground.
• Operate the circuit.
• The DMM will indicate how many volts are being used to “push” current through that part of the circuit.
Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.
SGI974
Measuring Voltage Drop — Step-by-Step

• The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those
in “Computer Controlled Systems”).
• Circuits in the “Computer Controlled System” operate on very low amperage.
GI-52
• The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the
system. Such resistance variation may be caused by poor connection, improper installation, improper wire GI
gauge or corrosion.
• The step by step voltage drop test can identify a component or wire with too much resistance.
B
SAIA0258E
G
CONTROL UNIT CIRCUIT TEST
System Description
• When the switch is ON, the control unit lights up the lamp. H
CASE 1
K
MGI034A
INPUT-OUTPUT VOLTAGE CHART

Terminal No. Description L
In case of high resistance such as single
Input/ Condition Value (Approx.)
+ − Signal name strand (V) *
Output
Lower than battery voltage Approx. 8 (Ex- M
Body Switch ON Battery voltage
1 Switch Input ample)
ground
Switch OFF 0V Approx. 0
N
Body Switch ON Battery voltage Approx. 0 (Inoperative lamp)
2 Lamp Output
ground Switch OFF 0V Approx. 0
• The voltage value is based on the body ground. O
• *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit
does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the
lamp.
P
GI-53
CASE 2
MGI035A
INPUT-OUTPUT VOLTAGE CHART

Terminal No. Description
In case of high resistance such as single
Input/ Condition Value (Approx.)
+ − Signal name strand (V) *
Output
Body Switch ON 0V Battery voltage (Inoperative lamp)

1 Lamp Output
ground Switch OFF Battery voltage Battery voltage
Body Switch ON 0V Higher than 0 Approx. 4 (Example)

2 Switch Input
ground Switch OFF 5V Approx. 5
• The voltage value is based on the body ground.
• *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0 V. Control unit
does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the
lamp.
GI-54
CONSULT/GST CHECKING SYSTEM
GI
• When CONSULT/GST is connected with a data link connector B

equipped on the vehicle side, it will communicate with the control
unit equipped in the vehicle and then enable various kinds of diag-
nostic tests.
C
: Instrument lower panel
• Refer to CONSULT Software Operation Manual for more informa-

D
tion.
JSAIA3602ZZ E
CONSULT Function and System Application*1 INFOID:0000000010411449
FUNCTION F
Mode Function
All DTC Reading Display all DTCs or diagnostic items that all ECUs are recording and judging. G
Work Support This mode enables a technician to adjust some devices faster and more accurately.
Self Diagnostic Results Retrieve DTC from ECU and display diagnostic items. H
Data Monitor Monitor the input/output signal of the control unit in real time.
CAN Diagnosis This mode displays a network diagnosis result about CAN by diagram.
CAN Diagnosis Support Monitor It monitors the status of CAN communication. I
Active Test Send the drive signal from CONSULT to the actuator. The operation check can be performed.
ECU Identification Display the ECU identification number (part number etc.) of the selected system.
J
Configuration Function to READ/WRITE vehicle configuration.
The state of System Readiness Test (SRT) items, the presence or absence of permanent DTC*,
SRT&P-DTC Confirmation
and driving conditions can be checked.
K
DTC work support DTC reproduction procedure can be performed speedily and precisely.
Others Other results or histories, etc. that are recorded in ECU are displayed.
*: Permanent DTC is not applied for regions where it is not mandated. L
SYSTEM APPLICATION*1
M
CAN Diagnosis Support Monitor
Self Diagnostic Results
DTC work support

ECU Identification
All DTC Reading
N
CAN Diagnosis
Work Support
Configuration
Data Monitor
Active Test
Others
System
O
P
AIR BAG x - x x x - - x - - - • TROUBLE DIAG RECORD
METER / M&A x x x x x x - - x - - • Warning History
BCM x x x x x x x x x - - -
IPDM E/R x - x x x x x x - - - -
EPS / DAST 3 x - x x x x - x - - - -
GI-55
CAN Diagnosis Support Monitor
Self Diagnostic Results
DTC work support

ECU Identification
All DTC Reading
CAN Diagnosis
Work Support
Configuration
Data Monitor
Active Test
Others
System
HVAC - x x x x x x x x - - -
ABS x x x x x x x x - - - -
TCU x x x x x x - x - - - -
HV BAT x x x x x x x*2 x - - - -
EV/HEV x x x x x x x x - - - • LOAD BATTERY ID
CHARGER/PD MODULE x x x x x x x x - - - -
MOTOR CONTROL x x x x x x - x - - - -
VSP x - x x x x x x - - - -
MULTI AV - - x x x x - x x - - -
HAS x x x x x x x x - - - -
AIR PRESSURE MONITOR x x x x x x x x x - - -
x: Applicable
*1: If GST application is equipped, functions in accordance with SAE J1979 and ISO 15031-5 can be used.
*2: With Li-ion battery cooler
CONSULT/GST Data Link Connector (DLC) Circuit INFOID:0000000010411450
INSPECTION PROCEDURE
If the CONSULT/GST cannot diagnose the system properly, check the following items.
Symptom Check item

CONSULT/GST cannot access
• CONSULT/GST DLC power supply circuit (Terminal 8 and 16) and ground circuit (Terminal 4 and 5)
any system.
• Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring
CONSULT cannot access indi- diagram for each system.)
vidual system. (Other systems • Open or short circuit between the system and CONSULT DLC (For detailed circuit, refer to wiring
can be accessed.) diagram for each system.)
• Open or short circuit CAN communication line. Refer to LAN-21, "Trouble Diagnosis Flow Chart".
NOTE:
The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A
short in a DDL circuit connected to a control unit in one system may affect CONSULT access to other systems.
If the GST cannot operate properly, check the circuit based on the information of SAE J1962 and ISO 15031-
3.
GI-56
Wiring Diagram - CONSULT/GST CHECKING SYSTEM - INFOID:0000000010411451
GI
JRAWC1380GB
P
GI-57
JRAWC1381GB
GI-58
GI
JRAWC1382GB
GI-59
JRAWC1383GB
GI-60
GI
JRAWC1384GB
GI-61
JRAWC1385GB
GI-62
INSPECTION AND ADJUSTMENT
GI
ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL
ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Re-
B
quired Procedure After Battery Disconnection INFOID:0000000010411452
SYSTEM ITEM REFERENCE C

Temperature setting trimmer HAC-284, "Temperature Setting Trimmer"
Foot position setting trimmer HAC-285, "Foot Position Setting Trimmer"
D
Inlet port memory function —
HAC-285, "Inlet Port Memory Function
Inlet port Memory function (FRE)
Automatic temperature con- (FRE)"
E
trol HAC-284, "Inlet Port Memory Function
Inlet port Memory Function (REC)
(REC)"
Gas Sensor Sensitivity Adjustment Function — F
Auto Intake Switch Interlocking Movement Change —
Clean Switch Interlocking Movement Change —
Automatic drive positioner Automatic drive positioner system — G
Power window control Power window control system PWC-26, "Description"
Sunroof system Sunroof system —
H
Sunshade system Sunshade system —
Rear view monitor predictive course line center position
Rear view monitor —
adjustment I
Around view monitor* Predictive conurse line center position adjustment —
Automatic back door system Automatic back door system —
Engine oil level read Engine oil level read — J
VCM timer set VCM timer set EVC-119, "Description"
*: Not equipped.
K
GI-63
ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL
ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Re-
quired Procedure After Battery Disconnection INFOID:0000000010411452
SYSTEM ITEM REFERENCE

Temperature setting trimmer HAC-286, "Temperature Setting Trimmer"
Foot position setting trimmer HAC-287, "Foot Position Setting Trimmer"
Inlet port memory function —
HAC-287, "Inlet Port Memory Function
Inlet port Memory function (FRE)
Automatic temperature con- (FRE)"
trol HAC-286, "Inlet Port Memory Function
Inlet port Memory Function (REC)
(REC)"
Gas Sensor Sensitivity Adjustment Function —
Auto Intake Switch Interlocking Movement Change —
Clean Switch Interlocking Movement Change —
Automatic drive positioner Automatic drive positioner system —
Power window control Power window control system PWC-20, "Description"
Sunroof system Sunroof system —
Sunshade system Sunshade system —
Rear view monitor predictive course line center position
Rear view monitor —
adjustment
Around view monitor* Predictive conurse line center position adjustment —
Automatic back door system Automatic back door system —
Engine oil level read Engine oil level read —
VCM timer set VCM timer set EVC-134, "Description"
*: Not equipped.
GI-64
ELECTRIC POWER TRAIN
SECTION
TRACTION MOTOR SYSTEM
TMS B
TMS
E
CONTENTS
PRECAUTION ............................................... 4 TRACTION MOTOR INVERTER : System De- F
scription ...................................................................18
PRECAUTIONS ................................................... 4 TRACTION MOTOR INVERTER : Circuit Diagram
Precaution for Technicians Using Medical Electric...... 4 ....18 G
Precaution for Supplemental Restraint System TRACTION MOTOR INVERTER : Fail-safe ............24
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- TRACTION MOTOR INVERTER : Protection
SIONER" ................................................................... 4 Control .....................................................................25
H
Precaution Necessary for Steering Wheel Rota-
tion after 12V Battery Disconnect .............................. 5 MOTOR POWER CONTROL .....................................25
Precaution for Procedure without Cowl Top Cover...... 5 MOTOR POWER CONTROL : System Descrip-
High Voltage Precautions .......................................... 5 tion ...........................................................................25 I
Precautions for Removing Battery Terminal ............. 8 MOTOR POWER CONTROL : Operating Princi-
General Precautions ................................................. 8 ple ............................................................................25
MOTOR REGENERATION CONTROL .....................25 J

PREPARATION ............................................ 9
MOTOR REGENERATION CONTROL : System
PREPARATION ................................................... 9 Description ...............................................................26
Special Service Tool ................................................. 9 MOTOR REGENERATION CONTROL : Operat- K
Commercial Service Tools ........................................ 9 ing Principle .............................................................26
SYSTEM DESCRIPTION ............................. 11 DIAGNOSIS SYSTEM (TRACTION MOTOR

L
INVERTER) ....................................................... 27
DESCRIPTION ...................................................11
Description .............................................................. 11 DIAGNOSIS DESCRIPTION ......................................27
Specifications (Traction Motor) ............................... 11 DIAGNOSIS DESCRIPTION : System Description M
Location of Traction Motor Model Number and Se- ....27
rial Number Stamps ................................................ 11 DIAGNOSIS DESCRIPTION : DTC and Freeze
Frame Data ..............................................................27
N
COMPONENT PARTS .......................................12 DIAGNOSIS DESCRIPTION : Counter System ......27
Component Parts Location ...................................... 12 CONSULT Function .................................................27
Traction Motor Inverter ............................................ 13
Traction Motor ......................................................... 14 ECU DIAGNOSIS INFORMATION .............. 30 O
High Voltage Warning Label ................................... 15
TRACTION MOTOR INVERTER ....................... 30
STRUCTURE AND OPERATION .......................16 Reference Value ......................................................30
Fail-safe ...................................................................31 P
Structural Drawing ................................................... 16
Operation Description ............................................. 16 Protection Control ....................................................32
DTC Inspection Priority Chart ..................................33
SYSTEM .............................................................18 DTC Index ...............................................................34
TRACTION MOTOR INVERTER ............................... 18 WIRING DIAGRAM ...................................... 36
TMS-1
TRACTION MOTOR INVERTER ....................... 36 P0BE5 D-MOTOR A PHASE U CURRENT
Wiring Diagram ....................................................... 36 SEN .................................................................... 63
DTC Description ...................................................... 63
BASIC INSPECTION ................................... 39 Diagnosis Procedure ............................................... 63
DIAGNOSIS AND REPAIR WORK FLOW ........ 39 P0BE6 D-MOTOR A PHASE U CURRENT
Work Flow ............................................................... 39 SEN .................................................................... 64
Question sheet ....................................................... 40 DTC Description ...................................................... 64
RESOLVER WRITE ........................................... 42 Diagnosis Procedure ............................................... 64
Description .............................................................. 42 P0BE9 D-MOTOR A PHASE V CURRENT
Work Procedure ...................................................... 42 SEN .................................................................... 65
DTC/CIRCUIT DIAGNOSIS ......................... 44 DTC Description ...................................................... 65
Diagnosis Procedure ............................................... 65
P0A1B DRIVE MOTOR A CONTROL MOD-
P0BEA D-MOTOR A PHASE V CURRENT
ULE .................................................................... 44
DTC Description ..................................................... 44
SEN .................................................................... 66
DTC Description ...................................................... 66
Diagnosis Procedure .............................................. 44
P0A2C DRIVE MOTOR A TEMP SENSOR ....... 45
DTC Description ..................................................... 45
P0C79 DRIVE MOTOR A INVERTER VOLT-
Diagnosis Procedure .............................................. 45 AGE ................................................................... 67
Component Inspection (Traction Motor Tempera- DTC Description ...................................................... 67
ture Sensor) ............................................................ 46 Diagnosis Procedure ............................................... 67
P0A2D DRIVE MOTOR A TEMP SENSOR ....... 48 P318E CAN ERROR .......................................... 69
DTC Description ..................................................... 48 DTC Description ...................................................... 69
Diagnosis Procedure .............................................. 48 Diagnosis Procedure ............................................... 69
Component Inspection (Traction Motor Tempera- P3193 CAN ERROR .......................................... 70
ture Sensor) ............................................................ 49 DTC Description ...................................................... 70
P0A2F DRIVE MOTOR A OVER TEMPERA- Diagnosis Procedure ............................................... 70
TURE .................................................................. 51 P3199 CAN ERROR .......................................... 71
Diagnosis Procedure .............................................. 51 Diagnosis Procedure ............................................... 71
Component Inspection (Traction Motor Tempera-
ture Sensor) ............................................................ 52 P319E CAN ERROR .......................................... 72
Component Inspection (Traction Motor Stator DTC Description ...................................................... 72
Coil) ........................................................................ 53 Diagnosis Procedure ............................................... 72
P0A3F DRIVE MOTOR A POSITION SEN- P31A4 CAN ERROR ......................................... 73
SOR .................................................................... 54 DTC Description ...................................................... 73
DTC Description ..................................................... 54 Diagnosis Procedure ............................................... 73
Component Inspection (Traction Motor Resolver)... 55 P31A9 CAN ERROR ......................................... 74
DTC Description ...................................................... 74
P0A44 DRIVE MOTOR A OVER SPEED .......... 57 Diagnosis Procedure ............................................... 74
DTC Description ..................................................... 57
Diagnosis Procedure .............................................. 57 P3240 DRIVE MOTOR A INVERTER CRNT
Component Inspection (Traction Motor Resolver)... 58 CONT ................................................................. 75
DTC Description ...................................................... 75
P0A78 DRIVE MOTOR A INVERTER ............... 60 Diagnosis Procedure ............................................... 75
DTC Description ..................................................... 60
Diagnosis Procedure .............................................. 60 P3241 DRIVE MOTOR A INVERTER CRNT
CONT ................................................................. 78
P0A8D 14VOLT POWER VOLTAGE ................ 61 DTC Description ...................................................... 78
DTC Description ..................................................... 61 Diagnosis Procedure ............................................... 78
P3242 D-MOTOR A PHASE U CURRENT
SEN .................................................................... 80
TMS-2
DTC Description ...................................................... 80 P325C DRIVE MOTOR A POSITION ................ 96
Diagnosis Procedure ............................................... 80 DTC Description ......................................................96 A
Diagnosis Procedure ...............................................96
P3243 D-MOTOR A PHASE V CURRENT
SEN .....................................................................81 P325D DRIVE MOTOR A POSITION ................ 97
B
DTC Description ...................................................... 81 DTC Description ......................................................97
Diagnosis Procedure ............................................... 81 Diagnosis Procedure ...............................................97
P3244 DRIVE MOTOR A INVERTER ................82 P325E DRIVE MOTOR A POSITION ................ 98 TMS
P3245 DRIVE MOTOR A INVERTER ................84 P325F DRIVE MOTOR A POSITION ................ 99 D
E
P3247 DRIVE MOTOR A INVERTER ................85 U1000 CAN COMM CIRCUIT ......................... 100
DTC Description ...................................................... 85 DTC Description .................................................... 100
Diagnosis Procedure ............................................... 85 Diagnosis Procedure ............................................. 100
F
P3249 DRIVE MOTOR A INVERTER ................86 TRACTION MOTOR INSULATION RESIS-
DTC Description ...................................................... 86 TANCE CHECK ............................................... 101
Diagnosis Procedure ............................................... 86 Component Inspection ........................................... 101 G
P324A DRIVE MOTOR A INVERTER VOLT- TRACTION MOTOR INVERTER INSULA-
AGE ....................................................................87 TION RESISTANCE CHECK .......................... 103
H
DTC Description ...................................................... 87 Component Inspection ........................................... 103
SYMPTOM DIAGNOSIS ............................ 105
P324D DRIVE MOTOR A INVERTER IGBT ......89 I
DTC Description ...................................................... 89 ELECTROMAGNETIC SOUND IS AUDIBLE . 105
Diagnosis Procedure ............................................... 89 DESCRIPTION ...................................................... 105
Component Inspection (Traction Motor Stator J
Coil) ......................................................................... 90 REMOVAL AND INSTALLATION ............. 106
P3252 DRIVE MOTOR A INVERTER IGBT .......92 TRACTION MOTOR INVERTER ..................... 106
DTC Description ...................................................... 92 Exploded View ....................................................... 106 K
Diagnosis Procedure ............................................... 92 Removal and Installation ....................................... 106
Inspection and Adjustment .................................... 110
P325A CAN ERROR ..........................................94
UNIT REMOVAL AND INSTALLATION .... 111 L
DTC Description ...................................................... 94
TRACTION MOTOR ........................................ 111
P325B DRIVE MOTOR A INVERTER ................95 Exploded View ....................................................... 111 M
DTC Description ...................................................... 95 Removal and Installation ....................................... 112
Diagnosis Procedure ............................................... 95 Inspection and Adjustment .................................... 115
N
TMS-3
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
OPERATION PROHIBITION
WARNING:
• Technicians using a medical electric device such as pacemaker must never perform operation on the
WARNING:
device manufacturer before starting the charge operation.
room [PDM (Power Delivery Module)] at the hood-opened condition during normal charge operation.
WARNING:
• The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or
able cardioverter defibrillator (ICD), the electromagnetic wave of TCU might affect the function of the
TCU use.
PRECAUTION AT INTELLIGENT KEY SYSTEM OPERATION
WARNING:
function of the device. The possible effects on the devices must be checked with the device manu-
WARNING:
TMS-4
PRECAUTIONS
< PRECAUTION >
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag A
B
connectors.
WARNING: TMS
D
injury.
the 12V battery, and wait at least 3 minutes before performing any service. E
INFOID:0000000010970772
F
procedure below before starting the repair operation. G
OPERATION PROCEDURE
1. Connect both 12V battery cables. H
NOTE:
2. Turn the power switch to ACC position. I
disconnected and the steering wheel can be turned. J
turn the power switch from ACC position to ON position, then to LOCK position. (The steering wheel will K
NOTE:
L
tion.
M
windshield. N
PIIB3706J
DANGER:
TMS-5
PRECAUTIONS
< PRECAUTION >
maintenance.
WARNING:
CAUTION:
high voltage harness connector, immediately dry the high voltage connector completely with an air
blow gun.
nected to charge port before starting maintenance work.
NOTE:
WARNING:
TMS-6
PRECAUTIONS
< PRECAUTION >
workers. A
TMS
JSAIA1600GB P
TMS-7
PRECAUTIONS
< PRECAUTION >
NOTE:
• Always disconnect the battery terminal within 60 minutes after
start after a lapse of 60 minutes from power switch OFF.
SEF289H
WORK PROCEDURE
NOTE:
tion.
NOTE:
detected.
4. Remove 12V battery terminal within 60 minutes after turning the power switch OFF → ON → OFF.
CAUTION:
battery terminals are disconnected, start over from Step 1.
NOTE:
Once the power switch is turned ON → OFF, the 12V battery automatic charge control does not start for
the power switch.
NOTE:
then DTC may be detected.
NOTE:
CAUTION:
If the traction motor inverter or traction motor was replaced, be sure to perform writing of the traction
motor resolver offset. Refer to TMS-42, "Description".
Take care when handling the traction motor inverter so that dust, dirt, and other substances do not enter into
the inside from the opening.
TMS-8
PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000010412117
B
Tool number
Description TMS
Tool name
KV99112300
Guide pin
Removing and installing traction mo- D
tor inverter
3 pins/set
A: 106 mm (4.17 in) (1 pin) / 96 mm
(3.78 in) (2 pins) E
JPCIA0332ZZ
Commercial Service Tools INFOID:0000000010412118 F
Tool name Description G
Removing and installing high voltage compo-

nents
Comply with EN60903: H
Insulated gloves • Use protective gloves made of insulating ma-
terial.
• The protective gloves must be capable of re-
sisting the voltage of 600 or more. I
JMCIA0149ZZ
J
• Removing and installing high voltage compo-
nents
Leather gloves • Protect insulated gloves
[Use leather gloves that can fasten the wrist K
tight]
JPCIA0066ZZ
L
nents
Comply with EN60903:
Insulated safety shoes • Use protective shoes made of insulating ma- M
terial.
• The protective shoes must be capable of re-
sisting the voltage of 600 or more.
JPCIA0011ZZ
N
• Removing and installing high voltage compo- O

nents
Face shield • To protect face from the spatter on the work
to electric line
[Comply with EN166.] P
JPCIA0167ZZ
TMS-9
PREPARATION
< PREPARATION >

Insulated helmet
nents
JPCIA0013ZZ
Insulation resistance tester Measuring insulation resistance, voltage, and

(Multi tester) resistance
JPCIA0014ZZ
TMS-10
DESCRIPTION
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION A
DESCRIPTION
B
• The traction motor contains a compact, lightweight, high output, high efficiency “Interior Permanent Magnet
Synchronous Motor (IPMSM)”.
• The traction motor inverter is a device which converts DC power from the Li-ion battery to AC power, and TMS
drives the traction motor. Because the AC power frequency and voltage can be varied when the DC power is
converted to AC power, it provides control performance with a high degree of freedom.
D
Specifications (Traction Motor) INFOID:0000000010412120
Max torque 254 Nm E

Max output 80 kW
Max speed 10,500 rpm
F
Cooling system Water cooling type
Location of Traction Motor Model Number and Serial Number Stamps INFOID:0000000010412121
G
JSCIA1111ZZ
TMS-11
COMPONENT PARTS
COMPONENT PARTS
Component Parts Location INFOID:0000000010412122
LHD models
JSCIA1110ZZ
Motor room
No. Item Function

• Transmits mainly the following signals to VCM via EV system CAN.
- Motor speed signal
- Motor torque limit signal
- Motor discharge status signal
- High voltage power supply preparation completion signal
- Input high voltage signal
• Receives mainly the following signals from VCM via EV system CAN.
- Target motor torque signal
- Pulse signal OFF signal
VCM
- High voltage power supply status signal
- System cut off signal
- Vibration control switching signal
- Motor charge preparation request signal
- Motor discharge request signal
- Regenerative torque command signal
- Shift position signal
• Refer to EVC-15, "Component Parts Location" for detailed installation location.
• Refer to EVC-21, "VCM" for details.
Traction motor inverter TMS-13, "Traction Motor Inverter"
Traction motor TMS-14, "Traction Motor"
TMS-12
COMPONENT PARTS
RHD models
A
TMS
I
JSCIA1372ZZ
Motor room
J
No. Item Function

• Transmits mainly the following signals to VCM via EV system CAN. K
- Motor speed signal
- Motor torque limit signal
- Motor discharge status signal
- High voltage power supply preparation completion signal L
- Input high voltage signal
• Receives mainly the following signals from VCM via EV system CAN.
- Target motor torque signal
- Pulse signal OFF signal
M
VCM
- High voltage power supply status signal
- System cut off signal
- Vibration control switching signal N
- Motor charge preparation request signal
- Motor discharge request signal
- Regenerative torque command signal
- Shift position signal O
• Refer to EVC-15, "Component Parts Location" for detailed installation location.
• Refer to EVC-21, "VCM" for details.
P
Traction Motor Inverter INFOID:0000000010412123
NOTE:
TMS-13
COMPONENT PARTS
Control of the traction motor and control of EV system CAN communications with other control modules is
actually performed by the motor controller. However, because the motor controller is installed inside the trac-
tion motor inverter, the motor controller is here referred to as the traction motor inverter.
• The traction motor inverter is composed of the motor controller, driver, smoothing condenser, 2 current sen-
sors, and power module.
• The traction motor inverter controls the traction motor based on the target motor torque signal transmitted by
EV system CAN from the VCM.
• Traction motor inverter drives traction motor accurately based on resolver detection signal and current sen-
sor detection signal.
• The traction motor inverter performs charging judgment for the high voltage circuit and also discharges the
voltage inside the circuit.
• The traction motor inverter performs vibration control in order to improve accelerator response and provide
good acceleration while driving.
MOTOR CONTROLLER
• The motor controller receives the rotor rotation angle from the traction motor resolver and the traction motor
current value from the current sensor, and creates the pulse signal for driving the IGBT (Insulated Gate Bipo-
lar Transistor).
• The motor controller detects the traction motor temperature by means of the traction motor temperature sen-
sor, and limits the output torque (protection control) according to the level of heat in the traction motor.
DRIVER
The driver converts the pulse signal (12 V) from the motor controller to a high voltage signal (300 V) and drives
the IGBT.
POWER MODULE
• The power module is composed of 6 power semiconductor IGBTs.
• An IGBT is a semiconductor switch that is capable of switching ON/OFF at high speed.
• An IGBT uses the IGBT drive signal from the driver to perform switching, converting the Li-ion battery DC
power to AC power and supplying AC power to the traction motor.
SMOOTHING CONDENSER
The smoothing condenser controls the voltage ripple which occurs as a result of IGBT switching.
CURRENT SENSOR
Current sensors are located in Phase U and V, respectively. These sensors detect a current supplied to the
drive motor and feed back a current value to the motor controller. The current sensors have two built-in sen-
sors.
A current of Phase W is calculated according to the values of Phase U and V.
DISCHARGE RESISTER
The discharge resistor discharges the high voltage in case the traction motor inverter is unable to discharge
the remaining high voltage in the high voltage circuit due to a malfunction.
Traction Motor INFOID:0000000010412124
• The traction motor contains an “Interior Permanent Magnet Synchronous Motor (IPMSM)”. A permanent
magnet is embedded inside the rotor core, and the rotating magnetic field generated by the stator coil is
used to generate rotational torque.
• The traction motor is able to generate torque even when the vehi-
cle is stopped, and outputs maximum drive torque when the vehi-
cle starts moving in order to provide good initial acceleration.
JPCIA0033GB
TRACTION MOTOR RESOLVER
TMS-14
COMPONENT PARTS
The traction motor resolver is located coaxially with the traction motor, and detects the rotor rotation angle.
The rotation angle is sent to the motor controller. A
CAUTION:
If the traction motor inverter or traction motor is replaced, be sure to perform writing of the traction
motor resolver offset. Refer to TMS-42, "Description".
B
TRACTION MOTOR TEMPERATURE SENSOR
The traction motor temperature sensor detects the temperature of the stator inside the traction motor, and
sends that temperature information to the motor controller. TMS
When replacing component parts make sure to affix the label in the original position. D
The label is affixed to the right side of traction motor.
: Vehicle front E
: Direction of the label
G
JSCIA0665ZZ
TMS-15
STRUCTURE AND OPERATION
Structural Drawing INFOID:0000000010412126
MOTOR MECHANISM (DIAGRAM)
JPCIA0072ZZ
Stator core Coil Shaft

Rotor core Permanent magnet
Operation Description INFOID:0000000010412127
OPERATION PRINCIPLE
JPCIA0034GB
• When 3-phase AC current is applied to the stator coil, a rotating magnetic field is generated. This rotating
magnetic field pulls on the permanent magnet inside the rotor core, generating rotational torque that is syn-
TMS-16
chronized with the rotating magnetic field. The generated torque is approximately proportional to the current,
and the rotating speed depends on the frequency of the 3-phase current. A
• In order to generate optimal rotor rotation, judgments regarding the position (angle) of the permanent mag-
net within the rotor core and the timing of current application to the coil are necessary. For this purpose, the
traction motor resolver and current sensor are used in order to continually detect the rotating position of the
B
rotor and control the timing of current application to the coil.
TMS
TMS-17
SYSTEM
SYSTEM
TRACTION MOTOR INVERTER
TRACTION MOTOR INVERTER : System Description INFOID:0000000010412128
• The traction motor inverter controls the traction motor based on the target motor torque signal transmitted by
EV system CAN from the VCM.
• Traction motor inverter converts DC power from Li-ion battery to AC power, and drives traction motor accu-
rately based on resolver detection signal and current sensor detection signal.
• At deceleration, traction motor is used as generator. It converts kinetic energy generated by rotary motion of
tires (AC power) to electric energy (DC power) and charges Li-ion battery.
• If malfunction is detected, the system enters fail-safe mode. Refer to TMS-31, "Fail-safe".
SYSTEM DIAGRAM
JSCIA1137GB
TRACTION MOTOR INVERTER : Circuit Diagram INFOID:0000000010412129
NOTE:
• For battery cooler circuit, refer to EVB-310, "Circuit Diagram". (with battery cooler models)
• For battery heater & cooler circuit, refer to EVB-598, "Circuit Diagram". (with battery heater & cooler models)
• TCU is included only in models with TELEMATICS system.
TMS-18
SYSTEM
TMS
JSCIA1156GB
TMS-19
SYSTEM
JSCIA1157GB
TMS-20
SYSTEM
TMS
JSCIA1158GB
TMS-21
SYSTEM
JSCIA1159GB
TMS-22
SYSTEM
TMS
JSCIA1160GB
TMS-23
SYSTEM
TRACTION MOTOR INVERTER : Fail-safe INFOID:0000000010971114
DTC Vehicle behavior

Any of the following statuses is observed.
• No impact to vehicle behavior
P0A1B • Stops drive control of traction motor
• Stops drive control of traction motor, and requires system main relay OFF to VCM
• Limits the maximum torque of traction motor to 40% or less
P0A2C Limits the maximum torque of traction motor to 40% or less
P0A2D Limits the maximum torque of traction motor to 40% or less
P0A2F Stops drive control of traction motor
P0A44 Stops drive control of traction motor
P0A8D Stops drive control of traction motor, and requires system main relay OFF to VCM
P0BE5 Stops drive control of traction motor
P0BEA Stops drive control of traction motor
P0C79 Stops drive control of traction motor
Either of the following statuses is observed.
P318E
• Stops drive control of traction motor
• Limits the maximum torque of traction motor to 0%
P3193 No impact to vehicle behavior
P3199
P319E No impact to vehicle behavior
P31A4
P31A9 No impact to vehicle behavior
P3240 Stops drive control of traction motor
P3249 Stops drive control of traction motor, and requires system main relay OFF to VCM
P324A Stops drive control of traction motor
P324D Stops drive control of traction motor
P325A No impact to vehicle behavior
P325B No impact to vehicle behavior
P325C No impact to vehicle behavior
TMS-24
SYSTEM
A
P325D Limits the maximum torque of traction motor to 40% or less
P325F No impact to vehicle behavior B
U1000 No impact to vehicle behavior
TRACTION MOTOR INVERTER : Protection Control INFOID:0000000010971165

TMS
When temperature of traction motor inverter or traction motor components rises, the traction motor inverter
temporarily enters a protective control state in order to protect the system. It automatically returns to the nor-
mal status if the safety is secured. D
Condition Control Normal return condition

Traction motor output torque is limited according to the E
Traction motor is overheated Traction motor temperature drops
traction motor temperature.
IGBT switching frequency is reduced.
IGBT high temperatures seen when • IGBT temperature drops
NOTE: F
traction motor speed is extremely low • Traction motor speed increases
Traction motor electromagnetic noise increases.
Traction motor output torque is limited according to the
IGBT is overheated IGBT temperature drops
IGBT temperature.
G
MOTOR POWER CONTROL
MOTOR POWER CONTROL : System Description INFOID:0000000010412132 H
The traction motor inverter applies AC power to the traction motor according to the target motor torque signal
calculated by VCM in order to generate drive force.
I
MOTOR POWER CONTROL : Operating Principle INFOID:0000000010412133
Flow of energy J
JPCIA0040GB
O
(4) (3) (2) (1)
The AC power from the
P
traction motor inverter is
The traction motor inverter (IG- The DC power from the
The drive torque from the ⇐ converted to magnetic en- ⇐ ⇐
BT) switches in order to convert Li-ion battery is input to
traction motor is output as ergy and a rotating mag-
the DC power from the Li-ion the traction motor invert-
kinetic energy. netic field is created in
battery to AC power. er.
order to generate drive
torque.
MOTOR REGENERATION CONTROL
TMS-25
SYSTEM
MOTOR REGENERATION CONTROL : System Description INFOID:0000000010412134
During deceleration, the traction motor inverter drives the traction motor to function as a generator based on
the regenerative torque command signal sent via EV system CAN from the VCM, converting the kinetic torque
generated by rotation of the tires into electrical energy. The converted electrical energy charges the Li-ion bat-
tery.
The regenerative torque that is generated when the traction motor is driven as a generator can be used as
braking force, acting similar to engine braking and reducing the burden on the service brakes.
MOTOR REGENERATION CONTROL : Operating Principle INFOID:0000000010412135
Flow of energy
JPCIA0039GB
(1) (2) (3) (4)

The kinetic energy generat- The traction motor inverter The DC power regenerat-
ed by rotation of the tires Rotation of the traction mo- (IGBT) switches in order to ed by the traction motor in-
operates the traction motor tor generates AC power. convert the AC power from the verter is used to charge
as a generator. traction motor to DC power. the Li-ion battery.
TMS-26
DIAGNOSIS SYSTEM (TRACTION MOTOR INVERTER)
A
DIAGNOSIS DESCRIPTION
DIAGNOSIS DESCRIPTION : System Description INFOID:0000000010412136
B
This is an on-board trouble diagnosis system which automatically detects malfunction. Detected malfunction is
memorized in ECU as DTC. Diagnosis information can be confirmed using CONSULT.
DIAGNOSIS DESCRIPTION : DTC and Freeze Frame Data INFOID:0000000010412137
TMS
NOTE:
Operate the power switch from OFF to ON. This operation is defined as 1 trip. D
• DTC (P0A1B, P0A8D, P0C79, etc.) is specified by SAE J2012/ISO 15031-6.
• Traction motor inverter memorizes DTC and freeze frame data when malfunction is detected.
• Traction motor inverter can memorize plural DTCs but only 1 set of freeze frame data.
E
• Freeze frame data is not updated even if a different DTC is detected in another trip. The first memorized data
is kept as freeze frame data.
• The procedure to erase DTC from traction motor inverter memory is described in “How to Erase DTC”. Refer
to TMS-27, "CONSULT Function". F
DIAGNOSIS DESCRIPTION : Counter System INFOID:0000000010412138
Counter system counts up at every operation of power switch from OFF to ON under condition that the same G
malfunction is not detected. On the other hand, if the same DTC as memorized one is detected again, the
count is reset and the counter system counts up again from “0”.
H
CONSULT Function INFOID:0000000010412139
APPLICATION ITEM
I
Item Function
All DTC Reading Display all DTCs or diagnostic items that all ECUs are recording and judging.
J
Work Support This mode enables a technician to adjust some devices faster and more accurately.
Self Diagnostic Results Retrieve DTC from ECU and display diagnostic items.
Data Monitor Monitor the input/output signal of the control unit in real time. K
CAN Diagnosis This mode displays a network diagnosis result about CAN by diagram.
CAN Diagnosis Support Monitor It monitors the status of CAN communication.
L
ECU Identification Display the ECU identification number (part number etc.) of the selected system.
WORK SUPPORT
M
Item Description
RESOLVER WRITE Performs writing of traction motor resolver offset.
Resets output limit history of traction motor and traction motor inverter.
N
NOTE:
CLEAR OUTPUT LIMIT REASON
Resets “OUTPUT LIMIT MOTOR TEMP” and “OUTPUT LIMIT INV TEMP” values of data
monitor. O
SELF DIAGNOSTIC RESULTS
Display Item List P
Refer to TMS-34, "DTC Index".
How to Read DTC
DTC is displayed on “Self Diagnostic results” of CONSULT.
When DTC is currently detected, “CRNT” is displayed. If “PAST” is displayed, it shows a malfunction occurred
in the past.The trip number of drive without malfunction of concerned DTC can be confirmed with “IGN
counter” inside “FFD”.
TMS-27
How to Erase DTC
NOTE:
If the power switch is kept ON after repair operation, operate the power switch to OFF. Operate the power
switch to ON again after waiting at least 10 seconds.
1. Touch “MOTOR CONTROL” of CONSULT.
2. Touch “Self Diagnostic Result”.
3. Touch “Erase”. (DTC memorized in electric traction motor inverter is erased.)
IGN Counter
IGN counter is displayed in “FFD”. It displays the number of operations of power switch from OFF to ON after
DTC recovery to normal.
• If malfunction (DTC) is currently detected, “0” is displayed.
• The displayed number counts up at each operation of power switch from OFF to ON after recovery to nor-
mal, such as 1 → 2 → 3...38 → 39.
• When the number reaches to 40, DTC is erased.
NOTE:
The counter display of “40” cannot be checked.
FREEZE FRAME DATA (FFD)
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT.
Monitored item (Unit) Remarks

DTC Displays the DTC which caused FFD memory
12V POWER VOLTAGE (V) Displays 12V battery power voltage input to traction motor inverter
CODE IN INVERTER Displays the trouble code inside traction motor inverter
RESOLVER OFFSET VALUES (1st and Displays 1st and 2nd symbols of traction motor resolver offset value written in
2nd symbols) traction motor inverter
DIAGNOSIS START HISTORY 1
Displays if DTC detection mode is started
DIAGNOSIS START HISTORY 2
DPA REQUEST Displays the request status of DPA
TORQUE LIMIT RATE 1 (%) Displays the motoring torque limit rate
TORQUE LIMIT RATE 2 (%) Displays the regeneration torque limit rate
MOTOR TEMPERATURE (°C or °F) Displays the temperature of traction motor
MAX MOTOR TEMPERATURE (°C or °F) Displays the highest temperature of traction motor detected
INV INPUT HIGH VOLTAGE (V) Displays high voltage input to traction motor inverter
COMMAND TORQUE (Nm) Displays the torque command value from VCM via EV system CAN
INSIDE COMMAND TORQUE (Nm) Displays the torque command value in motor controller
MOTOR SPEED (rpm) Displays the traction motor speed
MOTOR d CURRENT (A) Displays the detected value of current (d-axis) of traction motor
MOTOR q CURRENT (A) Displays the detected value of current (q-axis) of traction motor
U PHASE CURRENT (A) Displays the U-phase current detected value
V PHASE CURRENT (A) Displays the V-phase current detected value
PHASE ANGLE (deg) Displays the turning angle position of rotor
SEQUENCE MODE Displays the sequence number in motor controller
CARRIER FREQUENCY Displays the carrier frequency
IGBT HIGH TEMP DETECT Displays the status of high temperature detection of IGBT
HIGH VOLTAGE SUPPLY Displays the high voltage supply status from VCM via EV system CAN
VOLTAGE (S1-S3) (V) Displays the S1-S3 of resolver detected voltage
VOLTAGE (S2-S4) (V) Displays the S2-S4 of resolver detected voltage
ERROR LEVEL 1
ERROR LEVEL 2 Displays the diagnosis flag of resolver IC
ERROR LEVEL 3
TMS-28
A
ERROR CODE 1
Displays the diagnosis results of resolver IC
ERROR CODE 2
RESOLVER VOLTAGE (V) Displays the power supply voltage of resolver B
5V POWER SUPPLY (V) Displays the 5V control power supply voltage
3V POWER SUPPLY (V) Displays the 3V control power supply voltage
TMS
DATA MONITOR
NOTE:
The following table includes information (items) inapplicable to this vehicle. For information (items) applica-
D
bleto this vehicle, refer to CONSULT display items.

E
MOTOR TEMPERATURE (°C or °F) Displays the temperature of traction motor
12V POWER VOLTAGE (V) Displays 12V battery power voltage input to traction motor inverter
INV INPUT HIGH VOLTAGE (V) Displays high voltage input to traction motor inverter F
COMMAND TORQUE (Nm) Displays the torque command value from VCM via EV system CAN
MOTOR SPEED (rpm) Displays the traction motor speed
SEQUENCE MODE Displays the sequence number in motor controller G
• Displays presence of output limit due to traction motor temperature increase
after last deletion of output limit history
OUTPUT LIMIT MOTOR TEMP
• Values can be reset using “CLEAR OUTPUT LIMIT REASON” of work sup- H
port
• Displays presence of output limit due to temperature increase inside traction
motor inverter after last deletion of output limit history I
OUTPUT LIMIT INV TEMP
• Values can be reset using “CLEAR OUTPUT LIMIT REASON” of work sup-
port
CARRIER FREQUENCY Displays the carrier frequency
J
HIGH VOLTAGE SUPPLY Displays the high voltage supply status from VCM via EV system CAN
CHARGE RELAY READY REQ Displays the state of charge judgment start request of high voltage circuit
SHIFT POSITION (VCM) Displays the shift position from VCM via EV system CAN K
TMS-29
< ECU DIAGNOSIS INFORMATION >
ECU DIAGNOSIS INFORMATION
Reference Value INFOID:0000000010412140
CONSULT DATA MONITOR STANDARD VALUE

NOTE:
The following table includes information (items) inapplicable to this vehicle. For information (items) applicable
to this vehicle, refer to CONSULT display items.
Monitor item Condition Value / Status (Approx.)

Almost same as coolant temperature af-
ter temperature saturation. [approxi-
READY (stop the vehicle)
mately within 10°C (50°F) of coolant
MOTOR TEMPERATURE temperature]
The value changes along with accelera-
During driving
tion/deceleration.
12V POWER VOLTAGE Power switch ON 9 – 16 V
INV INPUT HIGH VOLTAGE READY (stop the vehicle) and during driving 240 – 403 V
The value changes along with accelera-
COMMAND TORQUE During driving
tion/deceleration.
READY (stop the vehicle) 0 rpm
MOTOR SPEED The value changes along with accelera-
During driving
tion/deceleration.
SEQUENCE MODE READY (stop the vehicle) 11
When the vehicle has history of output limit Yes
OUTPUT LIMIT MOTOR TEMP
When output limit is reset None
When the vehicle has history of output limit Yes
OUTPUT LIMIT INV TEMP
When output limit is reset None
CARRIER FREQUENCY READY (stop the vehicle) 5k
HIGH VOLTAGE SUPPLY READY (stop the vehicle) SUPPLY
CHARGE RELAY READY REQ READY (stop the vehicle) ON
P position P
R position R
SHIFT POSITION (VCM) READY (stop the vehicle)
N position N
D position D
TERMINAL LAYOUT
JSCIA0667ZZ
PHYSICAL VALUES
CAUTION:
TMS-30
• Check them with vehicle side harness connector, removing traction motor inverter connector. Never
touch terminals of traction motor inverter side connector at this operation. A
• If power switch is pushed ON with traction motor inverter connector removed, other control modules
might detect malfunction of traction motor inverter.
B
Terminal No.
Description
(Color)
Condition Value (Approx.)
Input/
+ − Signal name TMS
Output
14 Input/
— EV system CAN-H — —
(L) Output
15 Input/
D
— EV system CAN-L — —
(G) Output
18 17 Traction motor resolver
Input Power switch OFF 20 – 35 Ω E
(B) (W) signal (S2 – S4)
19 27 Traction motor resolver
Output Power switch OFF 8 – 15 Ω
(W) (B) signal (R1 – R2)
20 21 Traction motor resolver F
Input Power switch OFF 20 – 35 Ω
(B) (W) signal (S1 – S3)
42 Power ON power sup- Power switch ON 9 – 16 V

Ground — G
(LG) ply Power switch OFF 0V
Within ± 50% of temperature characteristics diagram
45 44 Traction motor tempera- I

Input Power switch OFF
(W) (B) ture sensor
JPCIA0030GB
K
46 12V battery power sup-
Ground — Power switch ON 9 – 16 V
(G) ply
47 L
Ground GND — Always 0V
(B)
48 12V battery power sup-
Ground — Power switch ON 9 – 16 V
(G) ply
M
49
Ground GND — Always 0V
(B)
Fail-safe INFOID:0000000010412141 N
DTC Vehicle behavior O

P0A1B • Stops drive control of traction motor
P
P0A2C Limits the maximum torque of traction motor to 40% or less
P0A2D Limits the maximum torque of traction motor to 40% or less
TMS-31
P0A8D Stops drive control of traction motor, and requires system main relay OFF to VCM
P0BEA Stops drive control of traction motor
P0C79 Stops drive control of traction motor
P318E
P3199
P31A4
P31A9 No impact to vehicle behavior
P3249 Stops drive control of traction motor, and requires system main relay OFF to VCM
P324A Stops drive control of traction motor
P324D Stops drive control of traction motor
P325A No impact to vehicle behavior
P325B No impact to vehicle behavior
P325C No impact to vehicle behavior
P325D Limits the maximum torque of traction motor to 40% or less
P325F No impact to vehicle behavior
U1000 No impact to vehicle behavior
Protection Control INFOID:0000000010412142
When temperature of traction motor inverter or traction motor components rises, the traction motor inverter
temporarily enters a protective control state in order to protect the system. It automatically returns to the nor-
mal status if the safety is secured.
TMS-32
Condition Control Normal return condition A

Traction motor output torque is limited according to the
Traction motor is overheated Traction motor temperature drops
traction motor temperature.
IGBT switching frequency is reduced. B
IGBT high temperatures seen when • IGBT temperature drops
NOTE:
traction motor speed is extremely low • Traction motor speed increases
Traction motor electromagnetic noise increases.
Traction motor output torque is limited according to the TMS
IGBT is overheated IGBT temperature drops
IGBT temperature.
DTC Inspection Priority Chart INFOID:0000000010412143

D
If some DTCs are displayed at the same time, perform inspections one by one based on the priority as per the-
following list.
E
Priority Detected items (DTC) Reference
1 P0A8D 14VOLT POWER VOLTAGE TMS-61
P0A2C DRIVE MOTOR A TEMP SENSOR TMS-45 F
P0A2D DRIVE MOTOR A TEMP SENSOR TMS-48
P0A2F DRIVE MOTOR A OVER TEMPERATURE TMS-51
G
P0A3F DRIVE MOTOR A POSITION SENSOR TMS-54
P0A44 DRIVE MOTOR A OVER SPEED TMS-57
P0A78 DRIVE MOTOR A INVERTER TMS-60 H
P0C79 DRIVE MOTOR A INVERTER VOLTAGE TMS-67
P318E CAN ERROR TMS-69
P3193 CAN ERROR TMS-70
I
P3199 CAN ERROR TMS-71

P319E CAN ERROR TMS-72 J
P31A4 CAN ERROR TMS-73
P31A9 CAN ERROR TMS-74
P3241 DRIVE MOTOR A INVERTER CRNT CONT TMS-78 K
2
P3244 DRIVE MOTOR A INVERTER TMS-82
L
P324A DRIVE MOTOR A INVERTER VOLTAGE TMS-87 M
P324D DRIVE MOTOR A INVERTER IGBT TMS-89
P3252 DRIVE MOTOR A INVERTER IGBT TMS-92
N
P325A CAN ERROR TMS-94
P325B DRIVE MOTOR A INVERTER TMS-95
P325C DRIVE MOTOR A POSITION TMS-96 O
P325D DRIVE MOTOR A POSITION TMS-97
P325E DRIVE MOTOR A POSITION TMS-98
P
P325F DRIVE MOTOR A POSITION TMS-99
U1000 CAN COMM CIRCUIT TMS-100
TMS-33
Priority Detected items (DTC) Reference
P0A1B DRIVE MOTOR A CONTROL MODULE TMS-44
P0BE5 D-MOTOR A PHASE U CURRENT SEN TMS-63
P0BE6 D-MOTOR A PHASE U CURRENT SEN TMS-64
3 P0BE9 D-MOTOR A PHASE V CURRENT SEN TMS-65
P0BEA D-MOTOR A PHASE V CURRENT SEN TMS-66
P3242 D-MOTOR A PHASE U CURRENT SEN 2 TMS-80
P3423 D-MOTOR A PHASE V CURRENT SEN 2 TMS-81
4 P3240 DRIVE MOTOR A INVERTER CRNT CONT TMS-75
DTC Index INFOID:0000000010412144
NOTE:
If some DTCs are displayed at the same time, perform inspections one by one based on the priority as per the
following list. Refer to TMS-33, "DTC Inspection Priority Chart".
DTC* Items
EV system warning lamp Reference
CONSULT (CONSULT screen terms)
P0A1B DRIVE MOTOR A CONTROL MODULE Can illuminate TMS-44

P0A2C DRIVE MOTOR A TEMP SENSOR — TMS-45
P0A2D DRIVE MOTOR A TEMP SENSOR — TMS-48
P0A2F DRIVE MOTOR A OVER TEMPERATURE ON TMS-51
P0A3F DRIVE MOTOR A POSITION SENSOR ON TMS-54
P0A44 DRIVE MOTOR A OVER SPEED ON TMS-57
P0A78 DRIVE MOTOR A INVERTER ON TMS-60
P0A8D 14VOLT POWER VOLTAGE ON TMS-61
P0BE5 D-MOTOR A PHASE U CURRENT SEN ON TMS-63
P0BE6 D-MOTOR A PHASE U CURRENT SEN ON TMS-64
P0BE9 D-MOTOR A PHASE V CURRENT SEN ON TMS-65
P0BEA D-MOTOR A PHASE V CURRENT SEN ON TMS-66
P0C79 DRIVE MOTOR A INVERTER VOLTAGE ON TMS-67
P318E CAN ERROR Can illuminate TMS-69
P3193 CAN ERROR — TMS-70
P3199 CAN ERROR Can illuminate TMS-71
P319E CAN ERROR — TMS-72
P31A4 CAN ERROR Can illuminate TMS-73
P31A9 CAN ERROR — TMS-74
P3240 DRIVE MOTOR A INVERTER CRNT CONT ON TMS-75
P3241 DRIVE MOTOR A INVERTER CRNT CONT ON TMS-78
P3242 D-MOTOR A PHASE U CURRENT SEN 2 ON TMS-80
P3243 D-MOTOR A PHASE V CURRENT SEN 2 ON TMS-81
P3244 DRIVE MOTOR A INVERTER — TMS-82
P3245 DRIVE MOTOR A INVERTER — TMS-84
P3247 DRIVE MOTOR A INVERTER ON TMS-85
P3249 DRIVE MOTOR A INVERTER ON TMS-86
P324A DRIVE MOTOR A INVERTER VOLTAGE ON TMS-87
P324D DRIVE MOTOR A INVERTER IGBT ON TMS-89
TMS-34
DTC* Items
(CONSULT screen terms)
EV system warning lamp Reference A
CONSULT
P3252 DRIVE MOTOR A INVERTER IGBT — TMS-92
P325A CAN ERROR — TMS-94 B
P325B DRIVE MOTOR A INVERTER — TMS-95
P325C DRIVE MOTOR A POSITION ON TMS-96
TMS
P325D DRIVE MOTOR A POSITION — TMS-97
P325E DRIVE MOTOR A POSITION — TMS-98
P325F DRIVE MOTOR A POSITION — TMS-99 D
U1000 CAN COMM CIRCUIT — TMS-100
*: These numbers are prescribed by SAE J2012/ISO 15031-6.
E
TMS-35
< WIRING DIAGRAM >
WIRING DIAGRAM
Wiring Diagram INFOID:0000000010412145
JRCWC0716GB
TMS-36
< WIRING DIAGRAM >
TMS
JRCWC0717GB
TMS-37
< WIRING DIAGRAM >
JRCWC0718GB
TMS-38
DIAGNOSIS AND REPAIR WORK FLOW
BASIC INSPECTION A
B
1.OBTAIN INFORMATION ABOUT SYMPTOM

Refer to TMS-40, "Question sheet" and interview the customer to obtain the malfunction information (condi- TMS
tions and environment when the malfunction occurred) as much as possible when the customer brings in the
vehicle.
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-98, "DTC Index".
NO >> GO TO 3.
3.CHECK DTC IN TRACTION MOTOR INVERTER G
1. Before checking the malfunction, check whether any DTC exists.
2. If DTC exists, perform the following operations.
- Record the DTC and freeze frame data. (Print out the data using CONSULT and affix them to the Work H
Order Sheet.)
- Erase DTCs.
- Check the relationship between the cause that is clarified with DTC and the malfunction information
described by the customer. I
3. Check the information of related service bulletins and others also.
Do malfunction information and DTC exist?
Malfunction information and DTC exists. >>GO TO 4. J
Malfunction information exists, but no DTC. >>GO TO 5.
No malfunction information, but DTC exists. >>GO TO 6.
4.REPRODUCE MALFUNCTION SYMPTOM K
Check any malfunction described by a customer, except those with DTC on the vehicle.
Also investigate whether the symptom is a fail-safe or normal operation. Refer to TMS-31, "Fail-safe".
L
When a malfunction symptom is reproduced, the question sheet is effective. Refer to TMS-40, "Question
sheet".
Verify the relationship between the symptom and the conditions in which the malfunction described by the cus-
tomer occurs. M
>> GO TO 6.
5.REPRODUCE MALFUNCTION SYMPTOM N
Check the malfunction described by the customer on the vehicle.

Also investigate whether the symptom is a normal operation. Refer to TMS-32, "Protection Control".
O
When a malfunction symptom is reproduced, the question sheet is effective. Refer to TMS-40, "Question
sheet".
Verify the relationship between the symptom and the conditions in which the malfunction described by the cus-
tomer occurs. P
>> GO TO 8.
6.PERFORM “DTC CONFIRMATION PROCEDURE”
Perform “DTC CONFIRMATION PROCEDURE” of the appropriate DTC to check if DTC is detected again.
Refer to TMS-33, "DTC Inspection Priority Chart" when multiple DTCs are detected, and then determine the
order for performing the diagnosis.
TMS-39
NOTE:
If no DTC is detected, refer to the freeze frame data.
Is any DTC detected?
YES >> GO TO 7.
NO >> Check according to GI-47, "Intermittent Incident".
7.REPAIR OR REPLACE THE MALFUNCTIONING PARTS
Repair or replace the detected malfunctioning parts.
Reconnect parts or connector after repairing or replacing, and then erase DTC if necessary.
>> GO TO 8.
8.FINAL CHECK
Perform “DTC CONFIRMATION PROCEDURE” again to make sure that the repair is correctly performed.
Check that malfunctions are not reproduced when obtaining the malfunction information from the customer,
referring to the symptom inspection result in step 4 or 5.
Is DTC or malfunction symptom reproduced?
YES >> GO TO 2.
NO >> Before delivering the vehicle to the customer, make sure that DTC is erased.
Question sheet INFOID:0000000010412147
DESCRIPTION
By understanding those conditions properly, a quick and exact diag-
nosis can be achieved.
In general, customers have their own criteria for a problem. There-
fore, it is important to understand the symptom and status well
enough by asking the customer about the concerns carefully. In
order to systemize all the information for the diagnosis, prepare the
question sheet referring to the question points.
SEF907L
WORKSHEET SAMPLE
Question Sheet
Customer name Motor No. Inverter No.
MR/MS
Incident Date VIN
Model & Year In Service Date
Trans. Mileage km/mile
Symptoms Power limitation indicator
Does not to READY EV system warning lamp is on
lamp is on
Water leak* Noise* Vibration* Shock* Gear noise*
Non driving* Poor acceleration* Poor torque* Radio noise*
Does not charge Other* *: If applied, enter in detail
Detailed symptom
Onomatopoeia
Frequency All the time Once Sometimes ( times a day) Other

Weather
Not affected
conditions
TMS-40
Question Sheet
A
Weather Fine Clouding Raining Snowing Other ( )
Temp. [Approx. °C
Temp. Hot Warm Cool Cold
( °F)]
B
Humidity High Middle Low Humidity (Approx. %)
Road conditions Deplorable
Not affected In town Freeway Off road (Up / Down)
road
TMS
Flat road While turning (Right / Left) Bump
Other
Shift position Not affected D
P position R position N position D position B position
ECO mode
E
Driving conditions Not affected
Power switch ON → OFF Power switch OFF → ON READY (stop the vehicle)
While cruis- While decel- Just before Just after stop- F
D position (stop the vehicle)
ing erating stopping ping
While recharging Other
Vehicle speed [ km/h ( MPH)] Accelerator pedal ( / 8) G
Battery level (Low / Middle / High)
Moments when mal- Disappears with select oper-
Disappears while driving Disappears when stopped H
function disappears ation
Disappears when power switch Disappears when battery charge is
Does not disappear
is pushed OFF stopped
Other I
Other
TMS-41
RESOLVER WRITE
RESOLVER WRITE
If the work listed below was performed, it is necessary to perform writing of the traction motor resolver offset to
the traction motor inverter.
• Replacement of traction motor
• Replacement of traction motor inverter
• Replacement of traction motor and traction motor inverter
Location of traction motor resolver offset stamp
NOTE:
Because the traction motor resolver offset stamp is located on the lower side of the traction motor, it is neces-
sary to remove the under cover in order to check it.
JSCIA0663ZZ
Work Procedure INFOID:0000000010412149
CAUTION:
If the traction motor inverter was replaced, then the EV system warning lamp illuminates when the
power switch is turned ON, and DTC “P325C” is detected. Therefore after writing of the traction motor
resolver offset is completed, verify that the EV system warning lamp has turned off and erase DTC
“P325C”.
1.CHECK BEFORE PERFORMING WRITING OF THE TRACTION MOTOR RESOLVER OFFSET
Check the replaced parts.
Which parts were replaced?
Traction motor>>GO TO 2.
Traction motor inverter>>GO TO 3.
Traction motor and traction motor inverter>>GO TO 3.
2.WRITING OF THE TRACTION MOTOR RESOLVER OFFSET
With CONSULT
1. Power switch ON.
2. Select “Work Support” in “MOTOR CONTROL”.
3. Select “RESOLVER WRITE”.
4. Enter the traction motor resolver offset.
5. Touch “WRITE”.
Is “Writing is complete”displayed?
YES >> 1. Power switch OFF.
2. Power switch ON and wait 2 seconds or more.
3. Confirm the value is changed according to the correction value input.
TMS-42
RESOLVER WRITE
4. Power switch OFF to complete the work.
NO >> Perform again STEP 2. A
3.WRITING OF THE TRACTION MOTOR RESOLVER OFFSET
With CONSULT B
1. Power switch ON.
NOTE:
EV system warning lamp turns on.
2. Select “Work Support” in “MOTOR CONTROL”. TMS
4. Enter the traction motor resolver offset.
5. Touch “WRITE”. D
Is “Writing is complete”displayed?
YES >> GO TO 4.
NO >> Perform again STEP 3. E
4.STEPS AFTER WRITING OF THE TRACTION MOTOR RESOLVER OFFSET
With CONSULT
1. Power switch OFF. F
3. Verify that the EV system warning lamp is off.
4. Select “Work Support” in “MOTOR CONTROL”. G
6. Confirm the value is changed according to the correction value input.
7. Perform “Self Diagnostic Results” in “MOTOR CONTROL”.
H
8. Erase the DTC “P325C”.
9. Power switch OFF.
I
>> END
TMS-43
P0A1B DRIVE MOTOR A CONTROL MODULE
< DTC/CIRCUIT DIAGNOSIS >
DTC/CIRCUIT DIAGNOSIS
P0A1B DRIVE MOTOR A CONTROL MODULE
DTC Description INFOID:0000000010412150
DTC DETECTION LOGIC
CONSULT screen terms

DTC Malfunction detected condition
(Trouble diagnosis content)
DRIVE MOTOR A CONTROL MODULE A malfunction is detected in the traction motor inverter
P0A1B
(Drive Motor “A” Control Module) (motor controller)
POSSIBLE CAUSE
Traction motor inverter
FAIL-SAFE
DTC CONFIRMATION PROCEDURE
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always power switch OFF and wait
at least 10 seconds before conducting the next test.
>> GO TO 2.
2.CHECK DTC DETECTION
With CONSULT
1. Power switch ON and wait for 10 seconds or more.
2. Check DTC.
Is “P0A1B” detected?
YES >> Go to TMS-44, "Diagnosis Procedure".
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident".
NO-2 >> Confirmation after repair: INSPECTION END
Diagnosis Procedure INFOID:0000000010412151
1.REPLACE TRACTION MOTOR INVERTER

Replace the traction motor inverter. Refer to TMS-106, "Removal and Installation".
>> END
TMS-44
P0A2C DRIVE MOTOR A TEMP SENSOR
A
DTC DETECTION LOGIC B

(Trouble diagnosis content) TMS
DRIVE MOTOR A TEMP SENSOR Traction motor temperature sensor signal interruption
P0A2C
(Drive Motor “A” Temperature Sensor Circuit Low) for 2 seconds or more
POSSIBLE CAUSE D
• Harness or connectors (Each circuit is open or shorted.)
• Traction motor
• Traction motor Inverter E
FAIL-SAFE
Limits the maximum torque of traction motor to 40% or less
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
2. Check DTC.
Is “P0A2C” detected? J
NO-2 >> Confirmation after repair: INSPECTION END K
1.CHECK TRACTION MOTOR INVERTER HARNESS CONNECTOR L

2. Check the connection conditions of the traction motor inverter harness connector.
M
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair or replace damaged parts.
N
2.CHECK TRACTION MOTOR HARNESS CONNECTOR
Check the connection conditions of the traction motor harness connector.
Is the inspection result normal? O
YES >> GO TO 3.
3.CHECK TRACTION MOTOR TEMPERATURE SENSOR CIRCUIT P
1. Disconnect the traction motor inverter harness connector.

2. Check the resistance between traction motor inverter vehicle side harness connector terminals and
ground.
TMS-45

Ground Resistance
Connector Terminal
44
F17 Ground 200 kΩ or more
45
YES >> GO TO 4.
4. CHECK TRACTION MOTOR TEMPERATURE SENSOR CIRCUIT
1. Disconnect the traction motor harness connector.
2. Check the resistance between traction motor inverter vehicle side harness connector terminals and trac-
tion motor vehicle side harness connector terminals.
Traction motor inverter Traction motor

Resistance
Connector Terminal Connector Terminal
44 4
F17 F14 1 Ω or less
45 3
3. Check the harness for short.

Resistance
44 3
F17 F14 100 kΩ or more
45 4
YES >> GO TO 5.
5.CHECK TRACTION MOTOR TEMPERATURE SENSOR
Check the traction motor temperature sensor. Refer to TMS-46, "Component Inspection (Traction Motor Tem-
perature Sensor)".
YES >> Replace the traction motor inverter. Refer to TMS-106, "Removal and Installation".
NO >> Replace the traction motor. Refer to TMS-112, "Removal and Installation".
Component Inspection (Traction Motor Temperature Sensor) INFOID:0000000010412154
1. CHECK TRACTION MOTOR TEMPERATURE SENSOR

Check the resistance between traction motor connector terminals.
Traction motor connector

Resistance
Terminal
3 4
JPCIA0030GB
TMS-46
YES >> INSPECTION END A
NO >> Replace the traction motor due to malfunction in the traction motor temperature sensor. Refer to
TMS-112, "Removal and Installation".
B
TMS
TMS-47
P0A2D DRIVE MOTOR A TEMP SENSOR
DTC DETECTION LOGIC

DRIVE MOTOR A TEMP SENSOR A maximum value signal from the traction motor temper-
P0A2D
(Drive Motor “A” Temperature Sensor Circuit High) ature sensor is detected for 2 seconds or more
POSSIBLE CAUSE
• Traction motor
• Traction motor Inverter
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.
Is “P0A2D” detected?
1.CHECK TRACTION MOTOR INVERTER HARNESS CONNECTOR

YES >> GO TO 2.
YES >> GO TO 3.
3.CHECK TRACTION MOTOR TEMPERATURE SENSOR CIRCUIT
ground.
TMS-48
Traction motor inverter A

Ground Resistance
Connector Terminal
44
F17 Ground 200 kΩ or more B
45
YES >> GO TO 4. TMS
4. CHECK TRACTION MOTOR TEMPERATURE SENSOR CIRCUIT
1. Disconnect the traction motor harness connector. D
E
Resistance
44 4 F
45 3
G
Resistance
H
44 3
F17 F14 100 kΩ or more
45 4
Is the inspection result normal? I
YES >> GO TO 5.
5.CHECK TRACTION MOTOR TEMPERATURE SENSOR J
perature Sensor)".
K
NO >> Replace the traction motor. Refer to TMS-112, "Removal and Installation". L
1. CHECK TRACTION MOTOR TEMPERATURE SENSOR M

Traction motor connector N

Resistance
Terminal
O
P
3 4
JPCIA0030GB
TMS-49
YES >> INSPECTION END
TMS-50
P0A2F DRIVE MOTOR A OVER TEMPERATURE
A

DRIVE MOTOR A OVER TEMPERATURE Traction motor temperature is higher than the usable
P0A2F
(Drive Motor “A” Over Temperature) temperature for 2 consecutive seconds or more
POSSIBLE CAUSE D
• Traction motor inverter
• Traction motor
• High voltage cooling system E
FAIL-SAFE
Stops drive control of traction motor
F
CAUTION:
Always drive vehicle at a safe speed.
G
1.PRECONDITIONING
at least 10 seconds before conducting the next test. H
>> GO TO 2.
I
With CONSULT
1. Set the vehicle to READY and wait for 10 seconds or more. J
2. Drive during 20 minutes for warm-up.
3. Repeat driving of 0 km/h (0 MPH) → 60 km/h (37 MPH) with full acceleration 10 times without interval.
4. Stop the vehicle.
5. Check DTC. K
Is “P0A2F” detected?
L
M
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of N
maintenance. O
WARNING:
ing inspection or maintenance of high voltage system harnesses and parts. P
• Refer to TMS-5, "High Voltage Precautions".
TMS-51
CAUTION:
1.CHECK DTC HIGH VOLTAGE COOLING SYSTEM
2. Perform “Self Diagnostic Results” in “EV/HEV”.
YES >> Check DTC detected item. Refer to EVC-98, "DTC Index".
NO >> GO TO 2.
2.CHECK COOLANT WATER
Check the coolant level and check for coolant leakage. Refer to HCO-11, "Inspection".
YES >> GO TO 3.
3.CHECK COOLANT HOSE
Check for clogging of fluid paths and twisting of hoses in traction motor inverter, traction motor, and PDM
(Power Delivery Module). Refer to HCO-7, "High Voltage Cooling System".
YES >> GO TO 4.
4.PRECONDITIONING
WARNING:
Follow the instructions below before starting the procedure.
1. Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage".
2. Check voltage in high voltage circuit. Refer to GI-31, "Check Voltage in High Voltage Circuit".
>> GO TO 5.
5.CHECK TRACTION MOTOR INSULATION RESISTANCE
Check the traction motor insulation resistance. Refer to TMS-101, "Component Inspection".
YES >> GO TO 6.
NO >> Remove the traction motor. Refer to TMS-112, "Removal and Installation".
6.CHECK TRACTION MOTOR TEMPERATURE SENSOR
perature Sensor)".
YES >> GO TO 7.
NO >> Remove the traction motor. Refer to TMS-112, "Removal and Installation".
7.CHECK RESISTANCE OF TRACTION MOTOR STATOR COIL
Check the resistance of traction motor stator coil. Refer to TMS-53, "Component Inspection (Traction Motor
Stator Coil)".
YES >> 1. Replace the traction motor. Refer to TMS-112, "Removal and Installation".
2. If DTC "P0A2F" is still detected after traction motor replacement, replace the traction motor
inverter. Refer to TMS-106, "Removal and Installation".
1. CHECK TRACTION MOTOR TEMPERATURE SENSOR

TMS-52
A
Resistance
Terminal
Within ± 50% of temperature characteristics diagram B
TMS
3 4
D
E
JPCIA0030GB

F
G
Component Inspection (Traction Motor Stator Coil) INFOID:0000000010412161
1.CHECK RESISTANCE OF TRACTION MOTOR STATOR COIL H

Using a milliohmmeter and check the resistance traction motor stator coil.
CAUTION:
As resistance of stator coil is affected by temperature, check it at least 8 hour after removal of service I
plug.
3-phase bus-bar
Resistance* J
Terminal
U-phase V-phase
V-phase W-phase 14.1 – 17.9 mΩ K
W-phase U-phase
*: The value is at 20°C (68°F). Calculate the resistance standard value based on actual ambient temperature
at operation based on the below calculation formula. L
Calculating formula
• R20=R/[1+ 0.00393 × (T−20)]
M
- R20: Resistance value (mΩ) at 20°C (68°F)
- R: Resistance value (mΩ) at actual ambient temperature at operation
- T: Actual ambient temperature [°C (°F)] at operation
Is the inspection result normal? N
NO >> Replace the traction motor due to malfunction in the stator coil. Refer to TMS-112, "Removal and
Installation". O
TMS-53
P0A3F DRIVE MOTOR A POSITION SENSOR
DTC DETECTION LOGIC

DRIVE MOTOR A POSITION SENSOR If there is an abnormality in the traction motor resolver
P0A3F
(Drive Motor “A” Position Sensor Circuit) detection circuit
POSSIBLE CAUSE
• Traction motor
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.
Is “P0A3F” detected?

YES >> GO TO 2.
YES >> GO TO 3.
3.CHECK TRACTION MOTOR RESOLVER CIRCUIT
ground.
TMS-54
Traction motor inverter A

Ground Resistance
Connector Terminal
17
18
B
19
20 TMS
21
27
Is the inspection result normal? D
YES >> GO TO 4.
E
4. CHECK TRACTION MOTOR RESOLVER CIRCUIT
2. Check the resistance between traction motor inverter vehicle side harness connector terminals and trac- F

Resistance G
17 6
18 7 H
19 5
20 1
I
21 8
27 2
3. Check the harness for short. J

Resistance
Connector Terminal K
17 18
F17 19 27 100 kΩ or more
L
20 21
YES >> GO TO 5. M
5.CHECK TRACTION MOTOR RESOLVER
Check the traction motor resolver. Refer to TMS-55, "Component Inspection (Traction Motor Resolver)". N
NO >> Replace the traction motor. Refer to TMS-112, "Removal and Installation". O
Component Inspection (Traction Motor Resolver) INFOID:0000000010412164
P
1. Disconnect the traction motor connector.
2. Check the resistance between traction motor connector terminals.
TMS-55

Resistance
Terminal
1 8 20 – 35 Ω
2 5 8 – 15 Ω
6 7 20 – 35 Ω
NO >> Replace the traction motor due to malfunction in the traction motor resolver. Refer to TMS-112,
"Removal and Installation".
TMS-56
P0A44 DRIVE MOTOR A OVER SPEED
A

DRIVE MOTOR A OVER SPEED If the value detected for motor speed at the traction mo-
P0A44
(Drive Motor “A” Position Sensor Circuit Overspeed) tor resolver is too high
POSSIBLE CAUSE D
• Traction motor
• Traction motor inverter E
FAIL-SAFE
F
CAUTION:
G
1.PRECONDITIONING
at least 10 seconds before conducting the next test. H
>> GO TO 2.
I
With CONSULT
1. Set the vehicle to READY and wait for 10 seconds or more. J
2. Accelerate to 60 km/h (37 MPH).
4. Check DTC.
K
Is “P0A44” detected?
L
M
2. Check the connection conditions of the traction motor inverter harness connector. N
YES >> GO TO 2.
NO >> Repair or replace damaged parts. O
P
YES >> GO TO 3.
3.CHECK TRACTION MOTOR RESOLVER CIRCUIT
TMS-57
ground.

Ground Resistance
Connector Terminal
17
18
19
20
21
27
YES >> GO TO 4.
4. CHECK TRACTION MOTOR RESOLVER CIRCUIT

Resistance
17 6
18 7
19 5
20 1
21 8
27 2

Resistance
Connector Terminal
17 18
F17 20 21 100 kΩ or more
19 27
YES >> GO TO 5.
Check the traction motor resolver. Refer to TMS-58, "Component Inspection (Traction Motor Resolver)".
Component Inspection (Traction Motor Resolver) INFOID:0000000010412167

1. Disconnect the traction motor connector.
2. Check the resistance between traction motor connector terminals.
T M S -5 8
Traction motor connector A

Resistance
Terminal
1 8 20 – 35 Ω
2 5 8 – 15 Ω
B
6 7 20 – 35 Ω
Is the inspection result normal? TMS
NO >> Replace the traction motor due to malfunction in the traction motor resolver. Refer to TMS-112,
"Removal and Installation". D
TMS-59
P0A78 DRIVE MOTOR A INVERTER
P0A78 DRIVE MOTOR A INVERTER
DTC DETECTION LOGIC

DRIVE MOTOR A INVERTER A malfunction is detected in the traction motor inverter
P0A78
(Drive Motor “A” Inverter Performance) (motor controller)
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.

>> END
TMS-60
P0A8D 14VOLT POWER VOLTAGE
A

14VOLT POWER VOLTAGE
P0A8D The voltage of 12V battery drops to approx. 8 V or less
(14 Volt Power Module System Voltage Low)
POSSIBLE CAUSE D
• Harness, fuse, or connectors (Each circuit is open or shorted.)
• M/C relay E
FAIL-SAFE
Stops drive control of traction motor, and requires system main relay OFF to VCM
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
2. Check DTC.
Is “P0A8D” detected? J
1.CHECK TRACTION MOTOR INVERTER HARNESS CONNECTOR L

M
YES >> GO TO 2.
N
2.CHECK POWER SUPPLY CIRCUIT
2. Check the 10A fuse (#82). O
3. Power switch ON.
4. Check the voltage between traction motor inverter vehicle side harness connector terminals.
P
Terminal Voltage
Connector
+ −
46
F17 47, 49 9 – 16 V
48
TMS-61
NO >> Check the M/C relay. Refer to EVC-371, "Diagnosis Procedure".
TMS-62
P0BE5 D-MOTOR A PHASE U CURRENT SEN
A

D-MOTOR A PHASE U CURRENT SEN Detection values differ between the current sensors (in-
P0BE5
(Drive Motor “A” Phase U Current Sensor Circuit) ner sensor 1 and 2) of the tranction motor U-phase
POSSIBLE CAUSE D
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
2.CHECK DTC DETECTION H
With CONSULT
1. Set the vehicle to READY and wait for 10 seconds or more.
2. Accelerate to 60 km/h (37 MPH). I
4. Check DTC.
Is “P0BE5” detected? J
1.REPLACE TRACTION MOTOR INVERTER L
M
>> END
TMS-63
DTC DETECTION LOGIC

D-MOTOR A PHASE U CURRENT SEN
If the value detected by the traction motor U-phase cur-
P0BE6 (Drive Motor “A” Phase U Current Sensor Circuit Range/
rent sensor is abnormal
Performance)
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.
Is “P0BE6” detected?

>> END
TMS-64
P0BE9 D-MOTOR A PHASE V CURRENT SEN
P0BE9 D-MOTOR A PHASE V CURRENT SEN
A

D-MOTOR A PHASE V CURRENT SEN Detection values differ between the current sensors (in-
P0BE9
(Drive Motor “A” Phase V Current Sensor Circuit) ner sensor 1 and 2) of the traction motor V-phase
POSSIBLE CAUSE D
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
2. Accelerate to 60 km/h (37 MPH). I
4. Check DTC.
Is “P0BE9” detected? J
1.REPLACE TRACTION MOTOR INVERTER L
M
>> END
TMS-65
P0BEA D-MOTOR A PHASE V CURRENT SEN
P0BEA D-MOTOR A PHASE V CURRENT SEN
DTC DETECTION LOGIC

D-MOTOR A PHASE V CURRENT SEN
If the value detected by the traction motor V-phase cur-
P0BEA (Drive Motor “A” Phase V Current Sensor Circuit Range/
rent sensor is abnormal
Performance)
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.
Is “P0BEA” detected?

>> END
TMS-66
P0C79 DRIVE MOTOR A INVERTER VOLTAGE
A

High voltage value is any of the following conditions:
DRIVE MOTOR A INVERTER VOLTAGE • Approx. 500 V or more
P0C79
(Drive Motor “A” Inverter Voltage Too Hight) • More than the traction motor inverter operable voltage
range for 100 ms or more continuously D
POSSIBLE CAUSE
• High voltage harness or connector
• Li-ion battery
• High voltage parts except for traction motor inverter
F
FAIL-SAFE
DTC CONFIRMATION PROCEDURE G
CAUTION:
1.PRECONDITIONING H
I
>> GO TO 2.
2.CHECK DTC DETECTION J
With CONSULT
2. Accelerate to 60 km/h (37 MPH). K
4. Check DTC.
Is “P0C79” detected? L
NO-2 >> Confirmation after repair: INSPECTION END M
DANGER: N
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are O
maintenance.
WARNING:
P
TMS-67
CAUTION:
1.CHECK DTC HIGH VOLTAGE SYSTEMS
2. Check DTC of the high voltage systems.
Were there any detected DTC related to a high voltage systems other than the traction motor inverter?
YES >> Check DTC detected item.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
3.CHECK HIGH VOLTAGE HARNESS
Check for an open circuit or short circuit between PDM (Power Delivery Module) and Li-ion battery. Refer to
TMS-18, "TRACTION MOTOR INVERTER : Circuit Diagram".
TMS-68
P318E CAN ERROR
P318E CAN ERROR
A

CAN ERROR Traction motor inverter is unable to receive the EV sys-
P318E
(CAN data error) tem CAN signal from VCM
POSSIBLE CAUSE D
VCM
FAIL-SAFE E
• Limits the maximum torque of traction motor to 0% F

1.PRECONDITIONING G
H
>> GO TO 2.
2.CHECK DTC DETECTION I
With CONSULT
2. Check DTC. J
Is “P318E” detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". K
L
1.REPLACE VCM
Replace the VCM. Refer to EVC-404, "Removal and Installation".
M
>> END
N
TMS-69
P3193 CAN ERROR
P3193 CAN ERROR
DTC DETECTION LOGIC

Traction motor inverter is unable to receive the EV sys-
CAN ERROR
P3193 tem CAN signal from Li-ion battery controller continu-
(CAN data error)
ously for 2 seconds or more
POSSIBLE CAUSE
FAIL-SAFE
No impact to vehicle behavior
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.
Is “P3193” detected?
1.REPLACE LI-ION BATTERY CONTROLLER

Replace the Li-ion battery controller. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal and
Installation" (Without battery cooler), EVB-511, "LI-ION BATTERY CONTROLLER : Removal and Installation"
(With battery cooler), EVB-807, "LI-ION BATTERY CONTROLLER : Removal and Installation" (With battery
heater & cooler).
>> END
TMS-70
P3199 CAN ERROR
P3199 CAN ERROR
A

CAN ERROR
P3199 If traction motor inverter detects CAN data error
(CAN data error)
POSSIBLE CAUSE D
VCM
FAIL-SAFE E

1.PRECONDITIONING G
H
>> GO TO 2.
With CONSULT
2. Check DTC. J
L
1.REPLACE VCM
M
>> END
N
TMS-71
P319E CAN ERROR
P319E CAN ERROR
DTC DETECTION LOGIC

CAN ERROR If traction motor inverter detects CAN data error contin-
P319E
(CAN data error) uously for 2 seconds or more
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.

heater & cooler).
>> END
TMS-72
P31A4 CAN ERROR
P31A4 CAN ERROR
A

CAN ERROR
P31A4 If traction motor inverter detects CAN data error
(CAN data error)
POSSIBLE CAUSE D
VCM
FAIL-SAFE E

1.PRECONDITIONING G
H
>> GO TO 2.
With CONSULT
2. Check DTC. J
L
1.REPLACE VCM
M
>> END
N
TMS-73
P31A9 CAN ERROR
P31A9 CAN ERROR
DTC DETECTION LOGIC

P31A9
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.

heater & cooler).
>> END
TMS-74
P3240 DRIVE MOTOR A INVERTER CRNT CONT
A

DRIVE MOTOR A INVERTER CRNT CONT
Abnormal output voltage of traction motor inverter due to
P3240 (Drive Motor “A” Inverter Performance/Motor Current
abnormal current flow to the traction motor
Control Error)
D
POSSIBLE CAUSE
• Traction motor E
• Li-ion battery
FAIL-SAFE F
CAUTION: G
1.PRECONDITIONING H
I
>> GO TO 2.
J
With CONSULT
2. Fully open the accelerator and accelerate the vehicle to 60 km/h (37 MPH).
3. Stop the vehicle. K
4. Check DTC.
YES >> Go to TMS-75, "Diagnosis Procedure". L
M
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 disconnect the high voltage circuits before perform- P
TMS-75
CAUTION:
NO >> GO TO 2.
2.CHECK TRACTION MOTOR RESOLVER OFFSET DATA
1. Use CONSULT to read the traction motor resolver offset, and record the result.
NOTE:
“Work support” - “RESOLVER WRITE” can be used to check the traction motor resolver offset that is cur-
rently stored by the traction motor inverter.
2. Remove the under cover and record the traction motor resolver offset that is stamped on the traction
motor.
NOTE:
For the location of traction motor resolver offset stamping, refer to TMS-42, "Description".
3. Check whether or not the value read with CONSULT matches the value which was stamped on the trac-
tion motor.
Do the values match?
YES >> GO TO 3.
NO >> Write the traction motor resolver offset to the traction motor inverter. Refer to TMS-42, "Work Pro-
cedure".
3.PRECONDITIONING
WARNING:
>> GO TO 4.
YES >> GO TO 5.
5.CHECK TRACTION MOTOR INVERTER HIGH VOLTAGE BUS BAR
Remove bus bar cover from PDM (Power Delivery Module) and check the tightness of high voltage bas bar.
Refer to VC-105, "Exploded View".
YES >> GO TO 6.
NO >> Tighten the high voltage bus bar to the specified torque. Refer to VC-105, "Exploded View".
6.CHECK THE CONNECTION CONDITIONS OF THE 3-PHASE BUS BAR
Remove bus bar cover from traction motor and check the tightness of the 3-phase bus bar. Refer to TMS-112,
YES >> GO TO 7.
NO >> Tighten the 3-phase bus bar to the specified torque. Refer to TMS-111, "Exploded View".
7.CHECK DISCONNECTION TRACTION MOTOR STATOR COIL
TMS-76
1. Remove the traction motor inverter. Refer to TMS-106, "Removal and Installation".
2. Check stator coil for open circuit from the opening of the traction motor 3-phase bus bar. A
3-phase bus bar

Resistance
Terminal B
U-phase V-phase
V-phase W-phase 1Ω or less
TMS
W-phase U-phase
YES >> Replace the traction motor inverter. Refer to TMS-106, "Removal and Installation". D
TMS-77
DTC DETECTION LOGIC

DRIVE MOTOR A INVERTER CRNT CONT
If no current is being applied to 1 phase of the traction
P3241 (Drive Motor “A” Inverter Performance/AC Error Detec-
motor
tion)
POSSIBLE CAUSE
• Traction motor
FAIL-SAFE
CAUTION:
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Fully open the accelerator and accelerate the vehicle to 10 km/h (6 MPH).
4. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
TMS-78
instructed in the Service Manual. A malfunction may occur if this is not observed. A
1.PRECONDITIONING
WARNING: B
TMS
>> GO TO 2.
2.CHECK THE CONNECTION CONDITIONS OF THE 3-PHASE BUS BAR D
Remove bus bar cover from traction motor and check the tightness of the 3-phase bus bar. Refer to TMS-112,
Is the inspection result normal? E
YES >> GO TO 3.
NO >> Tighten the 3-phase bus bar to the specified torque. Refer to TMS-111, "Exploded View".
3.CHECK DISCONNECTION TRACTION MOTOR STATOR COIL F
2. Check stator coil for open circuit from the opening of the traction motor 3-phase bus bar.
G
3-phase bus bar
Resistance
Terminal
H
U-phase V-phase
V-phase W-phase 1Ω or less
W-phase U-phase I
NO >> Replace the traction motor. Refer to TMS-112, "Removal and Installation". J
TMS-79
P3242 D-MOTOR A PHASE U CURRENT SEN
P3242 D-MOTOR A PHASE U CURRENT SEN
DTC DETECTION LOGIC

D-MOTOR A PHASE U CURRENT SEN 2 Abnormal detection value of the traction motor U-phase
P3242
(Drive Motor “A” Phase U Current Sensor Circuit) current sensor 2
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.

>> END
TMS-80
P3243 D-MOTOR A PHASE V CURRENT SEN
P3243 D-MOTOR A PHASE V CURRENT SEN
A

D-MOTOR A PHASE V CURRENT SEN 2 Abnormal detection value of the traction motor V-phase
P3243
(Drive Motor “A” Phase V Current Sensor Circuit) current sensor 2
POSSIBLE CAUSE D
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
2. Check DTC. I
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". J
K
Replace the traction motor inverter. Refer to TMS-106, "Removal and Installation". L
>> END
M
TMS-81
P3244 DRIVE MOTOR A INVERTER
DTC DETECTION LOGIC

High voltage detection value of Li-ion battery controller
DRIVE MOTOR A INVERTER
P3244 differs largely from that of traction motor inverter for 10
(Drive Motor “A” Inverter Voltage Sensor Performance)
consecutive seconds or more
POSSIBLE CAUSE
• Li-ion battery
FAIL-SAFE
CAUTION:
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Accelerate to 60 km/h (37 MPH).
4. Check DTC.
DANGER:
maintenance.
WARNING:
TMS-82
CAUTION: A
1.CHECK DTC HIGH VOLTAGE SYSTEMS B
Were there any detected DTC related to a high voltage systems other than the traction motor inverter? TMS
NO >> GO TO 2.
2.PRECONDITIONING D
WARNING:
Follow the instructions below before starting the procedure. E
F
>> GO TO 3.
Remove bus bar cover from PDM (Power Delivery Module) and check the tightness of high voltage bas bar. G
H
YES >> GO TO 4.
4.CHECK HIGH VOLTAGE HARNESS I
Is the inspection result normal? J
K
TMS-83
DTC DETECTION LOGIC

DRIVE MOTOR A INVERTER A malfunction is detected in high voltage sensor for 0.3
P3245
(Drive Motor “A” Inverter Voltage Sensor Circuit) seconds or more
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.

>> END
TMS-84
A

DRIVE MOTOR A INVERTER Driver circuit power does not come ON when starting EV
P3247
(Drive Motor “A” Inverter Driver Power Supply) system
POSSIBLE CAUSE D
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
2. Check DTC. I
K
>> END
M
TMS-85
DTC DETECTION LOGIC

DRIVE MOTOR A INVERTER Power supply voltage of the driver circuit is low or
P3249
(Drive Motor “A” Inverter Driver Signal) stopped
POSSIBLE CAUSE
FAIL-SAFE
Stops drive control of traction motor, and requires system main relay OFF to VCM
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.

>> END
TMS-86
P324A DRIVE MOTOR A INVERTER VOLTAGE
A

DRIVE MOTOR A INVERTER VOLTAGE Precharging does not start for 10 consecutive seconds
P324A
(Drive Motor “A” Inverter Charge Error) or more when starting EV system
POSSIBLE CAUSE D
• Li-ion battery E
FAIL-SAFE
Stops drive control of traction motor F

1.PRECONDITIONING G
H
>> GO TO 2.
With CONSULT
2. Check DTC. J
Is “P324A” detected?
L
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of M
maintenance.
N
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in O
before beginning work on the high voltage system. P
CAUTION:
TMS-87
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
Remove bus bar cover from PDM (Power Delivery Module) and check the tightness of high voltage bas bar.
YES >> GO TO 4.
TMS-88
P324D DRIVE MOTOR A INVERTER IGBT
A

Traction motor inverter detects any of the following con-
DRIVE MOTOR A INVERTER IGBT
ditions:
P324D [Drive Motor “A” Inverter IGBT Over Load (Over Current/
• Overcurrent to IGBT
Over Temperature)] D
• IGBT temperature exceeds the usable temperature
POSSIBLE CAUSE
• Traction motor
• High voltage cooling system
FAIL-SAFE F
CAUTION: G
1.PRECONDITIONING H
I
>> GO TO 2.
J
With CONSULT
3. Repeat driving of 0 km/h (0 MPH) → 60 km/h (37 MPH) with full acceleration 10 times without interval. K
5. Check DTC.
Is “P324D” detected? L
DANGER: N
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are O
maintenance.
WARNING:
P
TMS-89
CAUTION:
NO >> GO TO 2.
YES >> GO TO 3.
YES >> GO TO 4.
4.PRECONDITIONING
WARNING:
>> GO TO 5.
Check the traction motor insulation resistance. Refer to TMS-101, "Component Inspection".
YES >> GO TO 6.
6.CHECK RESISTANCE TRACTION MOTOR STATOR COIL
Check the resistance traction motor stator coil. Refer to TMS-90, "Component Inspection (Traction Motor Sta-
tor Coil)".
Component Inspection (Traction Motor Stator Coil) INFOID:0000000010412220
1.CHECK RESISTANCE OF TRACTION MOTOR STATOR COIL

Using a milliohmmeter and check the resistance traction motor stator coil.
CAUTION:
As resistance of stator coil is affected by temperature, check it at least 8 hour after removal of service
plug.
TMS-90
3-phase harness A
Resistance*
Terminal
U-phase V-phase
V-phase W-phase 14.1 – 17.9 mΩ
B
W-phase U-phase
*: The value is at 20°C (68°F). Calculate the resistance standard value based on actual ambient temperature TMS
at operation based on the below calculation formula.
Calculating formula
• R20=R/[1+ 0.00393 × (T−20)] D
- R20: Resistance value (mΩ) at 20°C (68°F)
- R: Resistance value (mΩ) at actual ambient temperature at operation
- T: Actual ambient temperature [°C (°F)] at operation E
NO >> Replace the traction motor due to malfunction in the stator coil. Refer to TMS-112, "Removal and F
Installation".
TMS-91
P3252 DRIVE MOTOR A INVERTER IGBT
DTC DETECTION LOGIC

DRIVE MOTOR A INVERTER IGBT The amount of rise in IGBT temperature is excessively
P3252
(Drive Motor “A” Inverter IGBT High Temperature) large compared with that of normal condition
POSSIBLE CAUSE
FAIL-SAFE
CAUTION:
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
3. Repeat driving of 0 km/h (0 MPH) → 60 km/h (37 MPH) with full acceleration 10 times without interval.
5. Check DTC.

NO >> GO TO 2.
YES >> GO TO 3.
TMS-92
YES >> Replace the traction motor inverter. Refer to TMS-106, "Removal and Installation". A
TMS
TMS-93
P325A CAN ERROR
P325A CAN ERROR
DTC DETECTION LOGIC

P325A
POSSIBLE CAUSE
VCM
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.
1.REPLACE VCM
>> END
TMS-94
P325B DRIVE MOTOR A INVERTER
P325B DRIVE MOTOR A INVERTER
A

DRIVE MOTOR A INVERTER IGBT high temperature detection signal sticks when
P325B
(Drive Motor “A” Inverter TEMP-M Circuit) starting EV system
POSSIBLE CAUSE D
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
2. Check DTC. I
Is “P325B” detected?
K
>> END
M
TMS-95
P325C DRIVE MOTOR A POSITION
P325C DRIVE MOTOR A POSITION
DTC DETECTION LOGIC

DRIVE MOTOR A POSITION When correction value memorized by traction motor in-
P325C
(Drive Motor “A” Position Value Unrecorded) verter is the initial value
POSSIBLE CAUSE
The traction motor resolver offset has not been written to the traction motor inverter
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1. Power switch OFF and wait for 10 seconds or more.
3. Check DTC.
Is “P325C” detected?
1.RECORDING THE TRACTION MOTOR RESOLVER OFSET THAT IS STAMPED ON THE TRACTION MO-
TOR
2. Write down the traction motor resolver correction value inscribed on traction motor.
NOTE:
For the traction motor stamp location, refer to TMS-42, "Description".
>> GO TO 2.
2.WRITING OF TRACTION MOTOR RESOLVER OFFSET
Write the traction motor resolver offset to the traction motor inverter. Refer to TMS-42, "Work Procedure".
>> GO TO 3.
3.READING AND CHECKING TRACTION MOTOR RESOLVER OFFSET
1. Power switch OFF and wait for 10 seconds or more.
2. Power switch ON.
3. Use CONSULT to read the traction motor offset that is written to the traction motor inverter.
4. Check whether or not the read value matches the value which is stamped on the traction motor.
>> INSPECTION END
TMS-96
P325D DRIVE MOTOR A POSITION
P325D DRIVE MOTOR A POSITION
A

DRIVE MOTOR A POSITION If the traction motor resolver angle data stored by the
P325D
(Drive Motor “A” Position Offset Value Error) traction motor inverter is abnormal
POSSIBLE CAUSE D
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
2. Check DTC. I
Is “P325D” detected?
K
>> END
M
TMS-97
P325E DRIVE MOTOR A POSITION
P325E DRIVE MOTOR A POSITION
DTC DETECTION LOGIC

DRIVE MOTOR A POSITION If the traction motor resolver offset stored by the traction
P325E
(Drive Motor “A” Position Value Error 1) motor inverter is abnormal
POSSIBLE CAUSE
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.

>> END
TMS-98
P325F DRIVE MOTOR A POSITION
P325F DRIVE MOTOR A POSITION
A

DRIVE MOTOR A POSITION If the traction motor resolver offset stored by the traction
P325F
(Drive Motor “A” Position Value Error) motor inverter is abnormal
POSSIBLE CAUSE D
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
2. Check DTC. I
Is “P325F” detected?
K
>> END
M
TMS-99
U1000 CAN COMM CIRCUIT
CAN (Controller Area Network) is a serial communication line for real-time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent malfunction detection abil-
ity.Many electronic control units are equipped onto a vehicle, and each control unit shares information and
linkswith other control units during operation (not independently). In CAN communication, control units are
connected with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmis-
sion with less wiring. Each control unit transmits/receives data but selectively reads required data only.
DTC DETECTION LOGIC

CAN COMM CIRCUIT If CAN communications signals continuously for 2 sec-
U1000
(CAN communication line) onds or more cannot be transmitted
POSSIBLE CAUSE
Harness or connectors (CAN communication line is open or shorted.)
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Check DTC.
Is “U1000” detected?
For the diagnosis procedure, refer to LAN-21, "Trouble Diagnosis Flow Chart".
TMS-100
TRACTION MOTOR INSULATION RESISTANCE CHECK
A
Component Inspection INFOID:0000000010412238
DANGER: B
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and TMS
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
CAUTION: G
1.PRECONDITIONING H
WARNING:
1. Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage". I
>> GO TO 2. J

WARNING: K
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 L
and be sure to work safely.
1. Remove the traction motor. Refer to TMS-112, "Removal and Installation".
2. Use 500V range of insulation resistance tester to measure insu-
lation resistance. Wait for 30 seconds until the value becomes M
stable.
CAUTION:
Be sure to set the insulation resistance tester to 500 V when N
performing this test. Using a setting higher than 500 V can
result in damage to the component being inspected.
NOTE:
As each bus bar (U-phase, V-phase, and W-phase) contacts to O
each other inside the traction motor, check resistance of a
phase.
JSCIA0668ZZ
P
3-phase bus bar
Ground Resistance
Terminal
U-phase
V-phase Traction motor case 10 MΩ or more
W-phase
TMS-101
TMS-102
TRACTION MOTOR INVERTER INSULATION RESISTANCE CHECK
A
DANGER: B
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and TMS
maintenance.
WARNING:
CAUTION: G
1.PRECONDITIONING H
WARNING:
1. Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage". I
>> GO TO 2. J
2.CHECK TRACTION MOTOR INVERTER INSULATION RESISTANCE

WARNING: K
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 L
2. Use 500V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until
the value becomes stable. M
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting
higher than 500 V can result in damage to the component being inspected. N
TMS-103

Ground Resistance
Item Terminal
50
High voltage bus bar
51
Traction motor in-
U-phase 14 MΩ or more
verter case
3-phase bus bar V-phase
W-phase
NO >> Replace the traction motor inverter. Refer to TMS-106,
JSCIA0669ZZ
TMS-104
ELECTROMAGNETIC SOUND IS AUDIBLE
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
ELECTROMAGNETIC SOUND IS AUDIBLE
DESCRIPTION INFOID:0000000010412240
B
The electromagnetic noise of the traction motor may become more noticeable when accelerating on a steep
slope (large output torque).
This occurs when the IGBT switching frequency is lowered by the traction motor inverter due to high tempera- TMS
ture of the IGBT inside the traction motor inverter. This does not indicate a problem with the traction motor
inverter characteristics or control.
This phenomenon is one of the protective controls. Refer to TMS-32, "Protection Control". D
TMS-105
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
Exploded View INFOID:0000000010412241
JSCIA0661GB
PDM (Power Delivery Module) Traction motor inverter Gasket

3-phase bus bar cover High voltage warning label Traction motor and reduction gear
Seal Bracket Sound insulating board
: Vehicle front
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
: Apply lithium-based grease including molybdenum disulphide.
Removal and Installation INFOID:0000000010412242
DANGER:
maintenance.
WARNING:
TMS-106
the tool box during the procedure to prevent the plug from being connected by mistake. A
B
CAUTION: TMS
REMOVAL D
WARNING:
• Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage". E
• Check voltage in high voltage circuit. Refer to GI-31, "Check Voltage in High Voltage Circuit".
1. Remove the PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation".
2. Remove the water hose between traction motor inverter and F
traction motor.
WARNING:
To prevent electric shock hazards, be sure to put on insulat- G
ing protective gear before beginning work on the high volt-
age system.
H
JSCIA0670ZZ
I
3. Remove the traction motor inverter connector cover .

WARNING: J
To prevent electric shock hazards, be sure to put on insulat-
age system. K
JSCIA0671ZZ
M
4. Disconnect the traction motor inverter connect .
WARNING:
To prevent electric shock hazards, be sure to put on insulat- N
age system.
5. Remove bracket. (Without air conditioning system) Refer to

TMS-111, "Exploded View". P
JSCIA0672ZZ
TMS-107
6. Remove the 3-phase bus bar cover and gasket.
WARNING:
age system.
JSCIA0673ZZ
7. Remove the 3-phase bus bar mounting bolts ( ).

WARNING:
age system.
CAUTION:
• When removing the 3-phase bus bar mounting bolt, never
drop the bolt into the traction motor. JSCIA0674ZZ
• After the 3-phase bus bar mounting bolt is removed, close

off the opening using tape or an equivalent to prevent dirt, dust, or foreign material from enter-
ing the traction motor. When leaving workspace for a long time, install the 3-phase bus bar
cover.
8. Remove the traction motor inverter mounting bolts ( ).

WARNING:
age system.
JSCIA0675ZZ
9. Install the guide pin (SST: KV99112300) (A) to the traction motor
inverter mounting bolt hole (2 holes located in vehicle rear).
WARNING:
age system.
Guide pin (A) : 96 mm (3.78 in) JSCIA0676ZZ
: Vehicle front
NOTE:
Perform installation and removal of guide pins manually.
10. Remove the traction motor inverter by hands.

WARNING:
TMS-108
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning
work on the high voltage system. A
B
CAUTION:
• Remove the traction motor inverter in the vertical direction.
• Never damage the 3-phase bus bar.
• Never damage the bolt hole threaded portion located on the traction motor side, where the guide TMS
pin is installed.
NOTE:
Dowel pins are located around the traction motor inverter mounting bolt hole (two locations) in vehicle D
front.
11. When leaving the traction motor inverter, use wooden blocks to
prevent 3-phase bus bar interference.
E
WARNING:
age system. F
G
CAUTION:
Never set the traction motor inverter on wood blocks in a JSCIA0687ZZ
position in which it is supported by dowel pins.
H
12. Cover the 3-phase bus bar with shop cloth .
WARNING:
To prevent electric shock hazards, be sure to put on insulat- I
age system.
J
CAUTION:
Always protect the bus bar section with a clean shop cloth. K
If the bus bar is touched or dirty, clean it using ethanol. JSCIA0688ZZ
13. Remove the seal from the opening of traction motor side 3- L
phase bus bar.
WARNING:
To prevent electric shock hazards, be sure to put on insulat- M
age system.
N
CAUTION:
Close off the opening using tape or an equivalent, for pre- JSCIA0677ZZ O
venting dirt, dust, or foreign material from entering the
drive motor.
INSTALLATION P
Pay attention to the following and install by following the procedure for removal in the reverse order.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work
on the high voltage system.
TMS-109
CAUTION:
It is necessary to perform writing of the traction motor resolver offset to the traction motor inverter
after the traction motor inverter is replaced. Refer to TMS-42, "Work Procedure".
• When installing the drive motor inverter, always use the guide pin (SST: KV99112300). After installation, be
sure to remove the guide pin.
CAUTION:
Never damage the 3-phase bus bar.
• Check that the dowel pin is inserted to the end position completely.
• When attaching the seal to the opening of traction motor side 3-
phase bus bar, be sure to install the convex portion of the seal
to the installation groove completely.
• Never reuse the seal for the opening of traction motor side 3-phase
bus bar.
• Never reuse gasket of 3-phase bus bar cover.
JSCIA0689ZZ
Inspection and Adjustment INFOID:0000000010412243
INSPECTION AFTER INSTALLATION

After installing traction motor inverter, measure resistance below.
• Between traction motor inverter and other high voltage system.
• Between traction motor inverter and body.
WARNING:
Standard : Less than 0.1 Ω

If result deviates from standard values, check that no paint, oil, dirt, or other substance is adhering to bolts or
conductive mounting parts. If any such substance is adhering, clean the surrounding area and remove the
substance.
ADJUSTMENT AFTER INSTALLATION
It is necessary to perform writing of the traction motor resolver offset to the traction motor inverter after the
traction motor inverter is replaced. Refer to TMS-42, "Work Procedure".
TMS-110
TRACTION MOTOR
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION A
TRACTION MOTOR
B
TMS
JSDIA6520GB K
High voltage warning label 3-phase bus bar cover Gasket

Seal Traction motor Motor mounting RH bracket L
Motor mounting RH O-ring Water inlet
Water outlet Drain plug Copper washer
M
Gasket Drain plug Motor mounting LH
Motor mounting LH bracket Clip Breather hose
Breather box Filler plug Reduction gear N
O-ring Motor mounting rear bracket Motor mounting rear
Bracket*
O
A. Shaft spline B. Inside of input shaft (inside of spline)
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb) P

*: Without air conditioning system
TMS-111
TRACTION MOTOR
DANGER:
maintenance.
WARNING:
CAUTION:
REMOVAL
WARNING:
• Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage".
1. Remove front under cover. Refer to EXT-27, "FRONT UNDER COVER : Removal and Installation".
2. Remove drain bolt of traction motor to drain coolant.
WARNING:
age system.
3. Drain reduction gear oil. Refer to TM-12, "Draining and Refill-

ing".
JSCIA0684ZZ
4. Remove electric power train and reduction gear from vehicle
together as suspension member assembly. Refer to FSU-22, "Removal and Installation".
5. Remove PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation".
6. Remove traction motor inverter. Refer to TMS-106, "Removal and Installation".
7. Remove joint bolt ( ) of motor mounting rear bracket and motor
mounting rear.
WARNING:
age system.
JSDIA3959ZZ
TMS-112
TRACTION MOTOR
8. Remove joint bolt ( ) of motor mounting LH bracket and motor
mounting LH. A
WARNING:
ing protective gear before beginning work on the high volt- B
age system.
TMS
JSDIA3960ZZ
D
9. Remove joint bolt ( ) of motor mounting RH bracket and motor
mounting RH.
WARNING: E
age system.
F
10. Hook the sling belt to each motor mounting bracket and prepare G
to disconnect the traction motor and reduction gear from the JSDIA3961ZZ
front suspension member assembly.

11. Hoist the traction motor and reduction gear and disconnect them from the front suspension member H
assembly.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning I
work on the high voltage system.
J
CAUTION:
When hoisting the traction motor and reduction gear, insert a long bolt into the motor mounting
bracket to prevent the sling belt from slipping out. At that time, be sure to install a nut. K
12. Remove support bearing bracket of drive shaft (right side). Refer to FAX-22, "Removal and Installation".
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning L
13. Remove motor mounting LH bracket .

WARNING: N
age system.
O
P
: Bolt
JSDIA6149ZZ
TMS-113
TRACTION MOTOR
14. Remove motor mounting rear bracket .
WARNING:
age system.
: Bolt
JSDIA3964ZZ
15. Remove motor mounting RH bracket .

WARNING:
age system.
: Bolt
JSCIA0685ZZ
16. Remove joint bolts ( ) traction motor and reduction gear.

WARNING:
age system.
17. Separate traction motor from reduction gear.

WARNING:
age system.
JSDIA6369ZZ
INSTALLATION
Note the following, and install in the reverse order of removal.
WARNING:
CAUTION:
When assembling the reduction gear and traction motor, clean the mating surface and be sure that no
dust, dirt, or foreign material is between the surfaces.
TMS-114
TRACTION MOTOR
• Before installing reduction gear and traction motor, apply grease to full periphery of shaft spline , and also
inject grease [minimum 10 g (0.4 oz), maximum less than 20 g (0.7 oz)] into reduction gear input shaft A
(inside spline) . Take care to prevent damage to O-ring when installing.
TMS
JSDIA2307ZZ F
CAUTION:
• Before applying grease, clean old grease and wear particles, that are adhered to the grease apply-
ing parts.
• When installing O-ring, clean the O-ring installation groove completely, and then install. G
• When all parts are installed, be sure to check equipotential of traction motor, PDM (Power Delivery Module),
and traction motor inverter.
- Traction motor: Refer to TM-27, "Inspection and Adjustment". H
- PDM (Power Delivery Module): Refer to VC-119, "Inspection".
- Traction motor inverter: Refer to TMS-110, "Inspection and Adjustment".
Inspection and Adjustment INFOID:0000000010412246 I

After installing traction motor, measure resistance below. J
• Between traction motor (aluminum part) and body (ground bolt).
• Between traction motor (aluminum part) and other high voltage system.
WARNING: K
L
Standard : Less than 0.1 Ω M

substance. N

O
traction motor is replaced. Refer to TMS-42, "Work Procedure".
TMS-115
HIGH VOLTAGE COOLING SYSTEM

SECTION HCO B
HCO
E
CONTENTS
PRECAUTION ............................................... 2 Troubleshooting Chart .............................................10 F
PRECAUTIONS ................................................... 2 PERIODIC MAINTENANCE ........................ 11

Precaution for Technicians Using Medical Electric...... 2 G
Point to Be Checked Before Starting Maintenance COOLANT ......................................................... 11
Work .......................................................................... 2 Inspection ................................................................11
Precaution for Supplemental Restraint System Draining ...................................................................11
Refilling ....................................................................12 H
SIONER" ................................................................... 2 RESERVOIR TANK CAP .................................. 13
Precautions for Removing Battery Terminal ............. 3 Inspection ................................................................13
I
PREPARATION ............................................ 5 REMOVAL AND INSTALLATION ............... 14
PREPARATION ................................................... 5 RADIATOR ........................................................ 14
Commercial Service Tools ....................................... 5 J
Exploded View .........................................................14
Sealant or/and Lubricant ........................................... 5
Removal and Installation .........................................15
SYSTEM DESCRIPTION .............................. 6 Inspection ................................................................20
K
COMPONENT PARTS ........................................ 6 COOLING FAN .................................................. 21
Exploded View .........................................................21
Radiator ..................................................................... 6
Removal and Installation .........................................21 L
Cooling fan (electric fan) ........................................... 6
Disassembly and Assembly .....................................22
Electric water pump ................................................... 6
SYSTEM .............................................................. 7 ELECTRIC WATER PUMP ............................... 24

Exploded View .........................................................24 M
High Voltage Cooling System ................................... 7
BASIC INSPECTION .................................... 9
SERVICE DATA AND SPECIFICATIONS N
RADIATOR .......................................................... 9 (SDS) ............................................................ 26
Inspection .................................................................. 9
SERVICE DATA AND SPECIFICATIONS
O
SYMPTOM DIAGNOSIS .............................. 10 (SDS) ................................................................. 26
Periodical Maintenance Specification ......................26
OVERHEATING CAUSE ANALYSIS .................10
P
HCO-1
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
NOTE:
HCO-2
PRECAUTIONS
< PRECAUTION >
“SEAT BELT” of this Service Manual. A
WARNING:
Always observe the following items for preventing accidental activation. B
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal HCO
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser- D
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS E
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the F
injury.
• When using air or electric power tools or hammers, always switch the power switch OFF, disconnect G
H
NOTE: I
then a DTC detection error or ECU data corruption may occur. J
start after a lapse of 60 minutes from power switch OFF. K
SEF289H
WORK PROCEDURE L
NOTE:
If EVSE is connected, the air conditioning system may be automatically activated by the timer A/C func- M
tion.
3. Check that the charge status indicator lamp does not blink and wait for 5 minutes or more. N
NOTE:
detected.
O
CAUTION:
battery terminals are disconnected, start over from Step 1. P
NOTE:
the power switch.
HCO-3
PRECAUTIONS
< PRECAUTION >
NOTE:
NOTE:
HCO-4
PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
B

HCO
Reservoir tank cap tester Checking radiator and reservoir tank cap
NOTE:
RENAULT tool number: M.S. 554-07
D
E
MLIA0012E
Reservoir tank cap tester adapter A Checking radiator and reservoir tank
NOTE:
RENAULT tool number: M.S. 554-01 F
MLIA0013E
Reservoir tank cap tester adapter B Checking reservoir tank cap H

NOTE:
RENAULT tool number: M.S. 554-06
MLIA0014E J
Sealant or/and Lubricant INFOID:0000000011008694
K
Name Description Note
Strength thread locking sealant
(Three Bond Thread Lock Super 1303 or an Cooling fan — L
equivalent)
HCO-5
COMPONENT PARTS
SYSTEM DESCRIPTION
COMPONENT PARTS
Radiator INFOID:0000000010411787
• This radiator is a side-flow type and made of aluminum.

• The radiator side tank has a water temperature sensor.
: Radiator assembly
: Water temperature sensor
JPCIA0337ZZ
Cooling fan (electric fan) INFOID:0000000010411788
• This cooling fan has a resin shroud.
: Cooling fan control module

: Cooling fan motor
: Cooling fan
• The installation of shroud to the cooling fan control module allows

the controlling of cooling fan motor revolutions.
• The cooling fan control module is controlled by a control signal
transmitted from VCM (Vehicle Control Module), according to a
coolant temperature, vehicle speed, and request from air condi- JPCIA0338ZZ
tioner.
Electric water pump INFOID:0000000010411789
• An electric water pump is used.

• It is installed at the bottom of the reservoir tank on the right side of
the motor room.
• An electric water pump is installed in the coolant circuit, and the
VCM (Vehicle Control Module) controls the coolant flow according
to the coolant temperature and vehicle speed.
JPCIA0339ZZ
HCO-6
SYSTEM
SYSTEM
A
High Voltage Cooling System INFOID:0000000010411790
• The HV cooling system is the system which cools the following high-voltage components. B
- Traction motor
- Traction motor inverter
- PDM (Power Delivery Module)
• Coolant is circulated by means of the electric water pump, and the electric water pump is controlled by the HCO
VCM (Vehicle Control Module).
COOLING SYSTEM DIAGRAM
D
L
JPCIA0340ZZ
PDM (Power Delivery Module) Electric water pump Traction motor inverter M
Traction motor
To reservoir tank To radiator To radiator
N
HCO-7
SYSTEM
HIGH VOLTAGE COOLING SYSTEM SCHEMATIC
JPCIA0375GB
HCO-8
RADIATOR
BASIC INSPECTION A
RADIATOR
Inspection INFOID:0000000010411791
B
Check radiator for mud or clogging. If necessary, clean radiator as follows.
CAUTION:
• Be careful not to bend or damage radiator fins. HCO
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan
assembly and horns. Then tape harness and harness connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward. D
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from radiator.
4. Blow air into the back side of radiator core vertically downward. E
• Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.81
in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out. F
HCO-9
OVERHEATING CAUSE ANALYSIS
SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000010411792
Symptom Check items

Water pump malfunction —
Dust contamination or paper clogging
Damaged fins
Poor heat transfer Physical damage
Clogged radiator cooling
Excess foreign material (rust, dirt, sand, etc.)
tube
Cooling fan does not oper-
ate
Reduced air flow High resistance to fan rota- Fan assembly
tion
Damaged fan blades
Damaged radiator shroud —
Cooling sys- Improper coolant mixture ratio —

tem parts Poor coolant quality Coolant viscosity
malfunction
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Degas tank cap
Poor sealing
Insufficient coolant Coolant leakage O-ring for damage, deterio-
ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Degas tank Cracked degas tank
Blocked bumper —
Installed car brassiere
Except cool- Blocked radiator grille
ing system Blocked or restricted air Mud contamination or paper clogging
parts mal- flow Blocked radiator —
function
Blocked condenser
Blocked air flow
Installed large fog lamp
HCO-10
COOLANT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
COOLANT
B
COOLANT AMOUNT INSPECTION

• When coolant temperature is low (about 50°C or less), confirm that HCO
the coolant level of the reservoir tank is in the range from MIN to
MAX.
: MAX D
: MIN
• Adjust level if it is outside the range. E
CAUTION:
• Refill Genuine NISSAN Long Life Antifreeze/Coolant (blue)
or equivalent in its quality mixed with water (distilled or
demineralized). Refer to MA-11, "Fluids and Lubricants"
JPBIA0102ZZ
F
• Confirm that the reservoir tank cap is tightened.
LEAKAGE CHECK G
• Apply pressure to the cooling system using radiator cap tester (A)
(commercial service tool). Check system for coolant leakage.
Maximum pressure : Refer to HCO-26, "Periodical H

Maintenance Specification".
CAUTION:
I
• Remove the degas tank cap when coolant temperature is
low.
• Perform the inspection with the radiator filled with water.
• Use hose adapter (B) (commercial service tool) between J
radiator cap tester (A) (commercial service tool) and the PBIC5121J
filler neck so that the degas tank filler neck is not deformed.
• Be sure to observe the maximum pressure standards. Otherwise, radiator may be damaged. K
• If there is a malfunction, repair and replace applicable part.
Draining INFOID:0000000010411794
L
CAUTION:
• Be sure to drain when coolant temperature is cold.
• This should be performed so that coolant does not come in contact with surrounding parts.
M
1. Remove radiator drain plug , and drain coolant.
JSCIA1149ZZ
HCO-11
COOLANT
2. Remove reservoir tank as per the following procedure if necessary.
a. Remove water hose (reservoir tank side) and reservoir tank mounting bolts.
Refilling INFOID:0000000010411795
REFILLING
CAUTION:
• Do not reuse O-rings.
• Do not put additive such as water leak preventive, since it may cause cooling waterway clogging.
• When refilling use Genuine NISSAN Long Life Antifreeze/Coolant (blue) or equivalent in its quality
mixed with water (distilled or demineralized). Refer to MA-11, "Fluids and Lubricants"
1. Install reservoir tank if removed and radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring.
Radiator drain plug : Refer to HCO-14, "Exploded View".

2. Check that each hose clamp has been firmly tightened.
3. Refill reservoir tank to “MAX” level line with engine coolant.
: MAX
: MIN
JPBIA0102ZZ
4. Install reservoir tank cap.

5. Set the vehicle to READY and operate the electric water pump.
6. If reservoir tank fluid level drops, set the vehicle in READY OFF state and fill with coolant to the “MAX” line
of the reservoir tank.
7. Repeat from Step 4 to 7 until the reservoir tank fluid level stops dropping.
8. Operate the electric water pump for approximately 10 minutes with the vehicle set in READY state, and
check that the reservoir tank fluid level does not drop.
9. If reservoir tank fluid level drops, repeat from Step 4 to 7.
CHECK WATER FLOW SOUND
CAUTION:
Prior to check, be sure to close windows, doors, and hood, and turn off audio system and other elec-
trical loads.
1. Set the vehicle to READY and operate the electric water pump.
2. Operate the electric water pump for 1 minute.
3. Check if water flow sound can be heard from the back of the compartment (near the on board charger).
4. If water flow sound is heard, operate the electric water pump until it cannot be heard.
5. When water flow sound cannot be heard, fill the reservoir tank up to “MAX” line.
CAUTION:
• Insufficient coolant may cause low power or stop of vehicle due to insufficient cooling of the traction
motor inverter. Be sure to bleed air thoroughly.
• Never operate the electric water pump without coolant.
HCO-12
RESERVOIR TANK CAP
RESERVOIR TANK CAP
A
• Fit the adapter to the reservoir tank cap tester (commercial service B
tool) (A) as shown.
• When connecting the reservoir tank cap to the reservoir tank cap
tester, apply water or LLC to the reservoir tank cap seal part.
• Check reservoir tank cap relief pressure. HCO
Standard: Refer to HCO-26, "Periodical Mainte-

nance Specification". D
• Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.
CAUTION: E1BIA0057ZZ E
When installing reservoir tank cap, thoroughly wipe out the res-
ervoir tank filler neck to remove any waxy residue or foreign material.
F
HCO-13
RADIATOR
RADIATOR
JSCIA1107GB
Reservoir tank cap Reservoir tank Chipping guard

Collar Bushing Radiator
Clamp Radiator hose (lower) Water hose
Pump bracket Mount rubber Electric water pump
Radiator hose (upper rear) Water hose adapter Radiator hose (upper front)
Water hose Water temperature sensor O-ring
Drain plug O-ring
Arrow view To PDM (Power Delivery Module) To traction motor
HCO-14
RADIATOR
A
REMOVAL
WARNING:
Never remove the reservoir tank cap if the drive motor or other high voltage part is hot. Hot liquid may B
spray out from the radiator, causing serious injury.
1. Remove the front under cover. Refer to EXT-27, "FRONT UNDER COVER : Removal and Installation".
2. Remove the front bumper fascia. Refer to EXT-16, "FRONT BUMPER : Removal and Installation". HCO
3. Remove the apron bracket. Refer to EXT-19, "APRON BRACKET : Removal and Installation".
4. Remove following parts. Refer to DLK-192, "Exploded View" (TYPE 1), DLK-427, "Exploded View" (TYPE
D
2) or DLK-645, "Exploded View" (TYPE 3).
• Air guide RH
• Air guide LH
• Air guide upper LH E
• Air guide upper RH
5. Drain coolant from radiator. Refer to HCO-11, "Draining".
6. Disconnect the water temperature sensor connector . F
JSCIA1112ZZ I
7. Disconnect the radiator hose (upper front) .

J
: Vehicle front
JSCIA0526ZZ
M
8. Disconnect the radiator side of the radiator hose (lower) .
: Vehicle front
N
P
JSCIA1114ZZ
HCO-15
RADIATOR
9. Use rope or other means to support the condenser with the
radiator core support assembly.
JSCIA1113ZZ
10. Remove the radiator core support lower. Refer to DLK-193, "RADIATOR CORE SUPPORT LOWER :
Removal and Installation".
CAUTION:
Be careful not to damage the radiator core.
11. Remove the condenser mounting bolt .
: Radiator hose (upper rear)
JSCIA0527ZZ
12. Remove the radiator mounting bolts and the chipping guard
mounting bolt .
JSCIA1115ZZ
13. Press the radiator top left tab while lowering the radiator downwards to disengage it from the con-
denser .
JSCIA0536ZZ
HCO-16
RADIATOR
CAUTION:
Because there is a risk of bending the air conditioner pipe, do not lift up the capacitor more than is A
necessary to disengage it.
14. Remove the radiator with chipping guard downwards.

B
: Radiator moving direction
CAUTION: HCO
Be careful not to damage the condenser core.
15. Separate the chipping guard from the radiator if necessary.
D
JSCIA1116ZZ
E
INSTALLATION
CAUTION: F
Be sure to perform correct air bleeding after adding coolant. Refer to HCO-12, "Refilling".
Radiator
• When installing the radiator, securely insert the engaging points shown by the arrows ( ) in the figure. G
L
JSCIA0538ZZ
Chipping Guard
M
HCO-17
RADIATOR
• When installing the chipping guard, securely insert the engaging points shown by the arrows ( ) in the fig-
ure.
JSCIA0539ZZ
Radiator Hose / Water Hose

• When inserting the radiator hose and water hose, insert all the way until it contacts the end, regardless of
whether or not there is a stopper .
JPCIA0358ZZ
With stopper No stopper
• Refer to the following table when installing the hose clamps.
JPCIA0359ZZ
HCO-18
RADIATOR
Direction of hose clamp tabs A
B
Hose location Hose end Direction of paint mark
JPCIA0366ZZ HCO
: Vehicle upper
: Vehicle front
D
Radiator hose Radiator side Vehicle right E

(upper front)
JPCIA0360ZZ F
G
Water hose Reservoir tank side Vehicle front
H
JSCIA1106ZZ
Radiator side Vehicle right

J
JPCIA0360ZZ
Radiator hose K
(upper rear)
L
Electric water pump side Toward vehicle upper
M
JPCIA0362ZZ
N
PDM (Power Delivery Mod-
Vehicle upper left
ule) side
O
JPCIA0362ZZ
Water hose
P
Electric water pump side Vehicle upper right
JPCIA0362ZZ
HCO-19
RADIATOR
Direction of hose clamp tabs
Hose location Hose end Direction of paint mark
JPCIA0366ZZ
: Vehicle upper
: Vehicle front
Motor side Toward vehicle upper
JPCIA0362ZZ
Radiator hose
(lower)
Radiator side Vehicle left
JPCIA0364ZZ
• The direction of the hose clamp tabs must be within ±30° of the
indicated position .
JPBIA4295ZZ
• When installing hose clamp , check that the distance “A”

between the end of the radiator hose paint mark and the hose
clamp is within the standard range.
Dimension “A” : 0 - 1mm (0 - 0.04 in)
JSBIA0241ZZ

• Confirm that the reservoir tank cap is tightened.
• With a radiator cap tester (commercial service tool), check that there is no leakage of coolant. Refer to HCO-
11, "Inspection".
• Start the electric pump, and check the joints for coolant leakage.
HCO-20
COOLING FAN
COOLING FAN
A
HCO
G
JPCIA0344GB
Cooling fan (right) Cooling fan (left) Fan shroud

H
Fan motor (left) Cooling fan control unit Fan motor (right)
Apply thread locking adhesive to the shaft
of fan motor.
I
: Thread locking adhesive

J

K
REMOVAL
1. Remove the reservoir tank installation bolts and move the reservoir tank to a location where it does not L
interfere with work.
2. Remove the quick charge port and normal charge port from radiator core support. Refer to VC-122,
"Removal and Installation" (quick charge port) and VC-127, "Removal and Installation" (normal charge
port). M
3. Remove or disconnect the following harness connectors and clips.
• Cooling fan control module harness connectors
• Cooling fan control module harness clip N
HCO-21
COOLING FAN
• Radiator hose (lower) fixing clip
JSCIA1151ZZ
4. Remove the cooling fan assembly mounting bolts.

5. Pull out and remove the cooling fan assembly at an angle, with the right side of the assembly raised up.
JSCIA1152ZZ
CAUTION:
Be careful not to damage radiator core.
INSTALLATION
Install in the reverse order of removal.
Disassembly and Assembly INFOID:0000000010411802
DISASSEMBLY
1. Disconnect sub-harness from fan motor and cooling fan control module.
2. Remove cooling fan control module from fan shroud.
CAUTION:
Handle it carefully and avoid subjecting it to impact.
3. Remove fan mounting nuts, and then remove the fan.
4. Remove fan motor.
• Identify installation position of each valve. Arrange removed valves so that they cannot be mixed up.
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
• If fan motor is reused, install in its original position.
• Install each fan in the following position.
Vehicle left Vehicle right
HCO-22
COOLING FAN
Models with A/C 9 fans 11 fans
A
Models without A/C 6 fans 9 fans
• Apply thread locking adhesive (Three Bond Thread Lock Super 1303 or an equivalent) to the threads of the
fan motor shaft, and tighten the fan mounting nuts. B
• Secure the sub-harness tightly to the fan shroud to prevent it from interfering with the fan rotation area.
HCO
HCO-23
ELECTRIC WATER PUMP
ELECTRIC WATER PUMP
JSCIA1107GB
Reservoir tank cap Reservoir tank Chipping guard

Collar Bushing Radiator
Clamp Radiator hose (lower) Water hose
Pump bracket Mount rubber Electric water pump
Radiator hose (upper rear) Water hose adapter Radiator hose (upper front)
Water hose Water temperature sensor O-ring
Drain plug O-ring
Arrow view To PDM (Power Delivery Module) To traction motor
CAUTION:
HCO-24
ELECTRIC WATER PUMP
Do not use an electric water pump that is dropped, or subjected to excessive impact due to contact
with other parts. A
REMOVAL
1. Drain coolant from radiator. Refer to HCO-11, "Draining".
CAUTION: B
Drain the coolant when it is cool.
2. Remove the apron bracket. Refer to EXT-19, "APRON BRACKET : Removal and Installation".
HCO
3. Remove the front under cover. Refer to DLK-651, "FENDER COVER : Removal and Installation".
4. Remove the fender protector. Refer toEXT-26, "Exploded View".
5. Remove the reservoir tank installation bolts and move the reservoir tank to a location where it does not D
interfere with work.
6. Disconnect the electric water pump harness connector and clip .
E
I
JSCIA1150ZZ
7. Disconnect the water hoses .

J
: Vehicle front
8. Remove the 2 mounting bolts and remove the electric water

pump together with the bracket. K
CAUTION:
• Take care that coolant does not contact the high voltage
connectors. L
• If coolant contacts a high voltage connector, immediately
use an air blow and fully remove the moisture. JPCIA0350ZZ
M
9. Remove each parts from the electric water pump if necessary.
INSTALLATION
Note the following, and install in the reverse order of removal. N
CAUTION:
• Hold the electric water pump with one hand while inserting the water hose into the electric water
pump.
• Be sure to perform correct air bleeding after adding coolant. Refer to HCO-12, "Refilling". O
HCO-25
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance Specification INFOID:0000000010411805
COOLANT CAPACITY (APPROXIMATE)

Unit: (Imp qt)
Coolant capacity (With reservoir tank at “MAX” level) 5.2 (4-5/8)
Reservoir tank coolant capacity (At “MAX” level) 0.43 (3/8)
RESERVOIR TANK CAP

Unit: kPa (bar, kg/cm2, psi)
Cap relief pressure Standard 19 - 34 (0.19 - 0.34, 0.19 - 0.34, 2.76 - 4.93)
RADIATOR
Unit: kPa (bar, kg/cm2, psi)
Leakage testing pressure 32 (0.32, 0.32, 4.64)
HCO-26
SECTION
EV CONTROL SYSTEM
EVC B
EVC
E
CONTENTS
PRECAUTION ............................................... 8 Approaching Vehicle Sound for Pedestrians F
(VSP) .......................................................................25
PRECAUTIONS ................................................... 8
Precaution for Technicians Using Medical Electric...... 8 SYSTEM ............................................................ 26
G
Precaution for Supplemental Restraint System
ELECTRIC POWER TRAIN SYSTEM .......................26
ELECTRIC POWER TRAIN SYSTEM : System
SIONER" ................................................................... 8
Description ...............................................................26 H
Precaution for Procedure without Cowl Top Cover...... 9
ELECTRIC POWER TRAIN SYSTEM : Circuit Di-
Precautions for Removing Battery Terminal ............. 9
agram ......................................................................26
High Voltage Precautions ........................................ 10
ELECTRIC POWER TRAIN SYSTEM : Fail-Safe....31
General Precautions ............................................... 12 I
EV SYSTEM START UP CONTROL .........................34
PREPARATION ........................................... 14 EV SYSTEM START UP CONTROL : System De-
PREPARATION ..................................................14 scription ...................................................................34 J
Commercial Service Tools ...................................... 14 HIGH VOLTAGE POWER SUPPLY CONTROL .......36
HIGH VOLTAGE POWER SUPPLY CONTROL :
SYSTEM DESCRIPTION ............................. 15 System Description ..................................................37 K
COMPONENT PARTS .......................................15 MOTOR POWER CONTROL .....................................38
Component Parts Location ...................................... 15 MOTOR POWER CONTROL : System Descrip-
VCM ........................................................................ 21 L
tion ...........................................................................38
M/C Relay ............................................................... 21
F/S Relay ................................................................ 21 MOTOR REGENERATION CONTROL .....................39
F/S CHG Relay ....................................................... 21 MOTOR REGENERATION CONTROL : System M
A/C Relay ................................................................ 21 Description ...............................................................39
System Main Relay 1 .............................................. 21
System Main Relay 2 .............................................. 22 ECO MODE/B MODE SYSTEM .................................40
ECO MODE/B MODE SYSTEM : System Descrip- N
Pre-charge Relay .................................................... 22
Reverse Lamp Relay ............................................... 22 tion ...........................................................................40
Accelerator Pedal Position Sensor .......................... 22 SHIFT POSITION JUDGEMENT ...............................41
Refrigerant Pressure Sensor ................................... 22 O
SHIFT POSITION JUDGEMENT : System De-
Stop Lamp Switch ................................................... 22 scription ...................................................................41
ASCD Steering Switch ............................................ 23
ECO mode switch ................................................... 23 LI-ION BATTERY CHARGE CONTROL ...................41 P
Brake Pedal Position Switch ................................... 23 LI-ION BATTERY CHARGE CONTROL : System
Battery Current Sensor (With Battery Tempera- Description ...............................................................41
ture Sensor) ............................................................ 23 LI-ION BATTERY CHARGE CONTROL : Normal
Coolant Temperature Sensor .................................. 24 Charge Control ........................................................42
Electric Water Pump ............................................... 24 LI-ION BATTERY CHARGE CONTROL : Quick
Cooling Fan Control Module ................................... 25 Charge Control ........................................................43
EVC-1
HIGH VOLTAGE SYSTEM COOLING CONTROL ... 44 SPEED LIMITER ....................................................... 65
HIGH VOLTAGE SYSTEM COOLING CONTROL SPEED LIMITER : Switch Name and Function ....... 65
: System Description ............................................... 44
ECO MODE SWITCH ................................................ 66
AIR CONDITIONER CONTROL ................................ 46 ECO MODE SWITCH : Switch Name and Func-
AIR CONDITIONER CONTROL : System De- tion .......................................................................... 66
scription .................................................................. 46
ON BOARD DIAGNOSTIC (OBD) SYSTEM ..... 67
POWER VOLTAGE VARIABLE CONTROL SYS- Diagnosis Description ............................................. 67
TEM ........................................................................... 48 Counter System ...................................................... 67
POWER VOLTAGE VARIABLE CONTROL SYS- DTC and Freeze Frame Data ................................. 67
TEM : System Description ...................................... 49
DIAGNOSIS SYSTEM (VCM) ............................ 69
AUTOMATIC 12V BATTERY CHARGE CONTROL CONSULT Function ................................................ 69
... 49
AUTOMATIC 12V BATTERY CHARGE CON- ECU DIAGNOSIS INFORMATION ............. 81
TROL : System Description .................................... 49
VCM ................................................................... 81
POWER CUT OFF CONTROL .................................. 50 Reference Value ..................................................... 81
POWER CUT OFF CONTROL : System Descrip- Fail-Safe .................................................................. 93
tion .......................................................................... 50 DTC Inspection Priority Chart ................................. 95
DTC Index .............................................................. 98
AUTOMATIC SPEED CONTROL DEVICE (ASCD)... 51
AUTOMATIC SPEED CONTROL DEVICE (AS- WIRING DIAGRAM ................................... 102
CD) : System Description ....................................... 52
VCM .................................................................. 102
SPEED LIMITER ....................................................... 52 Wiring Diagram ..................................................... 102
SPEED LIMITER : System Description .................. 53
BASIC INSPECTION ................................. 114
INFORMATION DISPLAY (COMBINATION
METER) ..................................................................... 54 DIAGNOSIS AND REPAIR WORK FLOW ....... 114
INFORMATION DISPLAY (COMBINATION Work Flow ............................................................. 114
METER) : Cooling Fan Maintenance Warning ........ 54 Diagnostic Work Sheet ......................................... 117
METER) : DC/DC Converter Warning .................... 55 ADDITIONAL SERVICE WHEN REMOVING
INFORMATION DISPLAY (COMBINATION 12V BATTERY NEGATIVE TERMINAL ........... 119
METER) : Low Battery Charge Warning ................. 56 Description ............................................................ 119
INFORMATION DISPLAY (COMBINATION Work Procedure .................................................... 119
METER) : Power Limitation Warning ...................... 57
INFORMATION DISPLAY (COMBINATION ADDITIONAL SERVICE WHEN REPLACING
METER) : Shift P Warning ...................................... 58 VCM .................................................................. 120
INFORMATION DISPLAY (COMBINATION Description ............................................................ 120
METER) : Shift Warning Message .......................... 60 Work Procedure .................................................... 120
WARNING/INDICATOR/CHIME LIST ....................... 60 ACCELERATOR PEDAL RELEASED POSI-

WARNING/INDICATOR/CHIME LIST : Warning TION LEARNING .............................................. 122
lamps/Indicator lamps ............................................. 60 Description ............................................................ 122
WARNING/INDICATOR/CHIME LIST : Warning Work Procedure .................................................... 122
Chime ..................................................................... 61
WARNING/INDICATOR/CHIME LIST : Warning/ LI-ION BATTERY GRADUAL CAPACITY
Indicator (On Information Display) .......................... 61 LOSS DATA CLEAR ........................................ 123
WARNING/INDICATOR/CHIME LIST : Indicator/ Description ............................................................ 123
Information .............................................................. 61 Work Procedure .................................................... 123
CAN COMMUNICATION ........................................... 63 LI-ION BATTERY JUNCTION BOX DATA

CAN COMMUNICATION : System Description ...... 63 CLEAR .............................................................. 124
Description ............................................................ 124
OPERATION ...................................................... 65 Work Procedure .................................................... 124
AUTOMATIC SPEED CONTROL DEVICE (ASCD)... 65 WRITE VEHICLE IDENTIFICATION NUMBER
AUTOMATIC SPEED CONTROL DEVICE (AS-
DATA ................................................................ 125
CD) : Switch Name and Function ........................... 65
Description ............................................................ 125
EVC-2
Work Procedure .................................................... 125 Diagnosis Procedure ............................................. 153
A
LOAD BATTERY IDENTIFICATION DATA ..... 126 P0A8F 12V BATTERY POWER SUPPLY ...... 155
Description ............................................................ 126 DTC Description .................................................... 155
Work Procedure .................................................... 126 Diagnosis Procedure ............................................. 155
B
COOLING FAN INTEGRATED OPERATION P0A94 DC/DC CONVERTER .......................... 158
TIME CLEAR .................................................... 127 DTC Description .................................................... 158
Description ............................................................ 127 Diagnosis Procedure ............................................. 158 EVC
Work Procedure .................................................... 127
P0AA0 SYSTEM MAIN RELAY ...................... 160
DTC/CIRCUIT DIAGNOSIS ....................... 128 DTC Description .................................................... 160
Diagnosis Procedure ............................................. 161 D
POWER SUPPLY AND GROUND CIRCUIT .... 128
P0AA1 SYSTEM MAIN RELAY + ................... 165
VCM ......................................................................... 128 DTC Description .................................................... 165 E
VCM : Diagnosis Procedure .................................. 128 Diagnosis Procedure ............................................. 166
U1000 CAN COMM CIRCUIT ........................... 131 P0AA2 SYSTEM MAIN RELAY + ................... 170
Description ............................................................ 131 DTC Description .................................................... 170 F
DTC Description .................................................... 131 Diagnosis Procedure ............................................. 170
Diagnosis Procedure ............................................. 131
P0AA4 SYSTEM MAIN RELAY - .................... 172
U1010 CONTROL MODULE (CAN) ................. 132 G
DTC Description .................................................... 172
P0AA5 SYSTEM MAIN RELAY - .................... 177 H
P0601 VCM ....................................................... 133 DTC Description .................................................... 177
P0AA6 HIGH VOLTAGE SYSTEM ISOLA- I
P0643 SENSOR POWER SUPPLY ................. 135 TION ................................................................ 179
DTC Description .................................................... 135 Description ............................................................. 179
Diagnosis Procedure ............................................. 135 DTC Description .................................................... 179 J
P0705, P0706 SHIFT SELECTOR ................... 137
DTC Description .................................................... 137 P1550, P1551, P1552 BATTERY CURRENT K
Diagnosis Procedure ............................................. 138 SENSOR .......................................................... 186
Component Inspection (Park Position Switch) ...... 140 DTC Description .................................................... 186
P0827, P0828 SHIFT SELECTOR ................... 142 Diagnosis Procedure ............................................. 187
L
Component Inspection ........................................... 189
DTC Description .................................................... 142
Diagnosis Procedure ............................................. 142 P1554 BATTERY CURRENT SENSOR .......... 190
P0A00 COOLANT TEMPERATURE SENSOR DTC Description .................................................... 190 M
.. 145
DTC Description .................................................... 145
Diagnosis Procedure ............................................. 145 P1556, P1557 BATTERY TEMPERATURE N
Component Inspection .......................................... 147 SENSOR .......................................................... 194
P0A0B HIGH VOLTAGE CONNECTOR CON- DTC Description .................................................... 194
Diagnosis Procedure ............................................. 194 O
NECTION DETECTING CIRCUIT .................... 148
Description ............................................................ 148
DTC Description .................................................... 148 P155A BATTERY TEMPERATURE SENSOR. 197
Diagnosis Procedure ............................................. 149 P
DTC Description .................................................... 197
P0A8D 12V BATTERY POWER SUPPLY ....... 151
DTC Description .................................................... 151
Diagnosis Procedure ............................................. 151 P1564 ASCD STEERING SWITCH ................. 200
DTC Description .................................................... 200
P0A8E 12V BATTERY POWER SUPPLY ....... 153
DTC Description .................................................... 153
Component Inspection (ASCD Steering Switch) .. 203
EVC-3
P1572 BRAKE PEDAL POSITION SWITCH ... 204 Diagnosis Procedure ............................................. 241
DTC Description ....................................................204
Diagnosis Procedure .............................................205 P312B EV SYSTEM RESTART ERROR .......... 244
Component Inspection (Brake Pedal Position DTC Description .................................................... 244
Switch) ...................................................................208 Diagnosis Procedure ............................................. 245
Component Inspection (Stop Lamp Switch) ..........209 P312C, P3130 TRACTION MOTOR INVERT-
P1574 ASCD VEHICLE SPEED SENSOR ...... 210 ER CONDENSER DISCHARGE ERROR ......... 246
Description .............................................................210 DTC Description .................................................... 246
DTC Description ....................................................210 Diagnosis Procedure ............................................. 247
Diagnosis Procedure .............................................210
P312D QUICK CHARGE ERROR .................... 248
P1805 BRAKE SWITCH .................................. 212 DTC Description .................................................... 248
P312E READY OFF ERROR ............................ 250
Component Inspection (Stop Lamp Switch) ..........213
DTC Description .................................................... 250
P2122, P2123 APP SENSOR .......................... 215 Diagnosis Procedure ............................................. 251
DTC Description ....................................................215
P312F CHARGE OFF ERROR ......................... 252
DTC Description .................................................... 252
Component Inspection (Accelerator Pedal Posi-
tion Sensor) ...........................................................217
P3131 SYSTEM SHUTOFF ERROR ................ 255
P2127, P2128 APP SENSOR .......................... 219
DTC Description .................................................... 255
DTC Description ....................................................219
Component Inspection (Accelerator Pedal Posi- P3135 SLIGHT COLLISION DETECTION ....... 259
tion Sensor) ...........................................................221 DTC Description .................................................... 259
P2138 APP SENSOR ...................................... 223
DTC Description ....................................................223 P3137 CAR CRASH DETECTION ................... 261
Diagnosis Procedure .............................................223 DTC Description .................................................... 261
Component Inspection (Accelerator Pedal Posi- Diagnosis Procedure ............................................. 261
tion Sensor) ...........................................................224
P3141 PDM (POWER DELIVERY MODULE) .. 263
P3100 EV SYSTEM CAN COMMUNICATION. 226 Description ............................................................ 263
P315C CHARGE RELAY ................................. 265
P3101 VCM ...................................................... 228 DTC Description .................................................... 265
P315E ABS/VDC .............................................. 266
P3102 LI-ION BATTERY ................................. 230 DTC Description .................................................... 266
Description .............................................................230 Diagnosis Procedure ............................................. 266
DTC Description ....................................................230
Diagnosis Procedure .............................................230 P316A MOTOR SPEED .................................... 267
DTC Description .................................................... 267
P3117 A/C SYSTEM ........................................ 232 Diagnosis Procedure ............................................. 267
Description .............................................................232
DTC Description ....................................................232 P316C, P316D, P316E PDM (POWER DELIV-
Diagnosis Procedure .............................................233 ERY MODULE) ................................................. 268
DTC Description .................................................... 268
P311C HIGH VOLTAGE CIRCUIT .................. 234 Diagnosis Procedure ............................................. 268
DTC Description ....................................................234
Diagnosis Procedure .............................................235 P316F PDM (POWER DELIVERY MODULE) .. 269
DTC Description .................................................... 269
P312A EV SYSTEM CAN COMMUNICATION. 240 Diagnosis Procedure ............................................. 269
Description .............................................................240
DTC Description ....................................................240
EVC-4
P3170, P3171 PDM (POWER DELIVERY P3194, P319F, P31AA CAN COMMUNICA-
MODULE) ......................................................... 271 TION ................................................................ 294 A
DTC Description .................................................... 271 DTC Description .................................................... 294
Diagnosis Procedure ............................................. 271 Diagnosis Procedure ............................................. 294
B
P3172, P3173 PDM (POWER DELIVERY P3195, P31A0, P31AB CAN COMMUNICA-
MODULE) ......................................................... 272 TION ................................................................ 296
Diagnosis Procedure ............................................. 272 Diagnosis Procedure ............................................. 296 EVC
P3176 TRACTION MOTOR INVERTER CON- P3196, P31A1, P31AE EV SYSTEM CAN
DENSER ........................................................... 273 COMMUNICATION ......................................... 298 D
P3177 ECU ACTIVATION ERROR .................. 278 P31AF, P31B3 EV SYSTEM CAN COMMUNI- E
DTC Description .................................................... 278 CATION ........................................................... 300
DTC Description .................................................... 300
TYPE 1 ..................................................................... 279 F
TYPE 1 : Diagnosis Procedure ............................. 279
P31B0, P31B4 CAN COMMUNICATION ........ 302
TYPE 2 ..................................................................... 280
DTC Description .................................................... 302
TYPE 2 : Diagnosis Procedure ............................. 280 G
TYPE 3 ..................................................................... 280
TYPE 3 : Diagnosis Procedure ............................. 280
P31B2, P31B5 CAN COMMUNICATION ........ 304
DTC Description .................................................... 304 H
P3178 ECU ACTIVATION ERROR .................. 282 Diagnosis Procedure ............................................. 304
DTC Description .................................................... 282
P31B6 CAN COMMUNICATION ..................... 306
DTC Description .................................................... 306 I
P3179, P317A, P317B TRACTION MOTOR Diagnosis Procedure ............................................. 306
INVERTER ........................................................ 284
P31B7 CAN COMMUNICATION ..................... 308 J
DTC Description .................................................... 284
DTC Description .................................................... 308
P317D TRACTION MOTOR INVERTER .......... 285 K
P31B8 EV SYSTEM CAN COMMUNICATION. 310
DTC Description .................................................... 285
DTC Description .................................................... 310
P317E, P3180, P3182 LI-ION BATTERY ......... 287 L
P31BA CAN COMMUNICATION .................... 312
DTC Description .................................................... 287
DTC Description .................................................... 312
M
P3183 LI-ION BATTERY .................................. 288
P31C5, P31C6 VCM ........................................ 314
DTC Description .................................................... 288
DTC Description .................................................... 314
Diagnosis Procedure ............................................. 314 N
P318D CAN COMMUNICATION ...................... 289
P31C7 VCM ..................................................... 316
DTC Description .................................................... 289
DTC Description .................................................... 316
P3191, P319C, P31A7 EV SYSTEM CAN
P31CA, P31CB QUICK CHARGE RELAY ..... 318
COMMUNICATION ........................................... 290 DTC Description .................................................... 318
DTC Description .................................................... 290 P
P31D3 M/C RELAY ......................................... 321
P3193, P319E, P31A9 EV SYSTEM CAN DTC Description .................................................... 321
COMMUNICATION ........................................... 292 Diagnosis Procedure ............................................. 321
DTC Description .................................................... 292 Component Inspection (M/C Relay) ...................... 322
P31D4 PRE-CHARGE RELAY ....................... 324
EVC-5
DTC Description ....................................................324 P31EE REFRIGERANT PRESSURE SEN-
Diagnosis Procedure .............................................324 SOR .................................................................. 362
DTC Description .................................................... 362
P31D5 PRE-CHARGE RELAY ........................ 326 Diagnosis Procedure ............................................. 362
DTC Description ....................................................326
Diagnosis Procedure .............................................326 P31F2 AV INFORMATION MISMATCH ........... 365
DTC Description .................................................... 365
P31D6 F/S RELAY ........................................... 331 Diagnosis Procedure ............................................. 366
DTC Description ....................................................331
Diagnosis Procedure .............................................331 COOLING FAN ................................................. 367
Component Function Check ................................. 367
P31D7 F/S RELAY ........................................... 334 Diagnosis Procedure ............................................. 367
DTC Description ....................................................334
Component Inspection (Cooling Fan Motor) ......... 370
Component Inspection (Cooling Fan Relay) ......... 370
P31DB SYSTEM MAIN RELAY + .................... 337 M/C RELAY ...................................................... 371
DTC Description ....................................................337
Component Inspection (M/C Relay) ...................... 372
P31DC SYSTEM MAIN RELAY - .................... 339 F/S CHG RELAY .............................................. 373
DTC Description ....................................................339
Component Inspection (F/S CHG Relay) .............. 375
P31DD PRE-CHARGE RELAY ....................... 341 REVERSE LAMP RELAY ................................. 376
DTC Description ....................................................341
Component Function Check ................................. 376
P31DE SYSTEM MAIN RELAY ....................... 343 Component Inspection (Reverse Lamp Relay) ..... 378
DTC Description ....................................................343 A/C RELAY ....................................................... 379
P31E0 HIGH VOLTAGE CIRCUIT INTER- Component Inspection (A/C Relay) ...................... 380
LOCK ERROR ................................................. 345 CHARGING STATUS INDICATOR .................. 382
Description .............................................................345 Component Function Check ................................. 382
IMMEDIATE CHARGING SWITCH .................. 384
P31E1 HIGH VOLTAGE CIRCUIT INTER- Diagnosis Procedure ............................................. 384
LOCK ERROR ................................................. 348 Component Inspection (Immediate Charging
Description .............................................................348 Switch) .................................................................. 386
DTC Description ....................................................348
Diagnosis Procedure .............................................349 ECO MODE SWITCH ....................................... 387
P31E5 VCM POWER SUPPLY ........................ 351 Component Inspection (ECO Mode Switch) ......... 389
DTC Description ....................................................351
Diagnosis Procedure .............................................351 SYMPTOM DIAGNOSIS ........................... 390
P31E7 RESTART INHIBITION ........................ 354 EV CONTROL SYSTEM ................................... 390
DTC Description ....................................................354 Symptom Index ..................................................... 390
Diagnosis Procedure .............................................354 READY Status Cannot Be Achieved ..................... 391
Unable to Travel .................................................... 392
P31E8 WATER PUMP ..................................... 355 Low Electrical Consumption .................................. 393
DTC Description ....................................................355 Power Switch Does Not Turn OFF ........................ 394
Diagnosis Procedure .............................................355 No Regeneration ................................................... 395
P31E9 WATER PUMP ..................................... 358 Decelerating Force Changes ................................ 396
Normal Charge Does Not Start ............................. 397
DTC Description ....................................................358
Timer Charge and Remote Charge Does Not Start
. 398
P31EC WATER PUMP .................................... 360 Immediate Charge Does Not Start ........................ 399
DTC Description ....................................................360 Normal Charge Is Not Completed ......................... 399
Diagnosis Procedure .............................................360 Quick Charge Does Not Start ............................... 400
EVC-6
Quick Charge Is Not Completed ........................... 400 REMOVAL AND INSTALLATION ............. 404
Full Charge Cannot Be Achieved .......................... 401 A
Climate Ctrl. Timer Does Not Start ........................ 401 VCM ................................................................. 404
Remote climate control Does Not Start ................. 402 Exploded View ....................................................... 404
Removal and Installation ....................................... 404
NORMAL OPERATING CONDITION ............... 403 B
Description ............................................................ 403 ECO MODE SWITCH ...................................... 406
EVC
EVC-7
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
WARNING:
EVC-8
PRECAUTIONS
< PRECAUTION >
B
connectors.
WARNING: EVC
D
injury.
When performing the procedure after removing cowl top cover, cover F
windshield.
G
PIIB3706J
I
J
NOTE:
ECU may be active for several minutes after the power switch is K
• Always disconnect the battery terminal within 60 minutes after L
• Disconnect 12V battery terminal according to the following steps. M
SEF289H
WORK PROCEDURE
1. Check that EVSE is not connected. N
NOTE:
tion. O
NOTE: P
detected.
CAUTION:
EVC-9
PRECAUTIONS
< PRECAUTION >
NOTE:
the power switch.
NOTE:
NOTE:
DANGER:
maintenance.
WARNING:
CAUTION:
blow gun.
NOTE:
WARNING:
EVC-10
PRECAUTIONS
< PRECAUTION >
metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage A
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT” B
workers.
EVC
JSAIA1600GB
EVC-11
PRECAUTIONS
< PRECAUTION >
• Never disassemble VCM.

• If the 12V battery is disconnected, the diagnostic information will be lost within 3 minutes.
• When connecting or disconnecting harness connectors into
or from VCM, take care not to damage pin terminals (bend or
break).
Check that there are not any bends or breaks on VCM pin ter-
minal, when connecting harness connectors.
PBIB0090E
• After performing each TROUBLE DIAGNOSIS, perform DTC

confirmation procedure or Component Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Component Func-
tion Check should be a good result if the repair is completed.
JSCIA0026ZZ
• When measuring ECU signals with a circuit tester, never allow

the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECU power transistor.
JMCIA0152GB
EVC-12
PRECAUTIONS
< PRECAUTION >
• When installing C.B. ham radio or a mobile phone, be sure to
observe the following as it may adversely affect electronic A
control systems depending on installation location.
- Keep the antenna as far as possible from the electronic con-
trol units.
B
- Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
- Adjust the antenna and feeder line so that the standing-wave EVC
radio can be kept smaller.
- Be sure to ground the radio to vehicle body.
SEF708Y
EVC-13
PREPARATION
< PREPARATION >
PREPARATION
PREPARATION

nents
Insulated gloves • Use protective gloves made of insulating ma-
terial.
JMCIA0149ZZ

nents
[Use leather gloves that can fasten the wrist
tight]
JPCIA0066ZZ

nents
Insulated safety shoes • Use protective shoes made of insulating ma-
terial.
JPCIA0011ZZ

nents
to electric line
[Comply with EN166.]
JPCIA0167ZZ

Insulated helmet
nents
JPCIA0013ZZ
EVC-14
COMPONENT PARTS
COMPONENT PARTS
B
LHD MODELS
Motor Room Compartment EVC
JSCIA1314ZZ
N
Electric power train Cooling fan assembly and radiator Charge port
assembly
O
No. Component parts Function
F/S relay (IPDM E/R) EVC-21, "F/S Relay"
P
12V battery PG-8, "12V Battery"
Hydraulic brake actuation module BR-17, "Hydraulic Brake Actuation Control Module"
F/S CHG relay EVC-21, "F/S CHG Relay"
Reverse lamp relay EVC-22, "Reverse Lamp Relay"
A/C relay EVC-21, "A/C Relay"
EVC-15
COMPONENT PARTS
Refrigerant pressure sensor EVC-22, "Refrigerant Pressure Sensor"
EVC-23, "Battery Current Sensor (With Battery Tempera-
Battery current sensor (with battery temperature sensor)
ture Sensor)"
M/C relay EVC-21, "M/C Relay"
The cooling fan relay supplies power to the cooling fan con-
Cooling fan relay
trol module.
PDM (Power Delivery Module) VC-13, "PDM (Power Delivery Module)"
Coolant temperature sensor EVC-24, "Coolant Temperature Sensor"
Cooling fan control module EVC-25, "Cooling Fan Control Module"
Electric water pump EVC-24, "Electric Water Pump"
Quick charge port VC-15, "Charge Port"
Normal charge port VC-15, "Charge Port"
Body Compartment
JSCIA1315ZZ
Left inside of front bumper
EVC-16
COMPONENT PARTS
No. Component parts Function A

EVB-33, "Battery Junction Box" (without battery cooler) or
EVB-303, "Battery Junction Box" (with battery cooler) or-
Battery junction box
EVB-588, "Battery Junction Box" (with battery heater &
B
cooler)
EVB-31, "Li-ion Battery Controller" (without battery cooler)
or EVB-299, "Li-ion Battery Controller" (with battery cooler)
Li-ion battery controller EVC
orEVB-584, "Li-ion Battery Controller" (with battery heater
& cooler)
VSP-7, "Approaching Vehicle Sound For Pedestrians
VSP control unit
(VSP) Control Unit" D
Interior Compartment
M
JSCIA1316ZZ
Behind of instrument lower panel Accelerator pedal and brake pedal N

upper part
No. Component parts Function O

Charge status indicator VC-16, "Charging Status Indicator"
Combination meter MWI-11, "METER SYSTEM : Combination Meter"

P
ASCD steering switch EVC-23, "ASCD Steering Switch"
Immediate charging switch VC-15, "Immediate Charging Switch"
ECO mode switch EVC-23, "ECO mode switch"
Shift selector The shift selector inputs the range position signal to VCM.
TCU (telematics communication unit)* AV-311, "TCU"
EVC-17
COMPONENT PARTS
A/C auto amp. HAC-31, "A/C Control (A/C Auto Amp.)"
BCM (Body Control Module) BCS-8, "BODY CONTROL SYSTEM : System Description"
VCM (vehicle control module) EVC-21, "VCM"
Brake pedal position switch EVC-23, "Brake Pedal Position Switch"
Stop lamp switch EVC-22, "Stop Lamp Switch"
Accelerator pedal position sensor EVC-22, "Accelerator Pedal Position Sensor"
*: Used only in models with TELEMATICS system.

RHD MODELS
Motor Room Compartment
JSCIA1317ZZ
Electric power train Cooling fan assembly and radiator Charge port
assembly

F/S relay (IPDM E/R) EVC-21, "F/S Relay"
12V battery PG-8, "12V Battery"
EVC-18
COMPONENT PARTS
A
Hydraulic brake actuation module BR-497, "Hydraulic Brake Actuation Control Module"
F/S CHG relay EVC-21, "F/S CHG Relay"
Reverse lamp relay EVC-22, "Reverse Lamp Relay" B
A/C relay EVC-21, "A/C Relay"
Refrigerant pressure sensor EVC-22, "Refrigerant Pressure Sensor" EVC

EVC-23, "Battery Current Sensor (With Battery Tempera-
Battery current sensor (with battery temperature sensor)
ture Sensor)"
M/C relay EVC-21, "M/C Relay" D
The cooling fan relay supplies power to the cooling fan con-
Cooling fan relay
trol module.
E
Traction motor TMS-14, "Traction Motor" F

Coolant temperature sensor EVC-24, "Coolant Temperature Sensor"
Cooling fan control module EVC-25, "Cooling Fan Control Module" G

Electric water pump EVC-24, "Electric Water Pump"
Quick charge port VC-15, "Charge Port"

H
Body Compartment
I
JSCIA1315ZZ
EVC-19
COMPONENT PARTS
Left inside of front bumper

EVB-33, "Battery Junction Box" (without battery cooler) or
EVB-303, "Battery Junction Box" (with battery cooler) or-
EVB-588, "Battery Junction Box" (with battery heater &
cooler)
EVB-31, "Li-ion Battery Controller" (without battery cooler)
or EVB-299, "Li-ion Battery Controller" (with battery cooler)
orEVB-584, "Li-ion Battery Controller" (with battery heater
& cooler)
VSP-7, "Approaching Vehicle Sound For Pedestrians
VSP control unit
(VSP) Control Unit"
Body Compartment
JSCIA1318ZZ
Behind of glove box Accelerator pedal and brake pedal

upper part

ASCD steering switch EVC-23, "ASCD Steering Switch"
Combination meter MWI-11, "METER SYSTEM : Combination Meter"
Charge status indicator VC-16, "Charging Status Indicator"
BCM (Body Control Module) BCS-8, "BODY CONTROL SYSTEM : System Description"
TCU (telematics communication unit)* AV-311, "TCU"
EVC-20
COMPONENT PARTS
A
Shift selector The shift selector inputs the range position signal to VCM.
ECO mode switch EVC-23, "ECO mode switch"
A/C auto amp. HAC-31, "A/C Control (A/C Auto Amp.)" B
VCM (vehicle control module) EVC-21, "VCM" EVC

Brake pedal position switch EVC-23, "Brake Pedal Position Switch"
Stop lamp switch EVC-22, "Stop Lamp Switch"

D
Accelerator pedal position sensor EVC-22, "Accelerator Pedal Position Sensor"
*: Used only in models with TELEMATICS system.

E
VCM INFOID:0000000010410074
VCM (Vehicle control module) judges the vehicle status according to

signals from various sensors and ECUs, and controls EV system in a F
comprehensive manner. VCM also has a gateway function for EV
system CAN communication and CAN communication, which
enables communication between an ECU performing EV system G
CAN communication and an ECU performing CAN communication.
JSCIA0078ZZ
I
M/C Relay INFOID:0000000010410075
The M/C (motor control) relay supplies the main power to the EV system. VCM activates the M/C relay and J
supplies power to the EV system when the EV system needs to be started.
F/S Relay INFOID:0000000010410076
K
The F/S (fail-safe) relay supplies the driving power for the system main relay inside the Li-ion battery. VCM
activates the F/S relay to make the system main relay controllable when the system is set to READY or when
the battery is charged.
When VCM detects a malfunction in the EV system and judges that the system main relay must be deacti- L
vated, VCM deactivates the F/S relay to shut off the system main relay driving power.
F/S CHG Relay INFOID:0000000010410077
M
The F/S CHG (fail-safe charge) relay supplies the driving power for the quick charge relay inside the PDM
(Power Delivery Module). When VCM recognizes a quick charge start, VCM activates the F/S CHG relay to
make the quick charge relay operable. During driving, F/S CHG relay remains OFF so that the quick charge N
relay is not activated.
A/C Relay INFOID:0000000010410080
O
The A/C (air conditioner) relay supplies power to the air conditioner system. VCM activates the A/C relay to
supply power to the air conditioner system when the power is turned on or an air conditioner operation request
signal is received. P
System Main Relay 1 INFOID:0000000010410081
The system main relay 1 is integrated in the Li-ion battery and controlled by VCM. The system main relay 1
connects and disconnects the high-voltage circuit (+) side and Li-ion battery.
If the pre-charge to the inverter condenser is complete while high voltage power is supplied, VCM activates
the system main relay 1 to supply power from the Li-ion battery to the EV system. Also when charging, VCM
activates the system main relay 1 to supply power from an external charger to the Li-ion battery.
EVC-21
COMPONENT PARTS
System Main Relay 2 INFOID:0000000010410082
The system main relay 2 is integrated in the Li-ion battery and controlled by VCM. The system main relay 2
connects and disconnects the high-voltage circuit (−) side and Li-ion battery. When high voltage power is sup-
plied, VCM activates the system main relay 2 to supply power from the Li-ion battery to the EV system. When
charging, power from an external charger is supplied from the system main relay 2 to the Li-ion battery.
Pre-charge Relay INFOID:0000000010410083
The pre-charge relay is integrated in the Li-ion battery and controlled by VCM. When high voltage power is
required, VCM activates the pre-charge relay before activating the system main relay to prevent abrupt appli-
cation of high voltage.
Reverse Lamp Relay INFOID:0000000010410084
When VCM receives a reverse range information from the shift selector, VCM activates the reverse lamp relay
to turn ON the reverse lamp.
Accelerator Pedal Position Sensor INFOID:0000000010410085
The accelerator pedal sensor is integrated with the accelerator

pedal. This sensor is a potentiometer that detects the acceleration
pedal stroke, converts it to a voltage signal, and transmits the signal
to VCM. The sensor transmits its signals through dual lines, provid-
ing a minimum driving function even if either line malfunctions.
Upon a POWER ON cycle, VCM learns the fully closed position of
the acceleration pedal from the accelerator pedal position sensor
signal.
PBIB1741E
Refrigerant Pressure Sensor INFOID:0000000010410086
The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. VCM
calculates refrigerant pressure based on the voltage and sends a refrigerant pressure signal to the A/C auto
amp. via EV system CAN communication.
JSCIA0484GB
Stop Lamp Switch INFOID:0000000010410087
The stop lamp switch is installed to the brake pedal bracket. The
switch detects the state of the brake pedal and transmits an ON/OFF
signal to VCM.
The contact of the stop lamp switch is usually open. When the brake
pedal is depressed, it closes and the stop lamp switch signal is
transmitted as a voltage signal.
JSBIA0308ZZ
EVC-22
COMPONENT PARTS
ASCD Steering Switch INFOID:0000000010410088
A
ASCD steering switch has various values of electrical resistance for
each button. VCM reads voltage variation of switch, and determines
which button is operated. B
EVC
D
JSCIA1154ZZ
ECO mode switch INFOID:0000000011191157

E
• The ECO mode switch is installed to the cluster lid C lower.
• When the ECO mode indicator on the combination meter is
OFFand the ECO mode switch is pressed, the ECO mode is active F
andthe ECO mode indicator is ON.
• When the ECO mode indicator on the combination meter is ONand
the ECO mode switch is pressed, the ECO mode is cancelledand
the ECO mode indicator is OFF. G
H
JSCIA1367ZZ
Brake Pedal Position Switch INFOID:0000000010410089

I
The brake pedal position switch is installed to the brake pedal
bracket. The switch detects the state of the brake pedal and trans-
mits an ON/OFF signal to VCM. J
The contact of the brake pedal position switch is usually closed.
When the brake pedal is depressed, it opens to disconnect the cir-
cuit, and shut off the output voltage. This constitutes an brake pedal K
position switch signal.
JSBIA0308ZZ
Battery Current Sensor (With Battery Temperature Sensor) INFOID:0000000010410090 M
BATTERY CURRENT SENSOR

The battery current sensor is installed to the negative cable of the N
battery. The battery current sensor detects the battery charge/dis-
charge current and transmits signals to VCM. VCM judges the bat-
tery load based on these signals and controls the power generation
by converting the target generation voltage to a power generation O
command signal and transmitting it to the DC/DC converter.
CAUTION:
Never connect the electrical component or the ground wire P
directly to the battery terminal. The connection causes the mal-
function of the power voltage variable control, and may cause
the battery to discharge.
JPBIA3262ZZ
BATTERY TEMPERATURE SENSOR

Battery temperature sensor is integrated in battery current sensor.
The sensor measures temperature around the battery.
EVC-23
COMPONENT PARTS
This sensor uses a thermistor and its electrical resistance varies as the temperature varies. VCM detects a
voltage change caused by the change in electrical resistance.
<Reference data>
Temperature [°C (°F)] Voltage (V) Resistance (kΩ)

25 (77) 3.333 1.9 - 2.1
90 (194) 0.969 0.222 - 0.258
SEF012P
Coolant Temperature Sensor INFOID:0000000010410091
The coolant temperature sensor is detects the coolant temperature.

This sensor uses a thermistor that changes its electrical resistance
according to the temperature. VCM detects a voltage change
according to electrical resistance change.
JSCIA0285ZZ
<Reference value>
Coolant temperature [°C (°F)] Voltage (V) Resistance (kΩ)

–10 (14) 4.4 7.0 - 11.4
20 (68) 3.5 2.35 - 2.73
50 (122) 2.2 0.68 - 1.00
90 (194) 0.9 0.236 - 0.260
SEF012P
Electric Water Pump INFOID:0000000010410092
The electric water pump feeds coolant by pressure, which circu-

lates in the high voltage system cooling circuit. They are controlled
by VCM independently so that the amount of pressure feed is
adjusted according to the vehicle speed and water temperature.
The electric water pump also integrates an interface circuit that mon-
itors the pump function for any malfunction, and it transmits a mal-
function signal to VCM.
JSCIA0046ZZ
EVC-24
COMPONENT PARTS
Cooling Fan Control Module INFOID:0000000010410093
A
The cooling fan control module is mounted on the cooling fan and
drives the cooling fan motor.
The cooling fan control module conducts communication between B
VCM via the PWM communication. The cooling fan control module
drives the cooling fan motor so that the cooling fan speed is con-
trolled in accordance with the control signal from VCM.
EVC
D
JSCIA0081ZZ
Approaching Vehicle Sound for Pedestrians (VSP) INFOID:0000000010410096

E
VSP informs the user of various information by electronic sounds.
In the following cases, VCM transmits a operation signal to VSP.
F
Condition Operation status
EVSE is connected to the normal charge port Short beep (once)
When normal charging starts G
Short beeps in sequence (twice)
When timer charge goes into standby mode
When EVSE is not connected correctly Three short beeps continue repeatedly for 30 seconds
H
For details of the charge sound system of VSP, Refer to VSP-16, "CHARGE SOUND SYSTEM : System
Description".
I
EVC-25
SYSTEM
SYSTEM
ELECTRIC POWER TRAIN SYSTEM
ELECTRIC POWER TRAIN SYSTEM : System Description INFOID:0000000010410097
CONTROL OUTLINE
EV requires electric power for the operation of all its systems.
The power stored in the Li-ion battery is supplied as high-voltage direct current to the high-voltage system
while also being converted to 13-15 V by the DC/DC converter and supplied to the 12 V power system.
VCM judges the vehicle status from various information and performs various EV system controls in a compre-
hensive manner.
Main Control Contents of EV
Control Reference
EVC-34, "EV SYSTEM START UP CONTROL : System Descrip-
EV system start-up control
tion"
EVC-37, "HIGH VOLTAGE POWER SUPPLY CONTROL : System
High voltage power supply control
Description"
Motor power control EVC-38, "MOTOR POWER CONTROL : System Description"
EVC-39, "MOTOR REGENERATION CONTROL : System De-
Motor regeneration control
scription"
ECO mode/B mode EVC-40, "ECO MODE/B MODE SYSTEM : System Description"
Shift position judgement EVC-41, "SHIFT POSITION JUDGEMENT : System Description"
EVC-41, "LI-ION BATTERY CHARGE CONTROL : System De-
Li-ion battery charge control
scription"
BR-34, "COOPERATIVE REGENERATIVE BRAKE FUNCTION :
System Description" (LHD models) or BR-514, "COOPERATIVE
Cooperative Regenerative brake control
REGENERATIVE BRAKE FUNCTION : System Description"
(RHD models)
EVC-44, "HIGH VOLTAGE SYSTEM COOLING CONTROL : Sys-
High voltage system cooling control
tem Description"
Air conditioner control EVC-46, "AIR CONDITIONER CONTROL : System Description"
EVC-49, "POWER VOLTAGE VARIABLE CONTROL SYSTEM :
Power voltage variable control
System Description"
EVC-49, "AUTOMATIC 12V BATTERY CHARGE CONTROL :
Automatic 12V battery charge control
System Description"
Power cut off control EVC-50, "POWER CUT OFF CONTROL : System Description"
EVC-52, "AUTOMATIC SPEED CONTROL DEVICE (ASCD) :
ASCD (automatic speed control device)
System Description"
Speed limiter EVC-53, "SPEED LIMITER : System Description"
ELECTRIC POWER TRAIN SYSTEM : Circuit Diagram INFOID:0000000010410098
NOTE:
• For battery cooler circuit, refer to EVB-310, "Circuit Diagram". (with battery cooler models)
• For battery heater & cooler circuit, refer to EVB-598, "Circuit Diagram". (with battery heater & cooler models)
• TCU is included only in models with TELEMATICS system.
EVC-26
SYSTEM
EVC
JSCIA1156GB
EVC-27
SYSTEM
JSCIA1157GB
EVC-28
SYSTEM
EVC
JSCIA1158GB
EVC-29
SYSTEM
JSCIA1159GB
EVC-30
SYSTEM
EVC
JSCIA1160GB
ELECTRIC POWER TRAIN SYSTEM : Fail-Safe INFOID:0000000011009156 P
FAIL-SAFE PATTERN
• Pattern A: Quick charge prohibited
• Pattern B: Normal charge prohibited
• Pattern C: READY OFF
• Pattern D: High-voltage power supply stop
EVC-31
SYSTEM
FAIL-SAFE LIST
×:Applicable
Pattern
DTC Others
A B C D
TYPE 1 ×
U1010
TYPE 2 × × × ×
P0601 × × ×
P0643 ×
TYPE 1 Traction motor output is limited.
P0705
TYPE 2 ×
P0706 A reaction of the shift becomes slow.
P0827 Shift position ″B″ inhibited.
P0A8D × × × ×
P0A8E × × × ×
P0AA0 × × × × Start not possible
P0AA2 × × × ×
P0AA5 × × × ×
P0AA6 × × Doing READY again is prohibited.
P1564 ASCD operation prohibited
P1610 × × × × Start not possible
P2122
P2123 • Traction motor output is limited.
P2127 • Reduced responsiveness during accelerator operation
P2128
TYPE 1 ×
TYPE 2
• Reduced responsiveness during accelerator operation
P3100 × × × ×
TYPE 1 ×
TYPE 2 × × × × Start not possible
P3101
TYPE 3 No fail-safe.
TYPE 4 × × ×
P3102 Traction motor output is limited.
• VCM inhibits the operation of the electric compressor.
P3117
• VCM inhibits the operation of the PTC heater.
P312B × × × ×
P312C × × × ×
P312D × × × ×
P312E × × × ×
P312F × × × ×
EVC-32
SYSTEM
Pattern
DTC Others A
A B C D
P3130 × × × ×
TYPE 1 × × × × B
P3131
P3141 × EVC
P315C × × × ×
P316A ×
D
P316C ×
P316D ×
P316F × × E
P3170 ×
P3173 × × Traction motor output is limited.
F
P3176 × × × ×
P3177 × × × ×
P3178 × × × × G
P317A ×
P317B × × × ×
H
P317D ×
P317E × ×
P3182 × × × × I
P3183 × ×
TYPE 1 ×
P3191 J
TYPE 1 × × Only driving in creep is possible.
P3193
K
TYPE 1 ×
P3196
TYPE 2 × × Traction motor output is limited.
P319C × L
P319E × × Only driving in creep is possible.
TYPE 1 ×
P31A1 M
P31A7 ×
P31A9 × × Only driving in creep is possible. N
TYPE 1 ×
P31AE
O
TYPE 1 VCM inhibits the timer charge.
P31B0 TYPE 2 VCM inhibits the timer charge and the remote climate control.
TYPE 3 No fail-safe. P
When the power is turned on and the vehicle is charging, the cooling
TYPE 1
P31B3 fan is operated at a constant speed.
P31B4 TYPE 2 VCM inhibits the remote climate control.
EVC-33
SYSTEM
Pattern
DTC Others
A B C D
ASCD operation prohibited
TYPE 1 NOTE:
P31B5 The ECO indicator value also becomes extremely poor.
P31B6 VCM sets the DC/DC converter output power to a constant 14 V.
• VCM inhibits the timer charge and the remote climate control.
P31C5
• VCM inhibits the automatic 12V battery charge control.
P31C6
P31C7
P31CA × Traction motor output is limited.
P31CB × Traction motor output is limited.
• Traction motor output is limited.
P31D5
• Vehicle speed is limited. [Approx. 40 km/h (25 MPH)]
P31DB × × × ×
P31DC × × × ×
P31DE
TYPE 1 × × × ×
P31E0
TYPE 1 × × × ×
P31E1
P31E7 Doing READY again is prohibited.
P31F2 VCM inhibits the timer charge and the remote climate control.
EV SYSTEM START UP CONTROL

EV SYSTEM START UP CONTROL : System Description INFOID:0000000010410100
SYSTEM DIAGRAM
JSCIA1161GB
NOTE:
TCU is included only in models with TELEMATICS system.
CONTROL DESCRIPTION
VCM judges the operation mode from signals sent by various sensors, switches, and ECUs, and controls the
start/stop of the EV system by activating the relays accordingly.
EVC-34
SYSTEM
Power Switch ON
A
EVC
JSCIA0487GB
When the power ON power supply from the IPDM E/R enters VCM, VCM turns ON the M/C relay to supply D
power to each ECU in the EV system.
READY
E
I
JSCIA0488GB
When the driver operates the POWER switch while depressing the brake pedal, VCM turns ON the M/C relay
to supply power to each ECU in the EV system. Furthermore, VCM activates the F/S relay to start the power
J
supply to the system main relay.
NOTE:
VCM inhibits the vehicle is set to READY in following conditions:
• Charge connector is connected K
• Li-ion battery remaining energy is too low.
• Li-ion battery temperature is too low. [Approximately -25°C (-13°F)]
In Normal Charging L
JSCIA0489GB
NOTE:
If VCM judges that the system is in normal charge mode, VCM turns ON the M/C relay to supply power to
each ECU in the EV system. Furthermore, VCM activates the F/S relay to start the power supply to the system
main relay.
EVC-35
SYSTEM
NOTE:
Normal charging does not start with the power switch ON.
In Quick Charging
JSCIA0490GB
When VCM judges that the system is in quick charge mode, VCM turns ON the M/C relay to supply power to
each ECU in the EV system. VCM also activates the F/S CHG relay to supply power to the quick charge relay
inside PDM (Power Delivery Module). Furthermore, VCM activates the F/S relay to start the power supply to
the system main relay.
When Air Conditioner Is Operating (Power OFF)
When air conditioner is activated (e.g. remote climate control and Climate Ctrl. Timer), VCM turns ON the M/C
relay to start the EV system. VCM also activates the A/C relay to supply power to the air conditioner system.
Furthermore, VCM activates the F/S relay to start the power supply to the system main relay.
When Automatic 12V Battery Charge Control is Operating
When VCM judges that the 12V battery requires automatic charging, VCM turns ON the M/C relay to start the
EV system. Furthermore, VCM activates the F/S relay to start the power supply to the system main relay.
Relay Activation Matrix
POWER ON
Condition
Relay Charging When 12V bat- Climate Ctrl.
POWER ON READY
Normal charge Quick charge tery is charged Timer
F/S relay ON ON ON ON ON ON
M/C relay ON ON ON ON ON ON
A/C relay ON ON ON ON ON ON
F/S CHG relay OFF OFF OFF ON OFF OFF
POWER OFF
Condition
Relay Charging When 12V battery Remote cli-
Climate Ctrl. Timer
Normal charge Quick charge is charged mate control
F/S relay ON ON ON ON ON
M/C relay ON ON ON ON ON
A/C relay OFF OFF OFF ON ON
F/S CHG relay OFF ON OFF OFF ON*
*: Only during quick charging
HIGH VOLTAGE POWER SUPPLY CONTROL
EVC-36
SYSTEM
HIGH VOLTAGE POWER SUPPLY CONTROL : System Description INFOID:0000000010410101
A
SYSTEM DIAGRAM
EVC
JSCIA0491GB
NOTE: G
TCU is used only in models with TELEMATICS system.
DESCRIPTION
When the driver performs the READY operation or connects the charge cable to a charging port or when VCM H
starts according to the timer control, VCM judges the necessity of connecting the high voltage circuit to Li-ion
battery and then VCM activates system main relay 1, system main relay 2, and the pre-charge relay located
inside the Li-ion battery to establish the circuit. I
Moreover, the high voltage circuit of the EV system has a pre-charge circuit to protect the high voltage circuit
from sudden application of high voltage current.
CONTROL FLOW J
To connect the high voltage circuit, VCM first activates the system main relay 2 and pre-charge relay.
JSCIA0492GB
O
As a result, the high voltage power is supplied to the respective systems via the pre-charge resistor in the pre-
charge circuit. When the condenser inside the traction motor inverter is fully charged by the applied power, the
traction motor inverter transmits a high voltage power supply preparation completion signal to VCM. Receiving
P
EVC-37
SYSTEM
the signal, VCM activates the system main relay 1 and deactivates the pre-charge relay. Then, normal power
is supplied to the respective systems.
JSCIA0493GB
MOTOR POWER CONTROL

MOTOR POWER CONTROL : System Description INFOID:0000000010410102
SYSTEM DIAGRAM
JSCIA1371GB
NOTE:
VCM calculates vehicle speed, based on a motor speed.
DESCRIPTION
The EV system generates traction force by converting the direct current from the Li-ion battery to an alternat-
ing current by the traction motor inverter and operating the traction motor with the alternating current.
VCM calculates target traction force, based on an accelerator pedal position, vehicle speed, and shift position.
After this, VCM adds creep force to the calculated target traction force.
Subsequently, VCM adds torque limitations to the calculated driving force, based on torque down signals
received from each system, to decide a motor torque request signal.
This motor torque request signal is transmitted to the traction motor inverter via EV system CAN communica-
tion.
For the operation principle of the motor, refer to TMS-25, "MOTOR POWER CONTROL : Operating Principle".
OUTPUT LIMIT AND OUTPUT STOP REQUEST LIST
EVC-38
SYSTEM
Power limitation indicator A

Request ECU Output limit cause Condition
lamp
Traction motor tempera- When the traction motor or traction motor inverter reaches
ON
ture high an abnormally high temperature
B
Traction Motor In-
When the high voltage power input to the traction motor in-
verter Input power low ON
verter is 240 V or less
DTC detected OFF Refer to TMS-31, "Fail-safe". EVC
Li-ion battery remained
ON When the Li-ion battery cell voltage is low
energy low
When the Li-ion battery reaches an abnormally high tem- D
Li-ion battery tempera-
ON perature
ture high
[Reference value: Approx. 55°C (131°F) or more]
Li-ion battery
controller When the Li-ion battery reaches an abnormally low temper-
Li-ion battery tempera- E
ON ature.
ture low
[Reference value: Approx. −10°C (14°F) or less]
Refer to EVB-50, "Fail-safe" (without battery cooler), EVB-
DTC detected OFF 324, "Fail-safe" (with battery cooler), EVB-612, "Fail-safe" F
(with battery heater & cooler).
Acceleration/brake signal When the accelerator pedal position sensor signal and stop
OFF
plausibility error lamp switch signal are input at the same time G
VCM Power train system pro-
OFF —
tection function
DTC detected OFF Refer to EVC-93, "Fail-Safe". H
MOTOR REGENERATION CONTROL

MOTOR REGENERATION CONTROL : System Description INFOID:0000000010410103
I
SYSTEM DIAGRAM
J
JSCIA1365GB O
NOTE:
VCM calculates vehicle speed, based on a motor speed.
DESCRIPTION P
The regenerative brake system is a function that operates the traction motor as a generator during decelera-
tion, not for generating traction force as in normal driving, and converts the kinetic energy from the vehicle
wheels to electric energy that is used to charge the Li-ion battery. At the same time, it utilizes the rotational
resistance from the power generation as a part of the braking force.
For the operation principle, refer to TMS-26, "MOTOR REGENERATION CONTROL : Operating Principle".
REGENERATIVE BRAKE CONTROL
EVC-39
SYSTEM
When the driver depresses the brake pedal during driving, Hydraulic brake actuation control module transmits
a target braking force signal to VCM. VCM calculates a target regenerative torque based on the signal and
transmits a target motor torque signal to the traction motor inverter. Moreover, VCM transmits the current
regenerative torque signal to Hydraulic brake actuation control module so that the Hydraulic brake actuation
control module can control the overall braking force.
For information on the Cooperative regenerative brake function, refer to BR-34, "COOPERATIVE REGENER-
ATIVE BRAKE FUNCTION : System Description".
REGENERATION CHARGE CONTROL

VCM determines the regenerative charging amount from the Li-ion battery maximum chargeable power signal
sent from the Li-ion battery. Moreover, VCM determines the energy recovery amount while performing a col-
laborative control with the electrically-driven intelligent brake system so that a suitable braking force is pro-
vided according to the brake pedal operation amount.
After determining the energy recovery amount, VCM transmits a target motor torque signal to the traction
motor inverter and starts regeneration charge.
If the Li-ion battery remaining energy is sufficient, VCM stops the regeneration charge control.
NOTICE:
VCM performs the regenerative charge control constantly at deceleration. However, when the Li-ion battery is
in the fully charged state, VCM stops the regenerative charge control. Accordingly, deceleration may be felt
weak when the accelerator pedal is released during driving.
ECO MODE/B MODE SYSTEM
ECO MODE/B MODE SYSTEM : System Description INFOID:0000000010410104
SYSTEM DIAGRAM
JSCIA1162GB
DESCRIPTION
ECO mode and B mode provide support for reducing the electricity consumption in actual traffic by reducing
power consumption of the drive motor and by increasing the regenerative power from the drive motor.
NOTE:
ECO mode and B mode performs the control according to the normal characteristics when in reverse range.
ECO MODE
When the driver selects ECO mode by operating the ECO mode switch, VCM controls to a gentle acceleration
(compared to normal mode) and reduces electricity consumption by reducing waste in acceleration and decel-
eration.
VCM transmits an ECO mode indication request signal to the combination meter via CAN communication to
turn ON the ECO mode indicator.
B MODE (REGENERATIVE BRAKE MODE)
When the driver selects B mode by operating the shift lever, VCM controls to a strong regeneration (compared
to normal mode) and collects more energy.
LIST OF DRIVE FORCE CHARACTERISTICS BY MODE
EVC-40
SYSTEM
Mode Power output Regeneration A

Normal Normal control Normal control
ECO mode Gentle acceleration Strongish
B
B mode Normal control Strong
B mode + ECO mode Gentle acceleration Strong
SHIFT POSITION JUDGEMENT EVC
SHIFT POSITION JUDGEMENT : System Description INFOID:0000000011008659
D
SYSTEM DIAGRAM
JSCIA1163GB I
DESCRIPTION
VCM judges a shift position according to the ON/OFF signal from the shift selector and park position switch
and transmits the shift position signal to traction motor inverter and combination meter. J
SHIFT POSITION SIGNAL LIST

K
Shift selector
Park posi- Shift posi- Shift posi- Shift posi- Shift posi- Shift posi- Shift posi- Shift posi- Shift posi-
Shift range
tion switch tion signal tion signal tion signal tion signal tion signal tion signal tion signal tion signal L
1 2 3 4 5 6 7 8
P L H H H H H L L H
R H L L H H H H L H M
N H H L L L H H L H
D H H H H L L H L H
N
B H H H H L L H H L
NOTE:
″L″ and ″H″ in the table show as follows: ″L″ outputs 0V and ″H,″ 5V.
O
LI-ION BATTERY CHARGE CONTROL
LI-ION BATTERY CHARGE CONTROL : System Description INFOID:0000000010410105
P
CONTROL OUTLINE
VCM activates the EV system by connecting the charging connector, performing remote control, or using the
built-in timer to start charging to the Li-ion battery. The following charge modes are available.
EVC-41
SYSTEM
Methods of charging Description

Immediate charge
Normal charge Timer charge
VC-19, "LI-ION BATTERY CHARGE CONTROL : System Description"
Remote charge
Quick charge
Regeneration charge EVC-39, "MOTOR REGENERATION CONTROL : System Description"
LI-ION BATTERY CHARGE CONTROL : Normal Charge Control INFOID:0000000010410106
SYSTEM DIAGRAM
JSCIA1117GB
NOTE:
BASIC CONTROL
When normal charge cable is connected under the power switch OFF condition, VCM judges that the system
is in a charge mode and activates the F/S relay and M/C relay to allow charging operation.
Then, VCM determines the charge power based on the Li-ion battery chargeable power signal received from
the Li-ion battery controller and the chargeable power signal received from the PDM (Power Delivery Module).
VCM then sends the maximum charge power signal to the PDM (Power Delivery Module).
The PDM (Power Delivery Module) determines a charge power based on the maximum charge power signal
and the maximum input current signal sent by the Mode2 EVSE control box or charging station.
Concurrently, the VCM activates the system main relay 1 and system main relay 2. Consequently, Li-ion bat-
tery charge starts.
NOTE:
• Li-ion battery charge does not start when the power switch is ON. When it is required to charge with the
power switch ON, start charging before turning ON the power switch.
• When the charging connector is connected to the charge port in the READY state, READY is turned OFF,
the power switch is turned ON, and the shift position is changed to N position.
IMMEDIATE CHARGE MODE
When normal charge cable is connected to the normal charge port, the PDM (Power Delivery Module) trans-
mits an EV system activation signal to VCM. Li-ion battery charge then starts immediately.
EVC-42
SYSTEM
When the timer charge is set, Li-ion battery charge does not start just after the PDM (Power Delivery Module)
transmits an EV system activation signal to VCM. When VCM detects an ON signal from the immediate charg- A
ing switch in that state, VCM judges that the immediate charge mode is selected and starts charging.
When the charge is finished and VCM receives a Li-ion battery charge completion signal from Li-ion battery
controller, VCM stops the charge control.
B
TIMER CHARGE MODE
VCM starts up automatically and starts charging at the set time.
When VCM receives a Li-ion battery charge completion signal from Li-ion battery controller or at a set timer EVC
charge finish time, VCM stops the charge control.
NOTE:
• The timer setting method varies according to vehicle specifications.
- Models with navigation system (7 inch display): Refer to AV-86, "MULTI AV SYSTEM : System Description". D
- Models without navigation system (7 inch display): Refer to MWI-74, "TIMER CHARGE AND A/C-HEATER
TIMER (CLIMATE CTRL. TIMER) [WITHOUT NAVIGATION (7 INCH DISPLAY)] : System Description".
• When timer charge and the Climate Ctrl. Timer operate simultaneously, VCM distributes power to the air E
conditioner system and the charge system according to the priority set on the navigation screen (7 inch dis-
play) or combination meter.
REMOTE CHARGE MODE F
When TCU transmits an EV system activation signal to VCM, VCM judges that the remote charge mode is
selected and starts charge control.
When VCM receives a Li-ion battery charge completion signal from Li-ion battery controller, VCM stops the G
charge control.
CANCEL CONDITIONS
VCM stops the normal charging when VCM detects the normal charge cable is disconnected. H
In addition, under the following conditions, VCM temporarily stops the normal charging and enters standby
status.
• When the AC voltage and PWM communication from the Mode2 EVSE or charging station are interrupted.
• When the normal charge cable connector release switch is pressed. I
• When the Li-ion battery temperature reaches 60°C (140°F) or higher.
LI-ION BATTERY CHARGE CONTROL : Quick Charge Control INFOID:0000000010410107
J
SYSTEM DIAGRAM
K
JSCIA1370GB
EVC-43
SYSTEM
BASIC CONTROL
When the quick charge connector is connected to the quick charge port and the start switch of quick charger is
pressed, the PDM (Power Delivery Module) transmits an EV system activation request signal to VCM. VCM
then activates the F/S CHG relay.
Next, VCM determines the target charge power based on the Li-ion battery chargeable power signal received
from the Li-ion battery controller and the chargeable power signal received from the PDM (Power Delivery
Module). VCM then sends the maximum charge power signal to the PDM (Power Delivery Module).
The PDM (Power Delivery Module) converts the Maximum charge power signal to a charge current request
signal and transmits it to the quick charger.
Simultaneously, the PDM (Power Delivery Module) activates the quick charge relay, and VCM activates sys-
tem main relay 1 and system main relay 2. Consequently, the quick charge starts.
When the charge amount reaches the prescribed amount and VCM receives the Li-ion battery charge comple-
tion signal from the Li-ion battery controller, VCM stops the charging.
NOTE:
• Even if the Li-ion battery remaining energy does not reach the predetermined level, VCM may stop the
charge control after a certain period of time.
• When the Li-ion battery temperature reaches 60ºC (140°F) or higher, VCM temporarily stops quick charging
and enters standby status.
HIGH VOLTAGE SYSTEM COOLING CONTROL
HIGH VOLTAGE SYSTEM COOLING CONTROL : System Description INFOID:0000000010410108
VCM controls water pump and cooling fan according to information from various sensors and ECUs.
SYSTEM DIAGRAM
JSCIA0494GB
WATER PUMP CONTROL

Control Description
VCM controls the electric water pump to achieve the flow rate corresponding to water temperature and vehicle
speed. The electric water pump contains an interface circuit. When a malfunction occurs in the pump, the elec-
tric water pump transmits an error signal to VCM and prevents the reduction in coolant flow rate. Since PDM
(Power Delivery Module) needs to be cooled during charge, VCM activates the electric water pump to circulate
coolant to PDM (Power Delivery Module).
EVC-44
SYSTEM
Electric Water Pump Operation During Traveling
A
EVC
E
JSCIA0495GB
< Reference value of electric water pump duty>
Electric water pump control duty

F
Electric water pump operation
(Approx.)
LOW 40%
G
MID 60%
HIGH 73%
NOTE: H
The values listed above may slightly differ from actual measurement values depending on conditions.
Fail-Safe
When a malfunction occurs in the electric water pump, VCM controls the electric water pump as follows: I
Feedback to VCM Control state

Malfunction in pump or abnormal power supply of J
STOP
pump
Normal control
• Abnormal feedback signal
NOTE: K
• A break in communication line or short circuit
Water pump operates at a maximum velocity
Abnormal signal input from pump Normal control
Speed fed back from pump differs largely from VCM- L
Normal control
indicated speed.
COOLING FAN CONTROL

M
Control Description
VCM calculates an appropriate speed according to coolant temperature, vehicle speed, and a cooling fan
speed request signal received from A/C auto amplifier and transmits a duty signal to the cooling fan control
N
module.VCM judges a maximum fan speed according to a cooling fan speed (calculated from coolant temper-
ature and a vehicle speed) and that requested from the A/C auto amplifier and outputs drive duty.
NOTE:
The cooling fan may be activated during charge even when the power switch is OFF. O
EVC-45
SYSTEM
The cooling fan speed control reduces variations in cooling fan
speed by setting a range in operating conditions as shown in the fig-
ure.
JSCIA0496GB
Cooling fan operation (During traveling or charging)

Cooling fan duty (%)
Engine coolant temper- Vehicle speed [km/h (MPH)]
ature [°C (°F)] 0 (0) – 20 (12) 20 (12) – 50 (31) 50 (31) – 80 (50) 80 (50) or more
60 (140) or less 0 0 0 0
60 (140) – 62 (144) 40 – 85 40 – 85 40 – 85 0
62 (144) or more 100 100 100 100
Cooling fan operation (Climate Ctrl. Timer ON or remote climate control ON)
Engine coolant tem-

Cooling fan duty (%)
perature [°C (°F)]
60 (140) or less 0
60 (140) – 62 (144) 40 – 100
62 (144) or more 100
AIR CONDITIONER CONTROL

AIR CONDITIONER CONTROL : System Description INFOID:0000000010410109
SYSTEM DIAGRAM
EVC-46
SYSTEM
Models with Automatic Air Conditioning System
A
EVC
H
JMIIA3804GB
NOTE:
I
Models with Automatic Heater System
N
JMIIA3805GB
DESCRIPTION O
In EV, VCM controls the A/C relay so that the air conditioner can operate even when power switch is OFF. The
Climate Ctrl. Timer (A/C-heater timer), remote climate control functions are enabled by this control.
When VCM recognizes a need for air conditioner or heater activation due to driver operation, Climate Ctrl.
Timer function or remote climate control function, VCM activates the A/C relay to supply power to the air con- P
ditioning system or heater system.
In addition, VCM calculates the power that can be used by the air conditioning system based on the Li-ion bat-
tery status and vehicle status and sends it to the A/C auto amp. or the heater auto amp.
For an overview of air conditioning system or heater system, refer to HAC-36, "AUTOMATIC AIR CONDI-
TIONING SYSTEM : System Description" (automatic air conditioning system) or HAC-242, "AUTOMATIC
HEATER SYSTEM : System Description" (automatic heater system).
EVC-47
SYSTEM
CONTROL DESCRIPTION
Cooling/heating Function Control During Power Supply Position ON
When the power supply position is ON (vehicle condition is not READY while power switch is ON), VCM
allows the operation of cooling/heating function control in the status that EVSE is connected.However, start of
cooling/heating function is allowed only while charging is in progress. Refer to HAC-53, "AUTOMATIC AIR
CONDITIONING SYSTEM : Description" (automatic air conditioning system) or HAC-253, "Description" (auto-
matic heater system) for details of cooling/heating function control during power supply position ON.
NOTE:
If the Li-ion battery available charge gauge level is lower than Level 2, the air conditioning system or heater
system does not operate during battery charge.
Climate Ctrl. Timer Control
When all of the following conditions are satisfied, VCM activates the timer air conditioner so that the in-vehicle
temperature reaches in-vehicle setting temperature*1 before the scheduled departure time*2.
• Timer of Climate Ctrl. Timer is ON
• There is AC power input during charging (or in a state where AC power input is possible).
VCM activates the EV system 2 hours before the scheduled departure time. The A/C auto amp. or heater auto
amp. judges the necessary operating time of Climate Ctrl. Timer within the range between 0 and 2 hours
according to the ambient temperature and interior temperature and sends the data to VCM. VCM calculates
and judges the operating time required for activating the Climate Ctrl. Timer, according to the scheduled
departure time and the received data.
NOTE:
• When turning ON the power switch during Climate Ctrl. Timer is activated, the air conditioning control or
heater control switches to normal.
• When the timer charge and timer air conditioner operate simultaneously, perform power distribution accord-
ing to the following settings.
- Models with 7-inch display: timer priority setting that are set on the navigation screen
- Models without 7-inch display: Climate Ctrl. Timer priority
• *1: The in-vehicle setting temperature can be set as per the following.
- Models with 7-inch display: A/C temperature that are set on the navigation screen
- Models without 7-inch display: 25°C (except for Europe) or 22°C (for Europe) (unchangeable)
• *2: Set the scheduled departure time from the navigation screen (models with 7-inch display) or from the
vehicle information display on the combination meter (models without 7-inch display).
Remote Climate Control
When VCM receives the remote climate control request signal from the TCU or BCM, the air conditioning is
operated.
Remote climate control operates as follows.
Condition Operating time (min.)

Charge connector is not connected. 15
When connecting EVSE (with AC input) 15 – 120
During quick charge 15 – 120
NOTE:
When the power is turned ON during remote climate control is activated, the remote climate control is ended.
POWER VOLTAGE VARIABLE CONTROL SYSTEM
EVC-48
SYSTEM
POWER VOLTAGE VARIABLE CONTROL SYSTEM : System Description INFOID:0000000010410110
A
SYSTEM DIAGRAM
EVC
JSCIA0808GB F
DESCRIPTION
The power voltage variable control system changes the output from the DC/DC converter built-in PDM (Power
Delivery Module) to 13-15 V to reduce the power consumption according to the status of use of electrical G
equipment and that of 12 V battery.
CONTROL DESCRIPTION H
The battery current sensor (with battery temperature sensor) measures the battery charge/discharge current
and the battery ambient temperature.
VCM judges the state of use of electric equipment and that of battery according to the measurement, decides
target output voltage of the DC/DC converter, and transmits a target DC/DC converter output signal to PDM I
(Power Delivery Module). PDM (Power Delivery Module) changes the output voltage of the DC/DC converter
according to the target DC/DC converter output signal. When an error occurs in the power voltage variable
control system or when a target DC/DC converter output signal is not transmitted to the DC/DC converter due J
to error, the DC/DC converter outputs 14 V. VCM detects an error in the DC/DC converter according to a DC/
DC converter status signal transmitted from PDM (Power Delivery Module).
AUTOMATIC 12V BATTERY CHARGE CONTROL K
AUTOMATIC 12V BATTERY CHARGE CONTROL : System Description INFOID:0000000010410111
SYSTEM DIAGRAM L
JSCIA0498GB
NOTE:
DESCRIPTION
EVC-49
SYSTEM
The automatic 12V battery charge control is a control to reduce the frequency of battery discharge by auto-
matically charging the 12V battery in case the 12V battery voltage is low when the key switch is turned to ON
or the vehicle is left unattended for a long time.
When VCM judges a need for automatic charge, VCM controls the DC/DC converter and the system main
relay and charges the 12V battery using the Li-ion battery power.
For 12V battery charge control during READY condition, refer to EVC-49, "POWER VOLTAGE VARIABLE
CONTROL SYSTEM : System Description".
Vehicle state 12V battery charge Shift position

READY Any position
Normal charge ON
Quick charge ON Always charged.
Climate Ctrl. Timer or remote

“P” position only
climate control ON
Power switch ON Automatically started when 12V battery voltage is low.
Power switch OFF Charge for 4 minutes when the vehicle is not used for a long time.
NOTE:
When any of the following operations is performed, the 12V battery automatic charge control is canceled: 1)
Vehicle to the READY state, 2) Normal charge, 3) Quick charge, 4) Climate Ctrl. Timer or remote climate con-
trol ON.
CONTROL DESCRIPTION
Power Switch ON
VCM monitors the 12V battery voltage during power switch ON cycle and immediately starts charging when
VCM judges that the voltage is lowered.
NOTE:
VCM does not perform the automatic 12V battery charge control when the shift position is in a range other
than “P” range.
When Vehicle is Not Used for A Long Time
VCM measures the time of no operation using its internal timer. If the time of no operation reaches 24 hours,
VCM performs automatic charge for 4 minutes.
VCM resets the no operation status continuous time when the vehicle satisfies one of the following conditions.
• READY continues for more than 4 minutes.
• Normal charge continues for more than 4 minutes.
• Quick charge continues for more than 4 minutes.
• Climate Ctrl. Timer or remote climate control continues for more than 4 minutes.
• When 12V battery is recognized as Full Charge during automatic charge (Charging voltage is 1.5A or less)
NOTE:
• During automatic 12V battery charge, the charging status indicator blinks.
• The automatic 12V battery charge control does not start within approximately one hour when the power
switch is turned ON/OFF.
POWER CUT OFF CONTROL
POWER CUT OFF CONTROL : System Description INFOID:0000000010410112
SYSTEM DIAGRAM
JSCIA1322GB
EVC-50
SYSTEM
DESCRIPTION
Because EV uses high voltage power, there is a risk of electric shock if the high voltage circuit is shorted to a A
body ground during a collision. To avoid such risks, if VCM detects a car crush information signal, VCM deac-
tivates the system main relay to cut off the Li-ion battery from the high voltage circuit so that the risk of electric
shock is reduced. B
When detecting a serious collision
When receiving a car crash information signal from the air bag diagnosis sensor unit, VCM turns OFF the sys-
tem main relay and quickly interrupts the high voltage circuit. In addition, VCM detects DTC P3137 and prohib- EVC
its the READY operation until the DTC is erased.
NOTE:
The collision detection level of VCM may differ from an actual vehicle damage state.
D
When detection a minor collision
When receiving a slight collision detection signal from the air bag diagnosis sensor unit, VCM turns OFF the
system main relay and quickly interrupts the high voltage circuit. The READY operation becomes possible
after a lapse of 90 seconds or more (VCM performs self shutoff) after the power switch is turned OFF. E
CAUTION:
When bringing VCM into self shut off, never perform vehicle handling such as opening and closing of
doors while the power switch is OFF. If some kind of vehicle handling is performed, then wait another F
90 seconds or more from the time of the vehicle handling.
NOTE:
• The collision detection level of VCM may differ from an actual vehicle damage state.
G
• When a collision occurs more than once during the same trip (no history of turning OFF the power switch),
VCM judges “detection of serious collision” and prohibits the READY operation.
Vehicle behavior by collision status H
Collision sta- CONSULT data monitor screen

Detected DTC Reset
tus Item Indication I
HEAVY
Serious P3137 CLASH DETECT INFO EVC-261, "DTC Description"
MID
After maintaining the power switch J
OFF state (self shutoff) for 90 sec-
onds or more, perform the READY
operation.
K
CAUTION:
When bringing VCM into self shut
Minor P3135 LIGHT CRASH JUDGMENT On off, never perform vehicle handling
such as opening and closing of L
doors while the power switch is
OFF. If some kind of vehicle han-
dling is performed, then wait an-
other 90 seconds or more from the M
time of the vehicle handling.
AUTOMATIC SPEED CONTROL DEVICE (ASCD)

N
EVC-51
SYSTEM
AUTOMATIC SPEED CONTROL DEVICE (ASCD) : System Description INFOID:0000000010410114
SYSTEM DIAGRAM
JSCIA1164GB
BASIC ASCD SYSTEM

Automatic Speed Control Device (ASCD) allows a driver to keep vehicle at a predetermined constant speed
without depressing accelerator pedal. Driver can set vehicle speed in advance between approximately 40 km/
h (25 MPH) and 133 km/h (83 MPH).
VCM controls the traction motor to regulate vehicle speed.
Operation status of ASCD is indicated on the information display in the combination meter. If any malfunction
occurs in ASCD system, it automatically deactivates control.
For the switch function, Refer to EVC-65, "AUTOMATIC SPEED CONTROL DEVICE (ASCD) : Switch Name
and Function".
For the ASCD indicator, Refer to EVC-61, "WARNING/INDICATOR/CHIME LIST : Indicator/Information".
CAUTION:
Always drive vehicle in a safe manner according to traffic conditions and obey all traffic laws.
CANCEL OPERATION
When any of following conditions exist, cruise operation is cancelled.
• CANCEL switch is pressed
• More than two switches on ASCD steering switch are pressed at the same time (Set speed is cleared)
• Brake pedal is depressed
• Selector lever position is N, P or R position
When VCM detects malfunction for some self-diagnoses regarding ASCD system, VCM cancels the cruise
operation and informs the driver by blinking SET indicator quickly.
If ASCD MAIN switch is turned to OFF while ASCD is activated, all of ASCD operations are cancelled and
vehicle speed memory is erased.
SPEED LIMITER
EVC-52
SYSTEM
SPEED LIMITER : System Description INFOID:0000000010410115
A
SYSTEM DIAGRAM
EVC
JSCIA1165GB F
BASIC SPEED LIMITER SYSTEM

The speed limiter is a system that enables to restrict the vehicle speed within the set speed that is selected by
the driver. Driver can set vehicle speed between 30 km/h and 130 km/h (in the metric system mode) or 20 G
MPH and 80 MPH (in the yard/pound system mode). VCM controls the traction motor to regulate vehicle
speed. Operation status of speed limiter is indicated on the information display in the combination meter. If any
malfunction occurs in speed limiter system, it automatically deactivates control. H
CAUTION:
Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws.
SET OPERATION I
Press speed limiter MAIN switch. (LIMIT indicated on the information display)
By pressing the SET / COAST switch, the vehicle speed can be set within the range between 30 km/h and 130
km/h (in the metric system mode) or 20 MPH and 80 MPH (in the yard/pound system mode). (SET and set J
speed is indicated on the information display)
When pressing the RES / ACCELERATE switch, the set speed can be increased.
When pressing the SET / COAST switch, the set speed can be decreased.
K
CANCEL OPERATION
When any of following conditions exist, speed limiter operation is cancelled.
• Speed limiter MAIN switch pressed (Set speed is cleared) L
• ASCD MAIN switch pressed (Set speed is cleared)
• CANCEL switch is pressed
• Accelerator pedal is fully depressed
M
EVC-53
SYSTEM
When the accelerator pedal is depressed within the range shown in the figure below, the accelerator
pedal reaction force strengthens. Further depressing the accelerator pedal within the range cancels the
speed limiter. This allows acceleration in emergencies.
JMBIA1518GB
RESUME OPERATION
When the speed limiter is cancelled without operating the speed limiter main switch, the pressing of the RES/
+ switch enables the resetting of the vehicle speed to the state before the speed limiter is cancelled.
INFORMATION DISPLAY (COMBINATION METER)
INFORMATION DISPLAY (COMBINATION METER) : Cooling Fan Maintenance Warn-
ing INFOID:0000000011117328
DESIGN/PURPOSE
The time for replacement of cooling fan is displayed.
Symbol Message
— Visit dealer check cooling fan
SYNCHRONIZATION WITH WARNING CHIME

Not applicable
OPERATION AT COMBINATION METER CAN COMMUNICATION CUT-OFF OR UNUSUAL SIG-
NAL
For actions on CAN communications blackout in the combination meter, refer to MWI-105, "Fail-Safe".
SYSTEM DIAGRAM
JSCIA1356GB
SIGNAL PATH
VCM counts operating time of cooling fan, and when the operating time exceeds the time of replacement,
VCM transmits a cooling fan maintenance request signal to the combination meter to display a cooling fan
maintenance warning.
WARNING/INDICATOR OPERATING CONDITION
When all the conditions listed below are satisfied:
• Power switch ON
EVC-54
SYSTEM
• The time for replacement of cooling fan is detected
A
WARNING/INDICATOR CANCEL CONDITION
Perform “COOLING FAN INTEGRATED OPERATING TIME CLEAR”. Refer to EVC-127, "Work Procedure".
INFORMATION DISPLAY (COMBINATION METER) : DC/DC Converter Warning B
INFOID:0000000011117329
DESIGN/PURPOSE EVC
DC/DC converter warning warns the driver of 12V battery voltage drop.
Symbol Message
D
• Stop vehicle*1
• Apply parking brake*2 F
G
JSCIA0030ZZ
*1: When 12V battery voltage drops while driving.

*2: When 12V battery voltage drops with the shift position not in P position. H
Synchronization is applied.
For warning chime, refer to WCS-12, "WARNING CHIME : DC/DC Converter Warning Chime". I
SYSTEM DIAGRAM
J
JSCIA1323GB
SIGNAL PATH M
• VCM monitors 12V battery voltage, and if the voltage drops, then VCM transmits a DC/DC converter warning
request signal to the combination meter to display a DC/DC converter warning.
• When receiving a P range signal from the shift selector, VCM cancels a DC/DC converter warning.
N
When all of the following conditions are satisfied:
• Shift position: Except P range O
• 12V battery voltage stays low (approximately 10 – 12 V or less)* for a few consecutive seconds.
*: Threshold voltage depends on vehicle speeds.
NOTE:
P
When 12V battery voltage drops sharply while in READY state, the READY state is also cancelled.
When any of the following conditions are satisfied:
• Shift position: P range
• The 12V battery voltage returns to approximately 12.5 V or more.
EVC-55
SYSTEM
TIMING CHART
JSCIA0542GB
INFORMATION DISPLAY (COMBINATION METER) : Low Battery Charge Warning

INFOID:0000000011117330
DESIGN/PURPOSE
Low battery charge warning is displayed when Li-ion battery power becomes low.
Symbol Message
— Battery level is low
SYSTEM DIAGRAM
JSCIA0511GB
SIGNAL PATH
• LBC transmits a Li-ion battery remained energy signal to VCM.
• VCM calculates a remaining Li-ion battery power according to a signal received from LBC. When judging low
remaining battery power, VCM transmits a low battery charge warning lamp request signal to the combina-
tion meter.
EVC-56
SYSTEM
A
• Power switch: ON or READY
• When Li-ion battery power is 4 kWh or less.
B
When Li-ion battery power returns to 4.5 kWh or more.
TIMING CHART EVC
Low battery charge warning is displayed in synchronization with the low battery charge warning lamp.
JSCIA1333GB
I
INFORMATION DISPLAY (COMBINATION METER) : Power Limitation Warning
INFOID:0000000011117331
DESIGN/PURPOSE J
Power limitation warning shows that traction motor output is limited.
Symbol Message K
— Motor power is limited
SYSTEM DIAGRAM L
JSCIA0517GB
O
SIGNAL PATH
• The traction motor inverter transmits a motor torque limit signal to VCM when the traction motor needs to be
protected. P
• When Li-ion battery cannot output power normally, a motor torque limit signal is transmitted to VCM.
For warning/indicator operating condition, refer to EVC-38, "MOTOR POWER CONTROL : System Descrip-
tion".
The traction motor or Li-ion battery returns from the output limiting state.
EVC-57
SYSTEM
TIMING CHART
Power limitation warning is displayed in synchronization with the power limitation indicator lamp.
JSCIA0518GB
INFORMATION DISPLAY (COMBINATION METER) : Shift P Warning INFOID:0000000011117335
DESIGN/PURPOSE
Shift P warning warns that the driver is getting off the vehicle with the shift position not in P position.
Symbol Message
Shift to P range
JSCIA1335ZZ

Synchronization is applied.
For warning chime, refer to WCS-24, "WARNING CHIME : Shift P Warning Chime".
EVC-58
SYSTEM
SYSTEM DIAGRAM
A
EVC
E
JSCIA1336GB
SIGNAL PATH
F
• The shift selector sends shift position information to VCM.
• BCM transmits a door switch signal to VCM.
• The traction motor inverter transmits a motor speed signal to VCM.
• VCM judges the vehicle condition according to shift position information and a door switch signal. VCM G
transmits a shift P range request display signal to the combination meter if the driver’s door is opened with
the shift position not in P position.
WARNING/INDICATOR OPERATING CONDITION H
• Shift position: Except P range
• Front door (driver side): Open I
• Vehicle speed: Less than 3 km/h
NOTE:
Shift P Warning is displayed when shift selector is shifted to the driving range while the READY lamp is blink-
ing. J

The indication is cancelled when any of the following conditions are satisfied: K
• The shift position is changed to P position.
• The driver’s door is closed.
TIMING CHART L
JSCIA0523GB
EVC-59
SYSTEM
INFORMATION DISPLAY (COMBINATION METER) : Shift Warning Message
INFOID:0000000011144932
DESIGN/PURPOSE
Shift Warning
This message warns the driver that shift system is not normal.
Symbol Message
— T/M system malfunction Visit dealer
Shift Position Warning

This message informs the driver that the selector lever is in between positions.
Symbol Message
— Check position of shift lever
OPERATION AT COMBNATION METER CNA COMMUNICATION CUT-OFF OR UNUSUAL SIGNAL

For actions on CAN communications blackout in the combination meter, refer to MWI-105, "Fail-Safe".
SYSTEM DIAGRAM
JSCIA1358GB
SIGNAL PATH
VCM transmits a shift warning lamp signal to the combination meter when detecting a malfunction in the shift
selector or park position switch.
WARNING/INDICATOR OPERATIONG CONDITION
Shift Warning
When VCM detects DTC of the shift selector or park position switch.
When selector lever is in between positions for 1 second.
Shift Warning
Erase DTC
Optimizing selector lever position
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning lamps/Indicator lamps INFOID:0000000010410117
Item Design Reference

For layout, refer to MWI-9, "METER SYSTEM : Design".
EV system warning lamp For function, refer to MWI-36, "WARNING LAMPS/INDICATOR LAMPS : EV System
Warning Lamp".
EVC-60
SYSTEM
A
Low battery charge warning
lamp For function, refer to MWI-45, "WARNING LAMPS/INDICATOR LAMPS : Low Bat-
tery Charge Warning Lamp".
B
Plug in indicator lamp For function, refer to MWI-48, "WARNING LAMPS/INDICATOR LAMPS : Plug In In-
dicator Lamp".
EVC
Power limitation indicator lamp For function, refer to MWI-51, "WARNING LAMPS/INDICATOR LAMPS : Power
Limitation Indicator Lamp".
D
Ready to drive indicator lamp For function, refer to MWI-52, "WARNING LAMPS/INDICATOR LAMPS : Ready To
Drive Indicator Lamp". E
12V battery charge warning
lamp For function, refer to MWI-66, "WARNING LAMPS/INDICATOR LAMPS : 12V Bat-
tery Charge Warning Lamp". F
WARNING/INDICATOR/CHIME LIST : Warning Chime INFOID:0000000010410118
Item Reference
DC/DC converter warning chime Refer to WCS-12, "WARNING CHIME : DC/DC Converter Warning Chime". H
Power switch reminder chime Refer to WCS-20, "WARNING CHIME : Power Switch Reminder Chime".
Shift P warning chime Refer to WCS-24, "WARNING CHIME : Shift P Warning Chime".
Speed limiter warning chime Refer to WCS-26, "WARNING CHIME : Speed Limiter Warning Chime". I
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)

INFOID:0000000010410119 J
Item Reference
K
Refer to EVC-54, "INFORMATION DISPLAY (COMBINATION METER) : Cooling
Cooling fan maintenance warning
Fan Maintenance Warning".
Refer to EVC-55, "INFORMATION DISPLAY (COMBINATION METER) : DC/DC
DC/DC converter warning L
Converter Warning".
Refer to EVC-56, "INFORMATION DISPLAY (COMBINATION METER) : Low Bat-
Low battery charge warning
tery Charge Warning".
Refer to EVC-57, "INFORMATION DISPLAY (COMBINATION METER) : Power Lim-
M
Power limitation warning
itation Warning".
Refer to EVC-58, "INFORMATION DISPLAY (COMBINATION METER) : Shift P
Shift P warning N
Warning".
Refer to EVC-60, "INFORMATION DISPLAY (COMBINATION METER) : Shift Warn-
Shift warning message
ing Message".
O
WARNING/INDICATOR/CHIME LIST : Indicator/Information INFOID:0000000010410120
ASCD INDICATOR P
EVC-61
SYSTEM
Symbol Function
EVC-52, "AUTOMATIC SPEED CONTROL DEVICE (ASCD) : System Descrip-

tion"
JSCIA1147GB
: CRUISE indicator
: SET indicator
: Set speed indicator
SPEED LIMITER INDICATOR
Symbol Function
EVC-53, "SPEED LIMITER : System Description"
JSCIA1148GB
: LIMIT indicator
: SET indicator
: Set speed indicator
ECO MODE INDICATOR
Symbol Function
EVC-40, "ECO MODE/B MODE SYSTEM : System Description"
JPNIA1941ZZ
TIMER SETTING STATUS

Design/Purpose
Various types of information on Climate Ctrl. Timer and timer charge is displayed.
EVC-62
SYSTEM
With color information display
A
EVC
E
JSCIA1146GB
With monochrome information display

F
J
JSCIA1166GB
No. Name Function K

Timer setting (charging and Climate The timer settings status (On or Off) and the air conditioning/heater or climate con-
Ctrl.) trol.
The charging timer starting and ending (where fitted) hour, minute and day (where L
Charging timer setting confirmation
fitted) for the next charge time that has been set can be checked.
Displays the estimated time to charge the battery to the customer selected charge
Charging time
level (80% or 100%) M
Climate Ctrl. Timer setting confirma-
The set time for ending hours and days of the Climate Ctrl. Timer is displayed.
tion
Display condition N
Timer setting status is displayed for ten seconds when the power switch is turned OFF and the indication
switches every time when the switch is pressed. The indication can be shown for approximately 10 seconds
by operating the switch. O
Display cancel condition

When any of the following conditions is satisfied.
• power switch ON P
• A lapse of 10 seconds or more with no switch operation.
CAN COMMUNICATION
CAN COMMUNICATION : System Description INFOID:0000000010410121
DESCRIPTION
EVC-63
SYSTEM
• CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle
multiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, 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 line, CAN-L line) allowing a high rate of information transmission with
less wiring. Each control unit transmits/receives data but selectively reads required data only.
• VCM includes a gateway function and communicates signals between the CAN communication circuit and
EV system CAN circuit.
For CAN communication details, Refer to LAN-35, "CAN COMMUNICATION SYSTEM : System Description".
EVC-64
OPERATION
OPERATION
A
AUTOMATIC SPEED CONTROL DEVICE (ASCD)
AUTOMATIC SPEED CONTROL DEVICE (ASCD) : Switch Name and Function
INFOID:0000000010410122 B
Function
Functions of each switch are listed in the following table. EVC
JSCIA1168ZZ F
Switch Function
No. Name Function G
CANCEL switch When the switch is pressed, the ASCD control is cancelled.
Speed limiter MAIN switch Refer to EVC-65, "SPEED LIMITER : Switch Name and Function". H
ASCD MAIN switch Turns the ASCD ON/OFF.
• When the switch is pressed after the cruise control is cancelled in any method other
than main switch operation, the vehicle speed is reset to the previous speed setting I
RESUME/ACCELERATE switch before the cancellation*.
• When the switch is pressed during cruise control, the setting speed is increased
and the vehicle speed increases. J
• When the switch is pressed at the preferred vehicle speed, the cruise control starts
to operate.
SET/COAST switch
• When the switch is pressed during cruise control, the set speed is reduced and the
vehicle speed reduces. K
*: To reset vehicle speed, the vehicle condition must be as follows:

• Brake pedal is released
• Selector lever is in a position other than P, R, and N. L
• Vehicle speed is greater than 40 km/h (25 MPH) and 133 km/h (83 MPH)
SPEED LIMITER
M
SPEED LIMITER : Switch Name and Function INFOID:0000000010410123
Function N
Functions of each switch are listed in the following table.
JSCIA1168ZZ
Switch Function
EVC-65
OPERATION
No. Name Function

CANCEL switch Cancels the speed limiter control.
Speed limiter MAIN switch Master switch to activate the speed limiter system.
ASCD MAIN switch Turns the ASCD ON/OFF.

• Resumes the set speed.
RESUME/ACCELERATE switch
• Increases the set speed incrementally.
• Sets desired speed.
SET/COAST switch
• Decreases the set speed incrementally.
ECO MODE SWITCH

ECO MODE SWITCH : Switch Name and Function INFOID:0000000010410124
Function
When the ECO mode switch is operated with the power switch
ON, the mode switches between ON and OFF.
JSCIA1169ZZ
EVC-66
ON BOARD DIAGNOSTIC (OBD) SYSTEM
A
Diagnosis Description INFOID:0000000010410125
This system is an on-board diagnostic system that detects a malfunction automatically. A malfunction is stored B
in ECU memory as a DTC. The diagnostic information can be obtained with CONSULT.
Counter System INFOID:0000000010410126
EVC
In this system, “Power switch is turned OFF ON” is defined as 1 trip. VCM detects malfunctions while saving
the DTC and freeze frame data and continues saving this data for a maximum of 40 trips. In addition, if a DTC
that is the same as the saved DTC is detected again, the counter is reset and the count up starts from “0”
again. D
DTC and Freeze Frame Data INFOID:0000000010410127
E
VCM can store multiple DTCs and up to five Freeze Frame data.
After the detection of a malfunction and storing of DTC and Freeze Frame data by VCM, if a different malfunc-
tion is detected, multiple DTCs can be identified. In contrast, only up to five FFDs are stored according to the
preset priority. For priority, refer to EVC-95, "DTC Inspection Priority Chart". F
The DTC and freeze frame data are deleted when the self-diagnostic is deleted.
EVC-67
FREEZE FRAME DATA MEMORY IMAGE
JSCIA0585GB
EVC-68
DIAGNOSIS SYSTEM (VCM)
A
FUNCTION B
Diagnostic test mode Function

ECU Identification VCM part number can be read. EVC
Self-diagnostic result*1 Self-diagnostic results and freeze frame data can be read and erased quickly.*2
Data monitor Input/Output data in VCM can be read.
D
Diagnostic Test Mode in which CONSULT drives some actuators apart from VCM and also shifts some
Active test
parameters in a specified range.
This mode enables a technician to adjust some devices faster and more accurately by following the in- E
Work support
dications on the CONSULT.
Load battery ID Refer to “Li-ion Battery ID Registration Operation Manual”.
*1: DTC P0AA1 is not cleared even when “Self-diagnostic Result” is cleared. To clear DTC P0AA1, perform “SPECIFIC DTC CLEAR” in F
“WORK SUPPORT”.
*2: The following diagnosis information is cleared when the VCM memory is erased.
• Diagnostic trouble codes
G
• Freeze frame data
• Applicable operational history and count
SELF-DIAG RESULTS MODE H

Self Diagnostic Item
Regarding items of DTC, refer to EVC-98, "DTC Index".
I
How to Erase DTC
• If power is continuously in the ON position after a DTC is detected, turn power switch OFF for at least 90
seconds before turning power switch to the ON position again, and then erase DTC.
J
• Check the all self-diagnostic screen to confirm there are no DTCs in other ECUs.
CAUTION:
• When bringing VCM into self shut off, never perform vehicle handling such as opening and closing
of doors while the power switch is OFF. If some kind of vehicle handling is performed, then wait K
another 90 seconds or more from the time of the vehicle handling.
• DTC P0AA1 is not cleared even when “Self-diagnostic Result” is cleared. To clear DTC P0AA1, per-
form “SPECIFIC DTC CLEAR” in “WORK SUPPORT”. L
Freeze Frame Data
The Freeze Frame Data shows the state of the vehicle at the time a DTC is detected and is useful in re-creat-
ing the circumstances that caused the malfunction. M
Freeze Frame Data Item List
Freeze frame data
Description
item
N
DTC Displays a DTC.
Displays VCM status.
• 0-7: During VCM starts-up O
• 10: Power switch is ON and the charge connector is not connected.
• 11-29: Mode changing to READY
• 30: READY
• 31-49: During system shutdown P
VCM MODE • 50-59: Mode changing to charge mode.
• 60: During normal charging
• 90: During quick charging
• 80-89: Mode changing to charge mode.
• 110-120: When connected to high voltage circuit except when READY or charge*
• 131-144: During system shutdown
EVC-69
Freeze frame data
Description
item
Displays the connection status of the normal charge connector.
NORMAL CHARGE • 0: EVSE is not connected.
CONNECTOR CON- • 1: EVSE is semi-engaged.
NECTION • 2: EVSE is connected.
• 3: EVSE is malfunctioning.
QUICK CHARGE Displays the connection status of the quick charge connector.
CONNECTOR CON- • 0: Quick charge connector is not connected.
NECTION • 1: Quick charge connector is connected.
VEHICLE SPEED
Displays the vehicle speed that is calculated from the motor speed.
[km/h] or [mph]
SHIFT POSITION Displays the shift position.
COOLANT TEMP
Displays the coolant temperature.
[degC]
MOTOR SPEED [rpm] Displays the traction motor speed.
ACCEL OPEN AN-
Displays the accelerator pedal openness.
GLE [%]
TRG TORQ [Nm] Displays the target motor torque.
TRG POWER [N] Displays the target motor output.
TRG REGE TORQ
Displays the target motor regeneration torque.
[Nm]
HV BATT VOLT [V] Displays the Li-ion battery voltage.
HV BATT CURRENT
Displays the Li-ion battery current.
[A]
HV BATT TEMP
Displays the Li-ion battery temperature.
[degC]
REGENERABLE
Displays the Li-ion battery regenerable power.
PWR [kW]
CHARGEABLE PWR
Displays the Li-ion battery chargeable power.
MAX [kW]
AVAILABLE HV BAT
Displays the Li-ion battery available discharge power.
PWR [kW]
INVERTER DC INPUT
Displays DC input voltage of traction motor inverter.
VOLT [V]
DTC DETECTED
Displays detection date of DTC applicable to stored FFD.
MONTH [month]
DTC DETECTED DAY
[day]
DTC DETECTED
HOUR [hour]
DTC DETECTED
MINUTE [min]
INSULATION RESIS-
Displays insulation resistance of high voltage circuit.
TANCE VALUE[kohm]
12V BATTERY VOLT-
Displays voltage of 12V battery.
AGE[mV]
ESTMT PWR CNSM
Displays the amount of electric power used by electric compressor.
(A/C CMP)[W]
ESTMT PWR CNSM
Displays the amount of electric power used by PTC heater.
(PTC HTR)[kW]
OBC OUT PWR[kW] Displays electric power output of PDM (Power Delivery Module).
*: During 12V battery automatic charge and remote air conditioner operation.
EVC-70
DATA MONITOR MODE
NOTE: A
Monitored Item B
For reference values of the following items, refer to EVC-81, "Reference Value".
X: Applicable
Monitor Item Selection EVC
MONITOR ITEM Unit ECU INPUT MAIN SIG- Description
SIGNALS NALS
Displays VCM status. D
• 0-7: During VCM starts-up
• 10: Power switch is ON and the charge connector is
not connected.
• 11-29: Mode changing to READY E
• 30: READY
VCM MODE — X • 50-59: Mode changing to charge mode.
• 60: During normal charging
F
• 90: During quick charging
• 80-89: Mode changing to charge mode.
• 110-120: When connected to high voltage circuit ex- G
cept when READY or charge*
Displays that VCM has the EV system READY. H
NON/
VCM ACTIVATION • NON: Other than READY
READY
• READY: READY control in progress
Displays the traction motor revolution received from
MOTOR SPEED rpm X X I
the traction motor inverter.
Displays the high-voltage power supply voltage being
INVERTER DC INPUT VOLT V
input to the traction motor inverter.
J
The vehicle speed computed by the motor speed sig-
VEHICLE SPEED km/h or mph X X
nal sent from the traction motor inverter is displayed.
Displays the high accuracy vehicle speed from “VEHI-
HI SPEC VEHICLE SPEED km/h or mph K
CLE SPEED”
Displays the outside air temperature received from the
AMBIENT TEMP degC X
A/C auto amp.
Displays the car crush information received from the L
• MID air bag diagnosis sensor unit.
CLASH DETECT INFO • HEAVY X • MID: A non-serious impact was detected.
• ## • HEAVY: A serious impact was detected.
M
• ##: When the impact is not detected
12V BATTERY VOLTAGE mV X X The 12 V power supply voltage of VCM is displayed.
Displays the 12 V power supply voltage of VCM when N
VCM POWER SUPPLY (ACT) mV
VCM is started.
Displays the voltage on the F/S relay contact side that
F/S RELAY VOLT mV X
is being input to VCM.
O
The 12V battery temperature (determined by the sig-
12V BATTERY TEMP degC X nal voltage of the battery temperature sensor) is dis-
played.
P
12V BATTERY CURRENT AVG A X Displays the average current of 12V battery.
Accelerator pedal position sensor 1 signal voltage is
ACCEL SENSOR 1 VOLT mV X X
displayed.
Accelerator pedal position sensor 2 signal voltage is
ACCEL SENSOR 2 VOLT mV X X
displayed.
Displays the cumulative operation time of the cooling
COOLFAN INTEG OPE TIME hours
fan.
EVC-71
Monitor Item Selection
SIGNALS NALS
The accelerator pedal opening angle (determined by
ACCEL OPEN ANGLE % the signal voltage of the accelerator pedal position
sensor) is displayed.
Displays the traction motor actual output value (esti-
CURRENT MOTOR TORQ N·m X
mated value) received from the traction motor inverter.
Displays the motor torque demand value VCM is re-
TRG MOTOR TORQ 1 N·m
questing of the traction motor inverter.
Displays the traction motor output limit value received
MOTOR PWR LIMIT REQ (INV) %
from the traction motor inverter.
The operation history of the Charge Insulation Resis-
tance Loss Protection Control is indicated. For details
of the protection control, refer to EVC-403, "Descrip-
tion".
• 1-3: Operation history exists. (The number of oper-
PRTCTN CNT OPERAT HIST 1 0/1/2/3
ations is indicated.)
• 0: No operation history
NOTE:
This history can be cleared by “Self-diagnostic Result
Clear”.
Displays the in-meter gear display request status.
• P: When there is a P display request
• R: When there is an R display request
GEAR POSITION DISPLAY P/R/N/D/B X X
• N: When there is an N display request
• D: When there is a D display request
• B: When there is an B display request
The operation history of the charging connector-con-
necting protection control is indicated. For details of
the protection control, refer to EVC-403, "Description".
• ON: Operation history exists.
PRTCTN CNT OPERAT HIST 2 0/1/2/3
• OFF: No operation history
NOTE:
This history can be cleared by “Self-diagnostic Result
Clear”.
Displays the position of the selected selector lever.
• R
• R: When R range is selected
NEXT GEAR POSITION • N/P
• N/P: When N or P range is selected
• D
• D: When D, B, or ECO range is selected
Displays the position of the currently selected selector
• R lever.
GEAR POSITION • N/P • R: R range
• D • N/P: N or P range
• D: D, B, or ECO range
The coolant temperature (determined by the signal
COOLANT TEMP degC X X voltage of the coolant temperature sensor) is dis-
played.
Displays the water pump target rotation command du-
WATER PUMP 1 TRG DUTY % X
ty.
W/P 1 CRNT SPD DUTY % X Displays the water pump actual rotation duty.
COOLING FAN REQ DUTY % X Displays the cooling fan operation request duty.
Displays the status of DC/DC converter operation re-
quest sent from VCM to PDM (Power Delivery Mod-
ule).
DC/DC CONV STAT On/Stop X
• On: When there is a DC/DC converter operation re-
quest
• Stop: No operation request
EVC-72
MONITOR ITEM Unit Description A
ECU INPUT MAIN SIG-
SIGNALS NALS
Displays the status of the DC/DC status signal being
used for communication between VCM and the PDM B
(Power Delivery Module).
• 0: DC/DC converter does not operate.
DC/DC CONV STATUS 0/1/2/3 X
• 1: When normal operation
• 2: VCM is limiting a DC/DC converter output power.
EVC
• 3: VCM is prohibiting DC/DC converter operation
(error detection).
Displays the power voltage variable control authoriza- D
tion status of VCM.
VARIABLE V/CONT PERMIT On/Off
• On: Authorized
• Off: Prohibited
E
Displays the power generation request voltage being
DC/DC CONV REQ VOLT V
requested to the DC/DC converter.
Displays the POWER switch operation status.
POWER SW On/Off X • On: When the POWER switch is operated
F
• Off: On: When the POWER switch is not operated
Displays the status of READY permit signal received
from BCM via CAN communication. G
START SIGNAL On/Off X X
• On: Start signal input.
• Off: Start signal does not input.
Displays the operation status of the immediate charg- H
ing switch.
IMMEDIATE CHG SW On/Off X
• On: When the switch is operated
• Off: When the switch is not operated
I
Displays the A/C switch operation status received
from the A/C auto amp.
A/C SW On/Off X X
• On: When the A/C switch is operating
• Off: When the A/C switch is not operating J
Displays the front wiper operation status received
from the IPDM E/R
• LOW: Front wiper is operating at low speed
FRONT WIPER
LOW/HIGH/
• HIGH: Front wiper is operating at high speed
K
Off/INVALID
• Off: Front wiper is not operating
• INVALID: IPDM E/R cannot detect front wiper sta-
tus. L
Displays the operation status of the headlamp re-
ceived from the IPDM E/R.
HEAD LAMP LOW SIG On/Off
• On: When the low beam is operating
• Off: When the low beam is not operating M
Displays the operation status of the headlamp re-
ceived from the IPDM E/R.
HEAD LAMP HI SIG On/Off
• On: When the high beam is operating N
• Off: When the high beam is not operating
Displays the operation status of the blower fan re-
ceived from the A/C auto amp. O
BLOWER FAN ACTIV On/Off
• On: When the blower fan is operating
• Off: When the blower fan is not operating
Displays the rear window defogger operation status
received from the IPDM E/R. P
REAR DEFOGGER On/Off • On: When the rear window defogger is operating
• Off: When the rear window defogger is not operat-
ing
Displays the connection status of connection detect-
ing circuit built in PDF (Power Delivery Module).
HV INTERLOCK (DC/DC) On/Off X
• On: Interlock detection circuit is energized.
• Off: Except above.
EVC-73
SIGNALS NALS
Displays the connection status of the high voltage con-
nector connected to the Li-ion battery pack.
HV CNCTR INTRLCK (HV BAT) On/Off X • On: The high voltage connector is connected cor-
rectly.
• Off: Except above.
Displays the READY to drive indicator lamp operation
request status.
• On: This causes the READY to drive indicator lamp
On/BLINK/
READY LAMP SIGNAL X to light up.
Off
• BLINK: This causes the READY to drive indicator
lamp to flash.
• Off: No operation request
Displays the power limit indicator lamp operation re-
quest status.
PWR LIMIT INDICAT LAMP On/Off X
• On: The power limit indicator lamp is lit.
This displays the EV system warning lamp operation
request status.
• On: This causes the EV system warning lamp to
On/BLINK/
EV SYSTEM W/L SIGNAL X light up
Off
• BLINK: This causes the EV system warning lamp to
flash.
Displays the plug in indicator lamp operation request
status.
PLUG IN INDI LAMP On/Off X
• On: The plug in indicator lamp is lit.
Displays the charging status indicator 1 operation re-
quest status.
CHARGE STAT INDI 1 On/Off X
• On: The charging status indicator 1 is lit.
quest status.
quest status.
Displays the 12V battery charge warning lamp opera-
tion request status.
• On: The causes the 12V battery charge warning
On/BLINK/
CHARGE LAMP SIGNAL X lamp to light up.
Off
• BLINK: The causes the 12V battery charge warning
lamp to flash.
AVAILABLE MOT OUTPUT Displays the maximum value that can currently be out-
%
MAX put by the traction motor.
Displays the maximum value that is currently regener-
MOTOR REGE PWR MAX %
able by the traction motor.
Displays the number of segments indicated by the in-
ECO INDICATOR —
stant ECO indicator.
Displays the number of segments indicated by the
ECO TREE —
ECO tree.
EVC-74
ECU INPUT MAIN SIG-
SIGNALS NALS
Displays the traction motor estimated power con-
POWER CONSUM (MOTOR) kW sumption calculated by VCM from the traction motor B
torque and vehicle speed.
POWER CONSUM (AUXS) kW Displays the power consumption of the auxiliaries.
Displays the power consumption of the air conditioner
EVC
POWER CONSUMPTION (A/C) kW
system.
Displays the A/C compressor estimated power con-
ESTMT PWR CNSM (A/C CMP) W X
sumption. D
ESTMT PWR CNSM (PTC Displays the PTC heater estimated power consump-
kW X
HTR) tion.
When the motor power is limited, this shows the rea- E
son the power is being limited.
• B/T-LOW • B/T-LOW: Li-ion battery temperature is too low.
• B/T-HI • B/T-HI: Li-ion battery temperature is too high.
• B LEV • B LEV: The Li-ion battery remaining energy is low.
F
POWER LIMIT CAUSE • B CAP • B CAP: The Li-ion battery capacity is low.
• MOT-V • MOT-V: The input voltage to the traction motor or
• MOT-T traction motor inverter is low. G
• ## • MOT-T: Traction motor temperature or traction mo-
tor inverter temperature is too high.
• ##: No torque limitation.
Displays the charging status. H
• 100V: Charging using AC 100-120 V
100V/200V/
• 200V: Charging using AC 200-240 V
CHARGE MODE QUICK/NG/
• QUICK: During quick charge
OFF I
• NG: When in a state where charging is not possible
• OFF: Except above
Displays the normal charge connector engagement
state. J
• On: The normal charge connector is connected cor-
On/HALF/ rectly.
N/CHG PORT CONNECTION X X
OFF • HALF: The normal charge connector is semi-en-
gaged.
K
• OFF: The normal charge connector is not connect-
ed.
Displays the quick charger connector engagement L
status.
Q/CHG INTERLOCK On/OFF X X • On: The quick charger connector is connected cor-
rectly.
• OFF: The quick charger connector is not connected. M
Displays the type of AC power supply that is connect-
ed to the normal charge port.
100V/200V/
AC POWER TYPE • 100V: A 100-120 V power supply is connected. N
NONE
• 200V: A 200-240 V power supply is connected.
• NONE: An AC power supply is not connected.
Displays the power that can be output by the PDM O
ENABLE OBC OUT PWR kW
Displays that the Li-ion battery remaining energy is
low.
HV BATT EMPTY OK/EMPTY P
• OK: Normal
• EMPTY: When low
Displays the power being output by the PDM (Power
OBC OUT PWR kW X X
Delivery Module).
TRG HV BATT CHG LEVEL 100%/80% Displays the selected Li-ion battery charging level.
EVC-75
SIGNALS NALS
The Li-ion battery remained energy rate is displayed.
NOTE:
Battery power indication method of VCM differs from
HV BATT LEVEL (%) % X X
that of quick charger. A value displayed for this item
may not agree with a value displayed by quick charg-
er.
HV BATT LEVEL Wh X X The Li-ion battery remained energy is displayed.
Displays the Li-ion battery voltage received from the
HV BATT VOLT V X
Li-ion battery controller.
Displays the Li-ion battery current received from the
HV BATT CURRENT A X
Li-ion battery controller.
Displays the Li-ion battery temperature received from
HV BATTERY TEMP °C or °F X
the Li-ion battery controller.
Displays the peak to peak of the signal sent from the
IR SENSOR SIGNAL P-P mV
on-board isolation resistance monitoring system.
Displays the current of charge connector lock relay on
CHG CNECTR LOCK RLY V mV
the contact side.
Displays the DUTY rate of PWM signal transmitted
C/CNECTR LCK ACTR DUTY %
from VCM to charge connector lock actuator.
Displays the F/S relay operation status.
F/S RELAY On/Off X • On: F/S relay is ON
• Off: F/S relay is OFF
Displays the F/S CHG relay operation status.
F/S CHG RELAY On/Off X • On: F/S CHG relay is ON
• Off: F/S CHG relay is OFF
Displays the M/C relay operation status.
M/C RELAY On/Off X • On: M/C relay is ON
• Off: M/C relay is OFF
Displays the A/C relay operation status.
A/C RELAY On/Off X • On: A/C relay is ON
• Off: A/C relay is OFF
Displays the reverse lamp relay operation status.
REVERSE LAMP RELAY On/Off X • On: Reverse lamp relay is ON
• Off: Reverse lamp relay is OFF
Displays the status that VCM is operating the reverse
lamp relay.
REVERSE LAMP RLY STATUS OK/NG
• OK: Normal
• NG: Error
Displays the system main relay 1 operation status.
HV P MAIN RLY ACTIV On/Off X • On: System main relay 1 is ON
• Off: System main relay 1 is OFF
Displays the status that VCM is operating the system
main relay 1.
HV P MAIN RLY ACTIV MONI On/Off X
• On: Operation voltage is being output by VCM.
• Off: Operation voltage is not being output by VCM.
Displays the system main relay 2 operation status.
HV N MAIN RLY ACTIV On/Off X • On: System main relay 2 is ON
• Off: System main relay 2 is OFF
Displays the status that VCM is operating the system
main relay 2.
HV N MAIN RLY ACTIV MONI On/Off X
EVC-76
ECU INPUT MAIN SIG-
SIGNALS NALS
Displays the pre-charge relay operation status.
HV PRE CHG RLY ACTIV On/Off X • On: pre-charge relay is ON B
• Off: pre-charge relay is OFF
Displays the status that VCM is operating the pre-
HV PRE CHG RLY ACTIV MONI On/Off X
charge relay. EVC
Displays the quick charge relay operation status. D
Q/CHG RELAY On/Off • On: Quick charge relay is ON
• Off: Quick charge relay is OFF
ASCD SET VEHICLE SPEED km/h or mph X The preset ASCD vehicle speed is displayed
E
Displays the ASCD MAIN switch operation status.
ASCD MAIN SW On/Off X • On: When the ASCD MAIN switch is operated
• Off: When the ASCD MAIN switch is not operated
Displays the CANCEL switch operation status.
F
ASCD CANCEL SW On/Off X • On: When the CANCEL switch is operated
• Off: When the CANCEL switch is not operated
Displays the RESUME/ACCELERATE switch opera- G
tion status.
• On: When the RESUME/ACCELERATE switch is
RESUME/ACC SW On/Off X
operated
• Off: When the RESUME/ACCELERATE switch is H
not operated
Displays the SET/COAST switch operation status.
ASCD SET SW On/Off X • On: When the SET/COAST switch is operated I
• Off: When the SET/COAST switch is not operated
Displays the brake pedal position switch operation
status. J
ASCD BRAKE SW On/Off X
• On: The brake pedal is not depressed.
• Off: The brake pedal is depressed.
Displays the operation status of the stop lamp switch.
STOP LAMP SW On/Off X • On: The brake pedal is depressed.
K
• Off: The brake pedal is not depressed.
Indicates the vehicle cruise condition.
• NON: Vehicle speed is maintained at the ASCD set L
ASCD CANCEL (LOW SPEED) NON/CUT speed.
• CUT: Vehicle speed decreased to excessively low,
and ASCD operation is cut off.
M
Indicates the vehicle cruise condition.
• NON: Vehicle speed is maintained at the ASCD set
speed.
ASCD CANCEL (SPEED DIFF) NON/CUT
• CUT: Vehicle speed decreased to excessively low N
compared with the ASCD set speed, and ASCD op-
eration is cut off.
Indicates [ON/OFF] condition of CRUISE lamp deter- O
ASCD CRUISE LAMP On/Off
mined by the VCM according to the input signals.
Displays the SET indicator operation request status.
ASCD SET LAMP On/Off • On: The SET indicator is lit.
• Off: No operation request P
SL TARGET VEHICLE SPEED km/h or mph The preset speed limiter vehicle speed is displayed
Displays the cumulative READY count from the time
READY COUNT count
the vehicle is new.
Displays the cumulative READY time from the time
INTEG READY TIME sec
the vehicle is new.
EVC-77
SIGNALS NALS
Displays the cumulative quick charge count from the
QUICK CHG COUNT count
time the vehicle is new.
Displays the cumulative quick charge time from the
INTEG Q/CHG TIME sec
Displays the cumulative normal charge count from the
NORMAL CHG COUNT count
Displays the cumulative normal charge time from the
INTEG N/CHG TIME sec
EV SYS ACT REQ (VCM TIM-
The item is indicated, but not used.
ER)
Displays the status of vehicle speed indicator blink re-
quest of ASCD.
ASCD VHCL SPD BLINK REQ BLINK/FIX
• BLINK: Blink request
• FIX: No blink request
Displays a leaning value of slip rate calculated from
DIFF WHEEL SPD LRN VAL — the rotation difference between front wheel and rear
wheel.
The refrigerant pressure (determined by the signal
REFRIGERANT PRES SEN MPa X voltage of the refrigerant pressure sensor) is dis-
played.
Displays a regeneration side motor torque limit value
REGE TORQ LIMIT VAL (INV) %
received from traction motor inverter.
Displays minor collision detection information re-
LIGHT CRASH JUDGMENT —
ceived from the air bag diagnosis sensor unit.
Displays the control status of the charge port lid open-
er controlled by VCM.
CHARGE PORT LID OPENER On/Off
• On: Controlled, open
• Off: Inactive
Displays the control status of ECO mode controlled by
VCM.
ECO MODE On/Off
• On: ECO mode
• Off: Except above
Displays Kick Down decision state.
KICK DOWN On/Off • On: Accelerator pedal is depressed
• Off: Accelerator pedal is fully released
Displays the SET indicator operation request status.
SL SET LAMP On/Off • On: The SET indicator is lit
Displays the speed limiter indicator operation request
status.
SL LIMIT LAMP On/Off
• On: The speed limiter indicator is lit
Displays the speed limiter MAIN switch operation sta-
tus.
• On: When the speed limiter MAIN switch is operat-
SL MAIN SW On/Off
ed
• Off: When the speed limiter MAIN switch is not op-
erated
*: During 12V battery automatic charge, and remote climate control operation.
ACTIVE TEST MODE
Test Item
EVC-78
TEST ITEM CONDITION JUDGMENT CHECK ITEM (REMEDY) A

• POWER ON • VCM
PLUG IN INDICA- This confirms the indicator is ON/
• This turns ON and OFF the indi- • Combination meter
TOR OFF.
cator used by the ACTIVE TEST. • CAN communication
B
• POWER ON • Harness and connectors
CHARGE STAT This confirms the indicator is ON/
• This turns ON and OFF the indi- • Bulb and LED
INDICATOR 1 OFF.
cator used by the ACTIVE TEST. • VCM
EVC
INDICATOR 2 OFF.
• POWER ON • Harness and connectors D
INDICATOR 3 OFF.
• POWER ON E
• Harness and connectors
• This turns ON and OFF the F/S Check that the F/S CHG relay
F/S CHG RLY • F/S CHG relay
CHG relay used by the ACTIVE makes the operating sound.
• VCM
TEST.
F
• POWER ON • Check that the reverse lamp relay • Harness and connectors
REVERSE LAMP • This turns ON and OFF the re- makes the operating sound. • Bulb and LED
RLY verse lamp relay used by the AC- • Check that the reverse lamp is • Reverse lamp relay
TIVE TEST. turned ON. • VCM G
• READY ON • DC/DC converter
DC/DC CONV Check that the 12V battery power
• This changes the duty ratio used • VCM
DUTY supply voltage changes.
by the ACTIVE TEST. • CAN communication H
• POWER ON • DC/DC converter
VOLTAGE CON- Check that the 12V battery power
• This changes the voltage used by • VCM
TROL supply voltage changes.
the ACTIVE TEST. • CAN communication
I
• POWER ON • VCM
READY INDICA- This confirms the indicator is ON/
TOR OFF.
J
POWER LIMITA- • POWER ON • VCM
This confirms the indicator is ON/
TION INDICA- • This turns ON and OFF the indi- • Combination meter
OFF.
TOR cator used by the ACTIVE TEST. • CAN communication
• POWER ON • VCM K
EV SYSTEM W/L • This turns ON and OFF the indi- • Combination meter
OFF.
12V BATTERY
• POWER ON
• VCM L
CHARGE W/L OFF.
• VCM
• POWER ON M
Confirm that the ECO indicator dis- • Combination meter
ECO INDICATOR • This changes the display value
play in the upper meter changes. • Upper meter
used by the ACTIVE TEST.
• CAN communication
• VCM N
• POWER ON
Confirm that the ECO tree display in • Combination meter
ECO TREE • This changes the display value
the upper meter changes. • Upper meter
used by the ACTIVE TEST.
O
Check that the water pump opera-
WATER PUMP 1 • This turns changes the duty ratio • Water pump
tion speed changes.
used by the ACTIVE TEST. • VCM
P
Check that the cooling fan operation
COOLING FAN • This turns changes the duty ratio • Cooling fan system
speed changes.
used by the ACTIVE TEST. • VCM
WORK SUPPORT MODE

Work Item
EVC-79
WORK ITEM CONDITION USAGE

SAVE DATA FOR CPU REPLACE In this mode, the data saved in VCM is stored in CONSULT. When VCM is replaced.
WRITE DATA AFTER REPLACE In this mode, write data stored by “SAVE DATA FOR CPU
When VCM is replaced.
CPU REPLACE” in work support mode to VCM.
BATTERY GRADUAL CAP LOSS Always perform after Li-ion Battery
Li-ion Battery deterioration data stored in VCM is cleared.
DATA CLEAR controller is replaced as new one.
Always perform after Li-ion Battery
HV BATT J/B DATA CLEAR System Main Relay cutoff count stored in VCM is cleared. Junction Box is replaced as new
one.
VIN REGISTRATION VIN is registered in VCM. When registering VIN in VCM.
Self-diagnosis results of DTC P0AA1 and Freeze Frame
SPECIFIC DTC CLEAR* Data are cleared.
When DTC P0AA1 is detected.
COOLING FAN INTEGRATED Always perform after cooling fan is

Cooling fan operation time stored in VCM is cleared
OPERATION TIME CLEAR replaced as new one.
*: When this is performed, all self-diagnosis results in VCM and Freeze Frame Data are cleared.
EVC-80
VCM
ECU DIAGNOSIS INFORMATION A
VCM
B
VALUES ON THE DIAGNOSIS TOOL

NOTE: EVC
• Specification data are reference values.
• The displayed data may differ from an actual signal/value/operation, as some of them are calculated by
VCM, based on signals transmitted from VCM-related sensors to VCM.
• Li-ion battery charge does not start when the s switch is ON. When it is required to charge with the power D
switch ON, start charging before turning ON the power switch.
• The following table includes information (items) inapplicable to this vehicle. For information (items) applica-
ble to this vehicle, refer to CONSULT display items. E
For outlines of following items, refer to EVC-69, "CONSULT Function".
MONITOR ITEM CONDITION Values/Status

F
Charge connector is not con-
Power ON 10
nected
VCM MODE READY 30

G
During normal charge 60
During quick charge 90
READY READY H
VCM ACTIVATION
Except READY NON
When vehicle speed is 0 km/h 0 rpm
I
MOTOR SPEED 5000 rpm
When vehicle speed is 60 km/h
(Approx.)
INVERTER DC INPUT VOLT Power ON 200 – 403 V
J
The vehicle speed computed by the motor speed signal sent from the Almost the same speed as
VEHICLE SPEED
traction motor inverter is displayed. the speedometer indication.
Turn drive wheels and compare CONSULT value with the speedom- Almost the same speed as K
HI SPEC VEHICLE SPEED
eter indication. the speedometer indication.
Indicates depending on am-
AMBIENT TEMP Power: ON
bient temperature.
L
When a non-serious collision is detected MID
CLASH DETECT INFO When a serious collision is detected HEAVY
No collision is detected ## M
Power ON (not READY) 11000 – 15000 mV
12V BATTERY VOLTAGE
READY 13000 – 15000 mV
N
VCM POWER SUPPLY (ACT) Power ON 11000 – 15000 mV
Power ON 11000 – 15000 mV
F/S RELAY VOLT
READY 12000 – 15000 mV O
Indicates depending on mo-
12V BATTERY TEMP Power ON
tor room air temperature.
• READY (at idle*) P

• Li-ion battery remained energy: Full
12V BATTERY CURRENT AVG • Selector lever: P or N 0 – 50 A
• A/C switch: OFF
• Electrical load: No load
EVC-81
VCM
Accelerator pedal: Fully de-
4000 – 4800 mV
pressed
ACCEL SENSOR 1 VOLT Power ON
Accelerator pedal: Fully re-
600 – 900 mV
leased
3900 – 4800 mV
pressed
ACCEL SENSOR 2 VOLT Power ON
600 – 900 mV
leased
This shows the cooling fan
COOL FAN INTEG OPE TIME Power ON
cumulative operation time
90 – 100%
pressed
ACCEL OPEN ANGLE Power ON
0 – 5%
leased
0 – 254 N·m
CURRENT MOTOR TORQ READY (Depending on accelerator
pedal opening angle)
0 – 254 N·m
TRG MOTOR TORQ 1 READY (Depending on accelerator
pedal opening angle)
Normal 100%
MOTOR PWR LIMIT REQ (INV)
When output is limited 0 – 98%
The operation history of the Charge Insulation Resistance Loss Pro-
1–3
PRTCTN CNT OPERAT HIST 1 tection Control exists.
Except above 0
Selector lever: P Range P
Selector lever: R range R
GEAR POSITION DISPLAY READY Selector lever: N Range N
Selector lever: D range D
Selector lever: B range B
The operation history of the Charging Connector-connecting Protec-
On
PRTCTN CNT OPERAT HIST 2 tion Control exists.
Except above Off
Selector lever: R R
NEXT GEAR POSITION Power ON Selector lever: N or P N/P
Selector lever: D, B, or ECO D
Selector lever: R R
GEAR POSITION Power ON Selector lever: N or P N/P
Selector lever: D, B, or ECO D
Above the outside tempera-
ture and below 80°C (176°F)
COOLANT TEMP After 2 minutes have expired since READY (Value in accordance with
the cooling water tempera-
ture)
Power ON Pump is stopped 10%
WATER PUMP 1 TRG DUTY Pump speed 750 rpm – 4,700
READY 20 – 80%
rpm
Power ON Pump is stopped 10%
W/P 1 CRNT SPD DUTY Pump speed 750 rpm – 4,700
READY 17 – 82%
rpm
EVC-82
VCM
A
COOLING FAN REQ DUTY Power ON 15 – 85%
READY On
DC/DC CONV STAT
Power ON STOP B
DC/DC converter does not oper-
0
ate
When normal operation 1 EVC
DC/DC CONV STATUS Power ON When VCM limits a DC/DC con-
2
verter output power
When VCM prohibits the DC/DC D
converter operation (error detec- 3
tion)
• READY E
• The 12V battery is sufficiently charged On
VARIABLE V/CONT PERMIT • Wiper not operating
Except above. Off
F
Power ON 14 V
DC/DC CONV REQ VOLT
READY 13 – 15 V
POWER SW Power switch operation: ON OFF ON On Off On G
START SIGNAL Power switch operation: ON START ON Off On On
Immediate charging switch:
On H
Pressed
IMMEDIATE CHG SW Power ON
Immediate charging switch: Re-
Off
leased
A/C switch: ON On I
A/C SW Power ON
A/C switch: OFF Off
Front wiper operation status Low LOW
J
Front wiper operation status
HIGH
FRONT WIPER Power ON High
Front wiper operation status Not K
Off
operation
When the combination switch's low beam was selected On
HEAD LAMP LOW SIG
Except above Off L
When the combination switch's high beam was selected On
HEAD LAMP HI SIG
Except above Off
M
Blower fan: Operates On
BLOWER FAN ACTIV
Blower fan: Not operates Off
Rear defogger: Operates On N
REAR DEFOGGER
Rear defogger: Not operates Off
When the PDM (Power Delivery Module) cover and bus bar cover are
On
HV INTERLOCK (DC/DC) installed normally. O
Except above Off
When the Li-ion battery's high
voltage connector is connected On P
HV CNCTR INTRLCK (HV BAT) Power ON correctly
Except above Off
READY On
READY LAMP SIGNAL When READY is started BLINK
Except above Off
EVC-83
VCM
Power limitation indicator lamp: ON On
PWR LIMIT INDICAT LAMP
Power limitation indicator lamp: OFF Off
When VCM has detected an er-
On
EV SYSTEM W/L SIGNAL Power ON ror.
Except above Off
Plug in indicator lamp: ON On
PLUG IN INDI LAMP
Plug in indicator lamp: OFF Off
Charging status lamp 1: ON On
CHARGE STAT INDI 1
Charging status lamp 1: OFF Off
CHARGE STAT INDI 2
CHARGE STAT INDI 3
Power ON On
CHARGE LAMP SIGNAL
READY Off
AVAILABLE MOT OUTPUT
READY 0 – 100%
MAX
MOTOR REGE PWR MAX READY 0 – 100%
ECO INDICATOR Displays the same value as in the instant ECO indicator.
ECO TREE Displays the same value as in the ECO tree.
POWER CONSUM (MOTOR) READY (-100) – (+100)%
Power ON 0 – 0.6 kW
POWER CONSUM (AUXS) READY 0.2 – 0.8 kW
Charging 0.1 – 0.7 kW
• READY
POWER CONSUMPTION (A/C) 0 – 5 kW
• When the air conditioner is used
• READY
ESTMT PWR CNSM (A/C CMP) 0 – 5000 W
• A/C switch: ON
• When the air conditioner is operating
ESTMT PWR CNSM (PTC HTR) 0 – 10 kW
• Set temperature: HOT side maximum
Li-ion battery temperature is too
B/T-LOW
low.
Li-ion battery temperature is too
B/T-HI
high.
When the Li-ion battery remain-
B LEV
ing energy is low
Output being limited When the Li-ion battery capacity

B CAP
POWER LIMIT CAUSE is low
When the voltage input to the
traction motor or traction motor MOT-V
inverter is low
Traction motor temperature or
traction motor inverter tempera- MOT-T
ture is too high.
No torque limitation ##
EVC-84
VCM
A
Charging using AC 100-120 V 100V
Charging using AC 200-240 V 200V
CHARGE MODE During quick charge QUICK B
When in a state where charging is not possible NG
Except above Off
Normal charge connector is connected. On EVC
N/CHG PORT CONNECTION Normal charge connector is half-engaged HALF
Except above OFF
D
Quick charger connector is connected. On
Q/CHG INTERLOCK
Except above OFF
When an AC power supply is not connected NONE E
AC POWER TYPE When an AC 100-120 V power supply is connected 100V
When an AC 200-240 V power supply is connected 200V
F
When EVSE for 3.3 kW is used 3.3 kW
ENABLE OBC OUT PWR Charging
When EVSE for 6.0 kW is used 6.0 kW
The Li-ion battery remaining en-
OK
G
ergy is sufficient.
HV BATT EMPTY Power ON
The Li-ion battery remaining en-
EMPTY
ergy is low. H
When EVSE for 3.3 kW is used 0 – 3.3 kW
In Normal Charging
OBC OUT PWR When EVSE for 6.0 kW is used 0 – 6.0 kW
In Quick Charging 0 – 50 kW I
Selected 100% charge 100%
TRG HV BATT CHG LEVEL Charging
Selected 80% charge 80%
J
0 – 100%
HV BATT LEVEL (%) Power ON (Depending on Li-ion battery
remained energy)
K
HV BATT LEVEL Power ON 0 – 24000 Wh
HV BATT VOLT Power ON 200 – 403 V
HV BATT CURRENT • READY (at idle*) 0 – 10 A

L
• Electrical load: No load
Between the outside air tem-
HV BATTERY TEMP Power ON
perature and 50°C (122°F) M
IR SENSOR SIGNAL P-P Power ON 3150 mV or more
CHG CNECTR LOCK RLY V The item is indicated, but not used.
C/CNECTR LCK ACTR DUTY The item is indicated, but not used. N
F/S RELAY Power ON On
During quick charge On
F/S CHG RELAY O
Except above Off
M/C RELAY Power ON On
Power ON On P
A/C RELAY
Power OFF Off
Selector lever: R range On
REVERSE LAMP RELAY Power ON
Selector lever: Except R range Off
Reverse lamp relay: Normal OK
REVERSE LAMP RLY STATUS Power ON
Reverse lamp relay: Error NG
EVC-85
VCM
READY On
HV P MAIN RLY ACTIV
Power ON Off
READY On
HV P MAIN RLY ACTIV MONI
Power ON Off
READY On
HV N MAIN RLY ACTIV
Power ON Off
READY On
HV N MAIN RLY ACTIV MONI
Power ON Off
HV PRE CHG RLY ACTIV Immediately after the power OFF READY operation Off On Off
HV PRE CHG RLY ACTIV MONI Immediately after the power OFF READY operation Off On Off
Quick charging On
Q/CHG RELAY
Except above Off
The ASCD preset vehicle
ASCD SET VEHICLE SPEED ASCD: Operating
speed is displayed
ASCD MAIN switch: Pressed On
ASCD MAIN SW Power ON
ASCD MAIN switch: Released Off
CANCEL switch: Pressed On
ASCD CANCEL SW Power ON
CANCEL switch: Released Off
RESUME/ACCELERATE
On
switch: Pressed
RESUME/ACC SW Power ON
RESUME/ACCELERATE
Off
switch: Released
SET/COAST switch: Pressed On
ASCD SET SW Power ON
SET/COAST switch: Released Off
Brake pedal: Fully released On
ASCD BRAKE SW Power ON
Brake pedal: Depressed Off
Brake pedal: Fully released Off
STOP LAMP SW Power ON
Brake pedal: Depressed On
ASCD CANCEL (LOW SPEED) Power ON NON
ASCD CANCEL (SPEED DIFF) Power ON NON
ASCD MAIN switch: Pressed at
ASCD CRUISE LAMP Power ON On Off
the 1st time → at the 2nd time
ASCD SET LAMP After the ASCD MAIN switch has been pressed once, press it again. On Off
The speed limiter preset ve-
SL TARGET VEHICLE SPEED Speed limiter: Operating
hicle speed is displayed
This shows the READY cu-
READY COUNT Power ON
mulative count
This shows the READY cu-
INTEG READY TIME Power ON
mulative operation time
This shows the quick charge
QUICK CHG COUNT Power ON
cumulative count
This shows the quick charge
INTEG Q/CHG TIME Power ON
cumulative operation time
This shows the normal
NORMAL CHG COUNT Power ON
charge cumulative count
This shows the normal
INTEG N/CHG TIME Power ON charge cumulative operation
time
EVC-86
VCM
A
EV SYS ACT REQ (VCM TIM-
The item is indicated, but not used.
ER)
When vehicle speed exceeds
• Driving BLINK B
ASCD VHCL SPD BLINK REQ the set speed of ASCD
• ASCD: ON
Except above FIX
DIFF WHEEL SPD LRN VAL Power ON ± 0.02
EVC
• READY
REFRIGERANT PRES SEN • Both the A/C switch and blower fan switch are ON (A/C compres- 0.6 – 2.6 MPa
sor is operating)
D
Normal 100%
REGE TORQ LIMIT VAL (INV)
When output is limited 0 – 98%
When a light crash judgment signal is received from air bag diagnosis E
15
LIGHT CRASH JUDGMENT sensor unit.
Except above 0
CHARGE PORT LID OPENER Charge port lid opener switch: OFF ON Off On Off F
ECO mode indicator: ON On
ECO MODE
ECO mode indicator: OFF Off
G
KICK DOWN Power ON Accelerator pedal: Depressed On
SET indicator: ON On
SL SET LAMP
SET indicator: OFF Off H
LIMIT indicator: ON On
SL LIMIT LAMP
LIMIT indicator: OFF Off
Speed limiter MAIN switch: I
On
Pressed
SL MAIN SW Power ON
Speed limiter MAIN switch: Re-
Off
leased J
*: Idle is the state when not driving in the READY state.
TERMINAL LAYOUT K
PBIA9221J
N
PHYSICAL VALUES
NOTE:
Specification data are reference values. O
Terminal No.
Description
(Wire color) Value
Condition P
Input/ (Approx.)
+ – Signal name
Output
1 12V BATTERY VOLTAGE
Ground 12V Battery power supply Input Always
(G) (11 – 14 V)
4
— VCM ground — — —
(B)
EVC-87
VCM
Terminal No.
Description
(Wire color) Value
Condition
Input/ (Approx.)
+ – Signal name
Output
0V
Power switch: ON
5 (Approx.)
Ground A/C relay Output
(SB) A few seconds after turning power switch
11 – 14 V
OFF
Ground 12V Battery power supply Input Always
(R) (11 – 14 V)
8
— VCM ground — — —
(B)
9 Input/
— CAN-H — —
(L) Output
13 Input/
— CAN-L — —
(P) Output
• Power switch: ON
0V
15 Brake pedal position • Brake pedal: Depress
Ground Input
(BE) switch • Power switch: ON 12V BATTERY VOLTAGE
• Brake pedal: Fully released (11 – 14 V)
• Power switch: ON 12V BATTERY VOLTAGE
18 • Brake pedal: Depress (11 – 14 V)
Ground Stop lamp switch Input
(P) • Power switch: ON
0V
• Brake pedal: Fully released
Ground Power ON power supply Input Power switch: ON
(R) (11 – 14 V)
When the PDM (Power Delivery Module) 12V BATTERY VOLTAGE
23 Connection detecting cir- connection detecting circuit is met (11 – 14 V)
Ground Input
(P) cuit signal When the PDM (Power Delivery Module)
0V
connection detecting circuit is not met
25 Input/
— EV system CAN-H — —
(L) Output
• Power switch ON
• Pump operation duty: 0%
JSCIA0325ZZ
28 4
Water pump signal Input
(W) (B)
• Power switch ON
• Pump operation duty: Approx. 70%
JSCIA0326ZZ
29 Input/
— EV system CAN-L — —
(G) Output
0V
Eco mode switch: Pressed
31 (Approx.)
Ground ECO mode switch Input
(R) 12V BATTERY VOLTAGE
Eco mode switch: Released
(11 – 14 V)
EVC-88
VCM
Terminal No.
Description
(Wire color) Value A
Condition
Input/ (Approx.)
+ – Signal name
Output
Sensor power supply B
33 4
(Refrigerant pressure Output Power switch: ON 5V
(L) (B)
sensor)
34 35 Refrigerant pressure sen-
Input A/C compressor operating 1.0 V – 4.0 V
EVC
(BR) (B) sor
Sensor ground
35
— (Refrigerant pressure — — — D
(B)
sensor)
Sensor power supply
37 39
(Accelerator pedal posi- Output Power switch: ON 5V
(W) (B) E
tion sensor 1)
0.45 V – 1.0 V
38 39 Accelerator pedal posi- • Accelerator pedal: Fully released
Input F
(R) (B) tion sensor 1 • Power switch: ON
4.4 V – 4.8 V
• Accelerator pedal: Fully depressed
Sensor ground
39 G
— (Accelerator pedal posi- — — —
(B)
tion sensor 1)
40
— Shield — — —
(–) H
41 43 Sensor power supply 5V
Output Power switch: ON
(R) (L) (Battery current sensor) (Approx.)
42 43 • READY I
Battery current sensor Input 2.6 V – 3.5 V
(Y) (L) • 12V battery is fully charged
43 Sensor ground
— — — —
(L) (Battery current sensor) J
Sensor power supply
45 47 5V
(Accelerator pedal posi- Output Power switch: ON
(W) (B) (Approx.)
tion sensor 2)
K
0.22 V – 0.5 V
46 47 Accelerator pedal posi- • Accelerator pedal: Fully released
Input
(R) (B) tion sensor 2 • Power switch: ON
2.1 V – 2.5 V L
• Accelerator pedal: Fully depressed
Sensor ground
47
— (Accelerator pedal posi- — — —
(B) M
tion sensor 2)
48
— Shield — — —
(–)
49 Shift selector power sup- N
Ground Output Power switch: ON 5V
(SB) ply 2
0 V – 4.8 V
50 43 Battery temperature sen-
Input READY Output voltage varies with motor O
(L) (L) sor
room air temperature.
0 V – 4.8 V
51 52 Coolant temperature sen-
Input READY Output voltage varies with motor P
(O) (W) sor
room air temperature.
Sensor ground
52
— (Coolant temperature Input — —
(W)
sensor)
53 Shift selector power sup-
Ground Output Power switch: ON 5V
(P) ply 1
EVC-89
VCM
Terminal No.
Description
(Wire color) Value
Condition
Input/ (Approx.)
+ – Signal name
Output
Fan duty: 40 %
59 4 JSCIA0329ZZ
Cooling fan control signal Output
(V) (B)
Fan duty: 100 %
JSCIA0330ZZ
Pump operation duty: 0 %
62 4 JSCIA0331ZZ
Water pump signal Input
(G) (B)
Pump operation duty: Approx. 70 %
JSCIA0332ZZ
Selector lever is held in P 12V BATTERY VOLTAGE

64 and N positions (11 – 14 V)
Ground P/N position signal Output READY
(R)
Other than the above 0V
• P position
• Stop lamp switch: ON
• Normal charge connector is not con- 0V
68 nected
Ground Shift lock Output
(SB) • Quick charger connector is not connect-
ed
12V BATTERY VOLTAGE
Other than the above
(11 – 14 V)
12V BATTERY VOLTAGE
Power switch: OFF
73 (11 – 14 V)
Ground F/S relay Output
(GR) 0V
Power switch: ON
(Approx.)
0V
During quick charge
75 (Approx.)
Ground F/S CHG relay Output
(W) 12V BATTERY VOLTAGE
Except above
(11 – 14 V)
EVC-90
VCM
Terminal No.
Description
(Wire color) Value A
Condition
Input/ (Approx.)
+ – Signal name
Output
Power switch: OFF 0V B
77
Ground F/S relay power supply Input 12V BATTERY VOLTAGE
(LG) Power switch: ON
(11 – 14 V)
12V BATTERY VOLTAGE
EVC
Power switch: OFF
78 (11 – 14 V)
Ground M/C relay Output
(G) 0V
Power switch: ON
(Approx.) D
• Power ON 0V
80 • Selector lever: R range (Approx.)
Ground Reverse lamp relay Output
(SB) • Power ON 12V BATTERY VOLTAGE E
• Selector lever: Except R range (11 – 14 V)
• Power ON 12V BATTERY VOLTAGE
82 • ASCD MAIN switch: Pressed (11 – 14 V) F
Ground ASCD MAIN switch Input
(W) • Power ON 0V
• ASCD MAIN switch: Released (Approx.)
• Power ON 12V BATTERY VOLTAGE G
83 Speed limiter MAIN • Speed limiter MAIN switch: Pressed (11 – 14 V)
Ground Input
(Y) switch • Power ON 0V
• Speed limiter MAIN switch: Released (Approx.) H
0V
Charging status indicator 2: ON
85 Charging status indicator (Approx.)
Ground Output
(P) 2 12V BATTERY VOLTAGE I
Charging status indicator 2: OFF
(11 – 14 V)
0V
86 Charging status indicator (Approx.) J
Ground Output
(V) 1 12V BATTERY VOLTAGE
(11 – 14 V)
0V K
Plug in indicator lamp: ON
87 (Approx.)
Ground Plug in indicator lamp Output
(L) 12V BATTERY VOLTAGE
Plug in indicator lamp: OFF
(11 – 14 V)
L
12V BATTERY VOLTAGE
Immediate charging switch: Pressed
89 Immediate charging (11 – 14 V)
Ground Input
(V) switch 0V
Immediate charging switch: Released M
(Approx.)
For Approx. 2 seconds after power switch
ON under the following condition: 0V
• Selector lever: P or N (Approx.) N
90
Ground READY signal Input • Brake pedal: Depressed
(W)
12V BATTERY VOLTAGE
Except above
(11 – 14 V) O
0V
92 Charging status indicator (Approx.)
Ground Output
(G) 3 12V BATTERY VOLTAGE P
(11 – 14 V)
Selector lever is held in R
93 0V
Ground Shift position signal 2 Input READY and N positions
(L)
EVC-91
VCM
Terminal No.
Description
(Wire color) Value
Condition
Input/ (Approx.)
+ – Signal name
Output
Selector lever is held in R po-
94 0V
Ground Shift position signal 1 Input READY sition
(B)
95 P position 0V
Ground P position signal Input
(L) Other than the above 5V
Selector lever is held in D
97 0V
Ground Shift position signal 5 Input READY and B positions
(W)
Selector lever is held in N
98 0V
Ground Shift position signal 4 Input READY and D and B positions
(Y)
Selector lever is held in N po-
99 0V
(R)
Selector lever is held in B po-
101 0V
(B)
Other than the follows 0V
102
Ground Shift position signal 7 Input READY Selector lever is held in B po-
(R) 5V
sition
Selector lever is held in P po-
103 0V
(G)
• Power ON 4V
• ASCD steering switch: All OFF (Approx.)
• Power ON
3V
• RESUME/ACCELERATE switch:
104 4 (Approx.)
ASCD steering switch Input Pressed
(LG) (B)
• Power ON 2V
• SET/COAST switch: Pressed (Approx.)
• Power ON 1V
• CANCEL switch: Pressed (Approx.)
Immediately after the power OFF 12V BATTERY VOLTAGE*
105 4 READY operation (11 – 14 V)
Pre-charge relay Output
(R) (B)
Except above 0V
12V BATTERY VOLTAGE
107 4 During READY or during charging
System main relay 1 Output (11 – 14 V)
(B) (B)
Except above 0V
108 ASCD steering switch
— — — —
(SB) ground
12V BATTERY VOLTAGE
110 4 During READY or during charging
System main relay 2 Output (11 – 14 V)
(W) (B)
Except above 0V
111
— VCM ground Input — —
(B)
112
— VCM ground Input — —
(B)
*: This signal can be confirmed with oscilloscope.
EVC-92
VCM
Fail-Safe INFOID:0000000011009142
A
FAIL-SAFE PATTERN
• Pattern A: Quick charge prohibited
• Pattern B: Normal charge prohibited B
• Pattern C: READY OFF
• Pattern D: High-voltage power supply stop
FAIL-SAFE LIST EVC
×:Applicable
Pattern
DTC Others D
A B C D
TYPE 1 ×
U1010
TYPE 2 × × × × E
P0601 × × ×
P0643 ×
F
P0705
TYPE 2 ×
P0706 A reaction of the shift becomes slow. G
P0A8D × × × × H
P0A8E × × × ×
I
P0AA2 × × × ×
P0AA4 × × × × Start not possible J
P0AA5 × × × ×
P0AA6 × × Doing READY again is prohibited.
K
P1574 ASCD operation prohibited L
M
P2122
P2127 • Reduced responsiveness during accelerator operation N
P2128
TYPE 1 ×
P2138 • Traction motor output is limited. O
TYPE 2
P3100 × × × ×
P
TYPE 1 ×
P3101
TYPE 4 × × ×
P3102 Traction motor output is limited.
EVC-93
VCM
Pattern
DTC Others
A B C D
P3117
P312B × × × ×
P312C × × × ×
P312D × × × ×
P312E × × × ×
P312F × × × ×
P3130 × × × ×
TYPE 1 × × × ×
P3131
P3141 ×
P315C × × × ×
P316A ×
P316C ×
P316D ×
P316F × ×
P3170 ×
P3173 × × Traction motor output is limited.
P3176 × × × ×
P3177 × × × ×
P3178 × × × ×
P317A ×
P317B × × × ×
P317D ×
P317E × ×
P3182 × × × ×
P3183 × ×
TYPE 1 ×
P3191
TYPE 1 × × Only driving in creep is possible.
P3193
TYPE 1 ×
P3196
P319C ×
P319E × × Only driving in creep is possible.
TYPE 1 ×
P31A1
P31A7 ×
P31A9 × × Only driving in creep is possible.
TYPE 1 ×
P31AE
EVC-94
VCM
Pattern
DTC Others A
A B C D
P31B0 TYPE 2 VCM inhibits the timer charge and the remote climate control. B
When the power is turned on and the vehicle is charging, the cooling
TYPE 1
P31B3 fan is operated at a constant speed. EVC
D
P31B4 TYPE 2 VCM inhibits the remote climate control.
ASCD operation prohibited E
TYPE 1 NOTE:
P31B5 The ECO indicator value also becomes extremely poor.
F
P31B6 VCM sets the DC/DC converter output power to a constant 14 V.
P31C5
G
P31C6
• VCM inhibits the timer charge and the remote climate control. H
P31C7
P31CA × Traction motor output is limited.
P31CB × Traction motor output is limited. I
P31D5
P31DB × × × × J
P31DC × × × ×
P31DE K
TYPE 1 × × × ×
P31E0
TYPE 2 No fail-safe. L
TYPE 1 × × × ×
P31E1
M
P31E7 Doing READY again is prohibited.
P31F2 VCM inhibits the timer charge and the remote climate control.
DTC Inspection Priority Chart INFOID:0000000010410131 N
If multiple DTC are displayed at the same time, check each of them one at a time in accordance with the fol-
lowing priority table. O
EVC-95
VCM
Priority DTC Detection items

U1000 CAN communication line
U1010 Control unit (CAN)
P0643 VCM
P0A00 Coolant temperature sensor
P1551, P1552 Battery current sensor
P1556, P1557 Battery temperature sensor
P2122, P2123 Accelerator pedal position sensor 1
1 P2127, P2128 Accelerator pedal position sensor 2
P3101 VCM
P3135 Slight collision detection
P3137 Car crash
P318D, P3191, P3193, P3194, P3195, P3196, P319C, P319E,
P319F, P31A0, P31A1, P31A7, P31A9, P31AA, P31AB, P31AE,
Communication error
P31AF, P31B0, P31B2, P31B3, P31B4, P31B5, P31B6, P31B7,
P31B8, P31BA
P31C5, P31C6, P31C7 VCM
EVC-96
VCM
A
P0601 VCM
P0705 VCM
P0706 Shift selector B
P0827,P0828 Shift selector
P0A0B High Voltage system interlock error
P0A8D, P0A8E 14V power supply EVC
P0A94 DC/DC converter
P0AA0, P0AA1, P0AA2 System main relay 1
D
P0AA4, P0AA5 System main relay 2
P1550, P1554 Battery current sensor
P155A Battery temperature sensor E
P1564 ASCD switch
P1572 Brake pedal position switch
F
P1574 ASCD vehicle speed sensor
P1805 Brake switch
P2138 Accelerator pedal position sensor G
P3102 Invalid battery
2
P315C Charge relay
H
P315E VDC system
P316A Motor speed
P3172, P3173 PDM (Power Delivery Module) system I
P317D Motor system
P3183 High Voltage battery system
P31CA, P31CB PDM (Power Delivery Module) system
J
P31D3 M/C relay

P31D4, P31D5 Pre charge relay
K
P31D6, P31D7 F/S relay
P31DB System main relay 1
P31DC System main relay 2 L
P31DD Pre charge relay
P31E5 VCM power supply
M
P31E8, P31E9, P31EC Electric water pump
P31EE Refrigerant pressure sensor
P31F2 AV set information N
EVC-97
VCM
P0A8F 14V power supply
P0AA6 Li-ion battery voltage system isolation error
P3100, P312A Communication error
P3117 A/C system
P311C High voltage system
P312B Restart error
P312C Traction motor inverter discharge error
P312D Quick charge relay
P312E READY OFF error
3 P312F Charge OFF error
P3130 Traction motor inverter discharge error
P3131 System shutoff timeout
P3141 PDM (Power Delivery Module)
P316F PDM (Power Delivery Module) system
P3176 Inverter condenser
P3177, P3178 ECU activation error
P31DE Li-ion battery main relay
P31E0, P31E1 High voltage system interlock error
P31E7 Restart inhibition
P316C, P316D, P316E, P3170, P3171 PDM (Power Delivery Module) system
4 P3179, P317A, P317B Traction motor system
P317E, P3180, P3182 Li-ion battery system
×:Applicable —: Not applicable

Items EV system warning
DTC Trip Reference page
(CONSULT screen terms) lamp
U1000 CAN COMM CIRCUIT — 1 EVC-131
U1010 CONTROL UNIT (CAN) × 1 EVC-132
P0601 CONTROL MODULE × 1 EVC-145
P0643 SENSOR REFERENCE VOLTAGE A × 1 EVC-145
P0705 TRANSMISSION RANGE SENSOR A × 1 EVC-145
P0706 TRANSMISSION RANGE SENSOR A × 1 EVC-145
P0827 UP/DOWN SHIFT SWITCH — 1 EVC-145
P0828 UP/DOWN SHIFT SWITCH — 1 EVC-145
P0A00 COOLANT TEMPERATURE SENSOR — 1 EVC-145
P0A0B HV SYSTEM INTERLOCK ERROR × 1 EVC-148
P0A8D 14V POWER SUPPLY × 1 EVC-151
P0A8E 14V POWER SUPPLY × 1 EVC-153
P0A8F 14V POWER SUPPLY × 1 EVC-155
P0A94 DC/DC CONVERTER — 1 EVC-158
P0AA0 HYBRID BATT POSITIVE CONTACTOR × 1 EVC-160
P0AA4 HYBRID BATT NEGATIVE CONTACTOR × 1 EVC-172
EVC-98
VCM
(CONSULT screen terms) lamp A
P0AA5 HYBRID BATT NEGATIVE CONTACTOR × 1 EVC-177
P0AA6 HYBRID BATT VOLT SYS ISOLATION × 1 EVC-179
B
P1550 BATTERY CURRENT SENSOR — 1 EVC-186
P1552 BATTERY CURRENT SENSOR — 1 EVC-186 EVC
P1556 BATTERY TEMPERATURE SENSOR — 1 EVC-194
D
P1557 BATTERY TEMPERATURE SENSOR — 1 EVC-194
P155A BATTERY TEMPERATURE SENSOR — 1 EVC-197
P1564 ASCD SWITCH — 1 EVC-200 E
P1572 ASCD BRAKE SWITCH — 1 EVC-204
P1574 ASCD VEHICLE SPEED SENSOR — 1 EVC-210
P1610 LOCK MODE — 1 SEC-61 F
P1611 ID DISCORD, IMMU-VCM — 1 SEC-63
P1612 CHAIN OF VCM-IMMU — 1 SEC-64
G
P1805 BRAKE SWITCH × 1 EVC-212
P2122 APP SENSOR D × 1 EVC-215
P2123 APP SENSOR D × 1 EVC-215 H
P2127 APP SENSOR E × 1 EVC-219
P2128 APP SENSOR E × 1 EVC-219
I
P2138 APP SENSOR × 1 EVC-223
P3100 COMMUNICATION ERROR × 1 EVC-226
P3101 VCM × or — 1 EVC-228 J
P3102 INVALID BATTERY × 1 EVC-230
P3117 A/C SYSTEM — 1 EVC-232
K
P311C HIGH VOLTAGE SYSTEM — 1 EVC-234
P312A COMMUNICATION ERROR × 1 EVC-240
P312B RESTART ERROR × 1 EVC-244 L
P312C INVERTER DISCHARGE ERROR × 1 EVC-246
P312D QUICK CHARGE RELAY × 1 EVC-248
P312E READY OFF ERROR × 1 EVC-250
M
P312F CHARGE OFF ERROR × 1 EVC-252
P3130 INVERTER DISCHARGE ERROR × 1 EVC-246
N
P3131 SYSTEM SHUTOFF TIMEOUT × 1 EVC-255
P3135 SLIGHT COLLISION DETECTION × 1 EVC-259
P3137 CAR CRASH × 1 EVC-261 O
P3141 PDM (POWER DELIVERY MODULE) × 1 EVC-263
P315C CHARGE RELAY × 1 EVC-265
P
P315E VDC SYSTEM — 1 EVC-266
P316A MOTOR SPEED × 1 EVC-267
P316C PD MODULE SYSTEM — 1 EVC-268
P316D PD MODULE SYSTEM — 1 EVC-268
P316E PD MODULE SYSTEM — 1 EVC-268
P316F PD MODULE SYSTEM × 1 EVC-269
EVC-99
VCM
(CONSULT screen terms) lamp
P3170 PD MODULE SYSTEM — 1 EVC-271
P3171 PD MODULE SYSTEM × 1 EVC-271
P3172 PD MODULE SYSTEM × 1 EVC-272
P3173 PD MODULE SYSTEM × or — 1 EVC-272
P3176 INVERTER CONDENSER × 1 EVC-273
P3177 ECU ACTIVATION ERROR — 1 EVC-278
P3178 ECU ACTIVATION ERROR × 1 EVC-282
P3179 MOTOR SYSTEM × 1 EVC-284
P317A MOTOR SYSTEM × 1 EVC-284
P317B MOTOR SYSTEM × 1 EVC-284
P317D MOTOR SYSTEM × 1 EVC-285
P317E HV BATTERY SYSTEM — 1 EVC-287
P3180 HV BATTERY SYSTEM × 1 EVC-287
P3182 HV BATTERY SYSTEM — 1 EVC-287
P3183 HV BATTERY SYSTEM × 1 EVC-288
P318D COMMUNICATION ERROR × 1 EVC-289
P3191 COMMUNICATION ERROR × or — 1 EVC-290
P3193 COMMUNICATION ERROR × or — 1 EVC-292
P3194 COMMUNICATION ERROR — 1 EVC-294
P3195 COMMUNICATION ERROR — 1 EVC-296
P3196 COMMUNICATION ERROR × 1 EVC-298
P319C COMMUNICATION ERROR × 1 EVC-290
P319E COMMUNICATION ERROR × 1 EVC-292
P319F COMMUNICATION ERROR — 1 EVC-294
P31A0 COMMUNICATION ERROR — 1 EVC-296
P31A1 COMMUNICATION ERROR × 1 EVC-298
P31AA COMMUNICATION ERROR — 1 EVC-294
P31AB COMMUNICATION ERROR — 1 EVC-296
P31AE COMMUNICATION ERROR × 1 EVC-298
P31AF COMMUNICATION ERROR × 1 EVC-300
P31B0 COMMUNICATION ERROR — 1 EVC-302
P31B2 COMMUNICATION ERROR × 1 EVC-304
P31B3 COMMUNICATION ERROR × or — 1 EVC-300
P31B7 COMMUNICATION ERROR × 1 EVC-308
P31BA COMMUNICATION ERROR — 1 EVC-312
P31C5 VCM — 1 EVC-314
P31C6 VCM — 1 EVC-314
P31C7 VCM × 1 EVC-316
EVC-100
VCM
(CONSULT screen terms) lamp A
P31CA PD MODULE SYSTEM × 1 EVC-318
P31CB PD MODULE SYSTEM × 1 EVC-318
B
P31D3 M/C RELAY × 1 EVC-321
P31D4 PRE CHARGE RELAY × 1 EVC-324
P31D5 PRE CHARGE RELAY × 1 EVC-326 EVC
P31D6 F/S RELAY × 1 EVC-331
P31D7 F/S RELAY × 1 EVC-334
D
P31DB HV BATT MAIN RELAY + × 1 EVC-337
P31DC HV BATT MAIN RELAY - × 1 EVC-339
P31DD PRE CHARGE RELAY × 1 EVC-341 E
P31DE HV BATT MAIN RELAY × 1 EVC-343
P31E0 HV SYSTEM INTERLOCK ERROR × 1 EVC-345
P31E1 HV SYSTEM INTERLOCK ERROR × 1 EVC-348 F
P31E5 VCM POWER SUPPLY — 1 EVC-351
P31E7 RESTART INHIBITION × 1 EVC-354
G
P31E8 WATER PUMP 1 × 1 EVC-355
P31E9 WATER PUMP 1 × 1 EVC-358
P31EC WATER PUMP 1 — 1 EVC-360 H
P31EE REFRIGERANT PRESSURE SENSOR — 1 EVC-362
P31F2 AV SET INFORMATION — 1 EVC-365
I
*: To clear DTC P0AA1, perform “SPECIFIC DTC CLEAR” in “WORK SUPPORT” of CONSULT.
EVC-101
VCM
< WIRING DIAGRAM >
WIRING DIAGRAM
VCM
JRCWC0704GB
EVC-102
VCM
< WIRING DIAGRAM >
EVC
JRCWC0705GB
EVC-103
VCM
< WIRING DIAGRAM >
JRCWC0706GB
EVC-104
VCM
< WIRING DIAGRAM >
EVC
JRCWC0707GB
EVC-105
VCM
< WIRING DIAGRAM >
JRCWC0708GB
EVC-106
VCM
< WIRING DIAGRAM >
EVC
JRCWC0709GB
EVC-107
VCM
< WIRING DIAGRAM >
JRCWC0710GB
EVC-108
VCM
< WIRING DIAGRAM >
EVC
JRCWC0711GB
EVC-109
VCM
< WIRING DIAGRAM >
JRCWC0712GB
EVC-110
VCM
< WIRING DIAGRAM >
EVC
JRCWC0713GB
EVC-111
VCM
< WIRING DIAGRAM >
JRCWC0714GB
EVC-112
VCM
< WIRING DIAGRAM >
EVC
JRCWC0715GB
EVC-113
BASIC INSPECTION
OVERALL SEQUENCE
JSCIA0443GB
DETAILED FLOW
EVC-114
1.GET INFORMATION FOR SYMPTOM A
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the “Diagnostic Work Sheet”. (Refer to EVC-117, "Diagnostic Work
Sheet".)
B
>> GO TO 2.
2.CHECK DTC EVC
1. Check DTC.
2. If a DTC is detected, perform the following steps, and after this, erase DTC.
- Print (or write down) the detected DTC and freeze frame data. D
- Check DTC logic. Refer to EVC-98, "DTC Index".
- Check related Service Bulletins.
- Study the relationship between the cause detected by DTC and the symptom described by the customer. E
(Symptom Diagnosis is useful. Refer to EVC-390, "Symptom Index".)
Are any symptoms described and any DTCs detected?
Symptom is described, DTC is detected>>GO TO 3. F
Symptom is described, DTC is not detected>>GO TO 4.
Symptom is not described, DTC is detected>>GO TO 5.
3.CONFIRM THE SYMPTOM G
Try to confirm the symptom described by the customer.
Also study the normal operation and fail-safe related to the symptom. Refer to EVC-390, "Symptom Index"
and EVC-93, "Fail-Safe". H
Diagnosis Work Sheet is useful to verify the incident.
Verify relation between the symptom and the condition when the symptom is detected.
I
>> GO TO 5.
4.CONFIRM THE SYMPTOM
Try to confirm the symptom described by the customer. J
and EVC-93, "Fail-Safe".
Diagnosis Work Sheet is useful to verify the incident. K
>> GO TO 6. L
5.PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC CONFIRMATION PROCEDURE for the displayed DTC, and then check that DTC is detected
M
again.
If two or more DTCs are detected, refer to EVC-95, "DTC Inspection Priority Chart" and determine trouble
diagnosis order.
NOTE: N
• 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 O
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? P
YES >> GO TO 7.
6.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
Detect malfunctioning system according to GI-47, "Intermittent Incident" based on the confirmed symptom in
step 4, and determine the trouble diagnosis order based on possible causes and symptoms.
EVC-115
Is the symptom described?
YES >> GO TO 7.
NO >> Monitor input data from related sensors or check voltage of related VCM terminals using CON-
SULT. Refer to EVC-81, "Reference Value".
7.DETECT MALFUNCTIONING PART BY DIAGNOSIS PROCEDURE
Inspect according to Diagnosis Procedure of the system.
Is a malfunctioning part detected?
YES >> GO TO 8.
8.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 9.
9.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 7.
YES-2 >> Symptom remains: GO TO 4.
NO >> Before returning the vehicle to the customer, always erase DTC.
EVC-116
Diagnostic Work Sheet INFOID:0000000010410136
EVC
JSCIA0784GB
P
EVC-117
JSCIA0785GB
EVC-118
ADDITIONAL SERVICE WHEN REMOVING 12V BATTERY NEGATIVE TERMI-
NAL
ADDITIONAL SERVICE WHEN REMOVING 12V BATTERY NEGATIVE
A
TERMINAL
B
When the 12V battery negative terminal is disconnected, the timer mounted in VCM cannot be controlled nor-
mally because timer information stored in VCM is erased. In such case, the timer must be reset to correct time.
NOTE: EVC
If timer charge setting is previously set to ON, the timer charge ON setting can be cancelled by disconnecting
the 12 V battery negative terminal.
Work Procedure INFOID:0000000010410138 D
1.CHECK VEHICLE SPECIFICATIONS

Check vehicle specifications. E
Models with NISSAN genuine navigation system (7 inch display model)>>GO TO 2.

Except above>>GO TO 3. F
2.PERFORM VCM TIMER ADJUSTMENT

Perform VCM timer adjustment. Refer to AV-134, "ADDITIONAL SERVICE WHEN REMOVING BATTERY G
NEGATIVE TERMINAL : Work Procedure".
>> END H
3.SET COMBINATION METER TIME
Set the combination meter clock right.
I
>> END
J
EVC-119
ADDITIONAL SERVICE WHEN REPLACING VCM
When replacing VCM, this procedure must be performed.

NOTE:
The necessary operation is different depending on the operation result of VCM data save or write. Always per-
form the operation according to procedures. Refer to EVC-120, "Work Procedure".
1.SAVE VCM DATA

1. Turn off the power and wait at least 90 seconds.
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the
vehicle handling.
2. Turn power switch ON.
3. Select “SAVE DATA FOR CPU REPLACE” in “WORK SUPPORT” mode using CONSULT.
4. Follow the instruction of CONSULT display.
NOTE:
Necessary data in VCM is copied and saved to CONSULT.
Is operation completed successfully?
YES >> GO TO 2.
NO >> GO TO 5.
2.REPLACE VCM
CAUTION:
vehicle handling.
2. Replace VCM. Refer to EVC-404, "Removal and Installation".
>> GO TO 3.
3.PERFORM VCM KEY ID REGISTRATION
Refer to SEC-59, "VCM : Work Procedure".
>> GO TO 4.
4.WRITE VCM DATA
1. Select “WRITE DATA AFTER REPLACE CPU” in “WORK SUPPORT” mode using CONSULT.
2. Follow the instruction of CONSULT display.
NOTE:
The data saved by “SAVE DATA FOR CPU REPLACE” is written to VCM.
Is operation completed successfully?
YES >> GO TO 9.
NO >> GO TO 7.
5.REPLACE VCM
CAUTION:
vehicle handling.
EVC-120
>> GO TO 6.
6.PERFORM VCM KEY ID REGISTRATION A
Refer to SEC-59, "VCM : Work Procedure".

B
>> GO TO 7.
7.WRITE VIN DATA
EVC
Perform EVC-125, "Work Procedure".
>> GO TO 8. D
8.LI-ION BATTERY ID REGISTRATION
Refer to “Li-ion Battery Registration Operation Manual”.
E
>> GO TO 9.
9.PERFORM ACCELERATE PEDAL CLOSED POSITION LEARNING F
Perform EVC-122, "Work Procedure".
>> GO TO 10. G
10.SET VCM TIMER
Models with navigation system (7 inch display model): Perform AV-134, "ADDITIONAL SERVICE WHEN H
REMOVING BATTERY NEGATIVE TERMINAL : Work Procedure".
Models with navigation system (5.8 inch display model) or without navigation system: Set the combination
meter clock right. Refer to MWI-78, "INFORMATION DISPLAY : System Description".
I
>> GO TO 11.
11.CHECK DTC J
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some K
vehicle handling.
L
>> END
M
EVC-121
ACCELERATOR PEDAL RELEASED POSITION LEARNING
ACCELERATOR PEDAL RELEASED POSITION LEARNING
Accelerator Pedal Closed Position Learning is a function of VCM to learn the fully released position of the
accelerator pedal by monitoring the accelerator pedal position sensor output signal. This work must be per-
formed each time the harness connector of the accelerator pedal position sensor or VCM harness connector is
disconnected.
1.START
1. Check that accelerator pedal is fully released.
2. Turn power switch ON.and wait at least 2 seconds.
3. Turn power switch OFF and wait at least 90 seconds.
CAUTION:
vehicle handling.
4. Repeat steps 2 and 3 for 4 times.
CAUTION:
vehicle handling.
>> END
EVC-122
LI-ION BATTERY GRADUAL CAPACITY LOSS DATA CLEAR
LI-ION BATTERY GRADUAL CAPACITY LOSS DATA CLEAR
A
Perform Li-ion Battery Gradual Capacity Loss Data Clear when the Li-ion battery or Li-ion battery controller is B
replaced with a new one. VCM saves the Li-ion battery deterioration information sent from the Li-ion battery
controller and manages the Li-ion battery replacement timing. When the Li-ion battery or Li-ion battery control-
ler is replaced with a new one, there is a difference between the Li-ion battery deterioration data stored in
VCM and the actual Li-ion battery deterioration level. In this case, VCM will incorrectly manage the Li-ion bat- EVC
tery replacement timing. So perform Li-ion Battery Deterioration Data Clear to clear the Li-ion battery deterio-
ration data stored in VCM.
CAUTION: D
Never perform Li-ion Battery Deterioration Data Clear when the Li-ion battery or Li-ion battery control-
ler is not replaced as new one.
Work Procedure INFOID:0000000010410144 E
1.LI-ION BATTERY GRADUAL CAPACITY LOSS DATA CLEAR

With CONSULT F
2. On the CONSULT screen, select “EV/HEV” >> “WORK SUPPORT” >> “BATTERY GRADUAL CAP LOSS
DATA CLEAR”. G
3. Touch “START” and wait a few seconds.
4. Check that “COMPLETE” is displayed on CONSULT screen.
H
>> END
EVC-123
LI-ION BATTERY JUNCTION BOX DATA CLEAR
LI-ION BATTERY JUNCTION BOX DATA CLEAR
Perform Li-ion Battery Junction Box Data Clear when the Li-ion Battery Junction Box is replaced with a new
one. VCM counts the times system main relay is turned off due to a large current and use this information to
manage the system main relay deterioration status. As the system main relay deterioration status progresses,
a DTC “P31DE” is detected and notification that the Li-ion battery junction box needs to be replaced is given.
When the Li-ion Battery Junction Box is replaced with a new one, there is a difference between the System
Main Relay cutoff count stored in VCM and the actual System Main Relay cutoff count. In this case, VCM will
detect the DTC with incorrect timing. So perform Li-ion Battery Junction Box Data Clear to clear the System
Main Relay cutoff count stored in VCM.
1.LI-ION BATTERY JUNCTION BOX DATA CLEAR

With CONSULT
2. On the CONSULT screen, select “EV/HEV” >> “WORK SUPPORT” >> “LI-ION BATTERY JUNCTION
BOX DATA CLEAR”.
3. Touch “START” and wait a few seconds.
>> END
EVC-124
WRITE VEHICLE IDENTIFICATION NUMBER DATA
WRITE VEHICLE IDENTIFICATION NUMBER DATA
A
VIN Registration is an operation to register the VIN in VCM. B

NOTE:
If there is an error in the VIN recorded in VCM, the telematics system may not operate correctly.
Work Procedure INFOID:0000000010410148 EVC
1.CHECK VIN
Check the VIN of the vehicle and note it. Refer to GI-42, "Information About Identification or Model Code". D
>> GO TO 2.
E
2.PERFORM VIN REGISTRATION
With CONSULT
1. Turn power switch ON (not READY). F
2. On the CONSULT screen, select “EV/HEV” >> “WORK SUPPORT” >> “VIN REGISTRATION”.
3. Follow the instructions on the CONSULT display.
G
>> END
EVC-125
LOAD BATTERY IDENTIFICATION DATA
LOAD BATTERY IDENTIFICATION DATA
Load Battery Identification Data must be performed after the following operation.
• Li-ion battery is replaced.
• Li-ion battery controller is replaced.
• VCM is replaced.
NOTE:
If Load Battery Identification Data is not performed, VCM detects the DTC “P3102”.
Refer to “Li-ion Battery Registration Operation Manual”.
EVC-126
COOLING FAN INTEGRATED OPERATION TIME CLEAR
COOLING FAN INTEGRATED OPERATION TIME CLEAR
A
Perform Cooling Fan Integrated Operation Time Clear when the cooling fan is replaced with a new one. VCM B
saves the cooling fan operation time and manages the cooling fan replacement timing. When the cooling fan is
replaced with a new one, there is a difference between the cooling fan operation time data stored in VCM and
the actual cooling fan operation time. In this case, VCM will incorrectly manage the cooling fan replacement
timing. So perform Cooling Fan Integrated Operation Time Clear to clear the cooling fan operation data stored EVC
in VCM.
CAUTION:
Never perform Cooling Fan Integrated Operation Time Clear when the cooling fan is not replaced as D
new one.
E
1.COOLING FAN INTEGRATED OPERATION TIME CLEAR
With CONSULT
1. Turn power switch ON. F
2. On the CONSULT screen, select “EV/HEV” >> “WORK SUPPORT” >> “COOLING FAN INTEGRATED
OPERATION TIME CLEAR”.
3. Touch “START” and wait a few seconds. G
>> END H
EVC-127
POWER SUPPLY AND GROUND CIRCUIT
VCM
VCM : Diagnosis Procedure INFOID:0000000010410151
1.CHECK FUSE
Check that the following fuse is not fusing.
Power supply Fuse No.

37
12V Battery
43
Power switch ON 55
Is the fuse fusing?
YES >> Replace the fuse after repairing the applicable circuit.
NO >> GO TO 2.
2.CHECK VCM GROUND CIRCUIT
1. Turn power switch OFF.
2. Disconnect VCM harness connector.
3. Check the continuity between VCM harness connector and ground.
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
YES >> GO TO 3.
NO >> Repair or replace error-detected parts.
3.CHECK 12V BATTERY POWER SUPPLY-1
1. Insert the fuse which pulled out.
2. Check the voltage between VCM harness connector and ground.
+
VCM − Voltage
Connector Terminal
12V battery power
E81 6 Ground
supply
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK 12V BATTERY POWER SUPPLY CIRCUIT
1. Disconnect IPDM E/R harness connector.
3. Check the continuity between IPDM E/R harness connector and VCM harness connector.
EVC-128
+ − A
IPDM E/R VCM Continuity
B
E14 42 E81 6 Existed
4. Also check harness for short to ground.
Is the inspection result normal? EVC
YES >> Check power supply circuit for 12V battery power supply.
5.CHECK 12V BATTERY POWER SUPPLY-2 D
Check the voltage between VCM harness connector and ground.

E
+
Voltage
VCM −
(Approx.)
Connector Terminal F
E81 1 Ground 12V battery voltage
G
YES >> GO TO 7.
NO >> GO TO 6.
6.CHECK 12V BATTERY POWER SUPPLY CIRCUIT H
1. Pull out #37 fuse.
2. Check the continuity between #37 fuse terminal and VCM harness connector.
I
−
+ VCM Continuity
J
Connector Terminal
#37 fuse termi-
E81 1 Existed
nal
K
YES >> Check power supply circuit for 12V battery power supply. L
7.CHECK POWER ON POWER SUPPLY
1. Turn power switch ON. M
+ N
Voltage
VCM −
(Approx.)
Connector Terminal
O
YES >> INSPECTION END P
NO >> GO TO 8.
8.CHECK POWER ON POWER SUPPLY CIRCUIT
EVC-129
+ −
YES >> Check power supply circuit for power ON power supply.
EVC-130
A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, 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 line, CAN L line) allowing a high rate of information transmission with less wiring. EVC
Each control unit transmits/receives data but selectively reads required data only.
D
DTC DETECTION LOGIC

E
DTC No. DTC detecting condition
CAN COMM CIRCUIT When VCM is not transmitting or receiving CAN communication signal or
U1000 F
(CAN communication circuit) EV system CAN communication for 2 seconds or more.
POSSIBLE CAUSE
• CAN communication system G
• EV system CAN communication system
FAIL-SAFE
Not applicable H
1.PRECONDITIONING I
• Turn power switch OFF and wait at least 90 seconds.
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some J
vehicle handling.
• Check that 12V battery voltage is 11 V or more.
K
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE L
With CONSULT
1. Turn power switch ON and wait at least 5 seconds.
2. Check self-diagnostic result. M
Is DTC detected?
YES >> Proceed to EVC-131, "Diagnosis Procedure".
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". N
O
Perform the trouble diagnosis for CAN communication system. Refer to LAN-21, "Trouble Diagnosis Flow
Chart".
P
EVC-131
U1010 CONTROL MODULE (CAN)
DTC DETECTION LOGIC

CONTROL UNIT (CAN)
U1010 Detecting error during the initial diagnosis of CAN controller of VCM.
[Control unit (CAN)]
POSSIBLE CAUSE
VCM
FAIL-SAFE
TYPE 1
READY OFF
TYPE 2
• Quick charge prohibited
• Normal charge prohibited
• READY OFF
• High-voltage power supply stop
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT
2. Check self-diagnostic result.
Is DTC detected?
1.PERFORM DTC CONFIRMATION PROCEDURE AGAIN

With CONSULT
2. Erase self-diagnostic result.
3. Perform DTC confirmation procedure again. Refer to EVC-132, "DTC Description".
Is the DTC detected again?
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation".
NO >> INSPECTION END
EVC-132
P0601 VCM
P0601 VCM
A

(Trouble diagnosis content) EVC
CONTROL MODULE
When the results of redundant calculation are different between shift range
P0601 (Internal control module memory checksum
judgement.
error)
D
POSSIBLE CAUSE
VCM
E
FAIL-SAFE
• READY OFF F
1.PRECONDITIONING G
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some H
vehicle handling.
• Check 12V battery voltage is 11 V or more.
I
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE J
1. Turn power switch ON wait at least 10 seconds.
2. Set the vehicle to READY.
NOTE: K
If the vehicle does not enter the READY state, proceed to the next step with the power switch ON.
3. Shift selector lever to the entire position from “P” to “D”.
4. Turn power switch OFF and wait at least 90 seconds. L
CAUTION:
vehicle handling. M
CAUTION: N
vehicle handling.
7. Turn power switch ON. O
Is DTC detected?
YES >> Proceed to EVC-133, "Diagnosis Procedure". P
1.PERFORM CONFIRMATION PROCEDURE AGAIN

1. Erase DTC.
EVC-133
P0601 VCM
EVC-134
P0643 SENSOR POWER SUPPLY
A

• VCM detects that sensor voltage remains less than 4.6 V for 0.1 sec-
SENSOR REFERENCE VOLTAGE A onds.
P0643
(Sensor reference voltage ″A″circuit high) • VCM detects that sensor voltage remains more than 5.6 V for 0.1 sec-
onds. D
POSSIBLE CAUSE
• Harness or connectors E
- Refrigerant pressure sensor circuit is shorted.
- Accelerator pedal position sensor 1 circuit is shorted.
- Battery current sensor circuit is shorted.
- Accelerator pedal position sensor 2 circuit is shorted. F
• Refrigerant pressure sensor
• Accelerator pedal position sensor 1
• Battery current sensor G
• VCM
FAIL-SAFE H
READY OFF
I
1.PRECONDITIONING
CAUTION: J
vehicle handling.
K
>> GO TO 2. L
2. Check self-diagnostic result. M
Is DTC detected?
O
1.CHECK BATTERY CURRENT SENSOR POWER SUPPLY
1. Turn power switch OFF. P
2. Disconnect battery current sensor harness connector.
4. Check voltage between battery current sensor harness connector and ground.
EVC-135
+
Voltage
Battery current sensor −
(Approx.)
Connector Terminal
E119 4 Ground 5V
YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK SENSOR POWER SUPPLY ROUTING CIRCUIT FOR SHORT
3. Disconnect harness connectors of the following parts.
- Refrigerant pressure sensor
- Accelerator pedal position sensor 1
- Battery current sensor
- Accelerator pedal position sensor 2
4. Check harness for short to power and to ground, between the following terminals.
VCM Sensor
Connector Terminal Name Connector Terminal
33 Refrigerant pressure sensor E96 3
37 Accelerator pedal position sensor 1 E101 3
E82
41 Battery current sensor E119 4
YES >> GO TO 3.
3.CHECK COMPONENTS
Check the following parts for short to ground.
NO >> Replace malfunctioning component.
4.CHECK BATTERY CURRENT SENSOR
Check the battery current sensor for short to ground.
YES >> GO TO 5.
NO >> Replace malfunctioning component.
1. Erase DTC.
EVC-136
P0705, P0706 SHIFT SELECTOR
A

A DTC is set if either of the following statuses is detected consecutively.
1. Any of the range sensors No. 0, No. 1, No. 3, or No. 5 is stuck to OFF.
2. Any of the range sensors other than those detected in 1 above is stuck
to OFF. D
A DTC is set if either of the following statuses is detected consecutively.
TRANSMISSION RANGE SENSOR A
P0705 1. Either of the range sensors No. 2 or No. 4 is stuck to OFF.
(Transmission range sensor ″A″)
2. Any of the range sensors other than those detected in 1 above is/are E
stuck to OFF.
A DTC is set if 2 or more of the following sensors and switch are stuck to
ON or OFF consecutively: Range sensors No. 0, No. 1, No. 2, No. 3, No. 4 F
or No. 5, and park position switch.
A DTC is set if any of the following sensors and switch is/are stuck to ON
TRANSMISSION RANGE SENSOR A
P0706 or OFF consecutively: Range sensors No. 0, No. 1, No. 2, No. 3, No. 4 or
(Transmission range sensor ″A″) G
No. 5, and park position switch.
POSSIBLE CAUSE
• Harness or connectors (The switch and sensor circuit is open or shorted.) H
• Park position switch
• Shift selector
FAIL-SAFE I
P0705
TYPE 1 J
TYPE 2
• READY OFF K
P0706
A reaction of the shift becomes slow.
L
1.PRECONDITIONING
M
CAUTION:
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the N
vehicle handling.
O
>> GO TO 2.
P
With CONSULT
Is DTC detected?
EVC-137
1.CHECK PARK POSITION SWITCH POWER SUPPLY

2. Disconnect park position switch harness connector.
4. Check voltage between park position switch harness connector and ground.
+
Voltage
Park position switch −
(Approx.)
Connector Terminal
F19 1 Ground 5V
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK PARK POSITION SWITCH POWER SUPPLY CIRCUIT
3. Check continuity between park position switch harness connector and VCM harness connector.
+ −
Park position switch VCM Continuity
F19 1 E83 95 Existed
4. Also check harness for short to ground and short to power.
YES >> Perform trouble diagnosis for VCM power supply circuit. Refer to EVC-128, "VCM : Diagnosis
Procedure"
3.CHECK PARK POSITION SWITCH GROUND CIRCUIT
2. Check continuity between park position switch harness connector and ground.
+
Park position switch − Continuity
Connector Terminal
F19 2 Ground Existed
YES >> GO TO 4.
4.CHECK PARK POSITION SWITCH
Check the park position switch. Refer to EVC-140, "Component Inspection (Park Position Switch)".
YES >> GO TO 5.
NO >> Replace reduction gear. Refer to TM-24, "Removal and Installation".
5.CHECK SHIFT SELECTOR OUTPUT SIGNAL
1. Reconnect shift selector harness connector.
3. Check voltage between shift selector harness connector and ground.
EVC-138
+ A
Voltage
Shift selector − Condition
(Approx.)
Connector Terminal
B
Shift lever: R position 0V
6
Except R position 5V
Shift lever: N or D or B position 0V EVC
7
Except N or D or B position 5V
Shift lever: N position 0V
9 D
Except N position 5V
M57 Ground
Shift lever: R or N position 0V
18
Except R or N position 5V E
Shift lever: D or B position 0V
19
Except N or D or B position 5V
Shift lever: P position 0V
F
21
Except P position 5V
Is the inspection result normal? G
YES >> GO TO 9.
NO >> GO TO 6.
6.CHECK SHIFT SELECTOR POWER SUPPLY H
1. Disconnect shift selector harness connector.
3. Check voltage between shift selector harness connector and ground. I
+
Voltage J
Shift selector −
(Approx.)
Connector Terminal
10 K
M57 Ground 5V
22
YES >> GO TO 8. L
NO >> GO TO 7.
7.CHECK SHIFT SELECTOR POWER SUPPLY CIRCUIT M
3. Check continuity between shift selector harness connector and VCM harness connector.
N
+ −
Shift selector VCM Continuity O
10 53
M57 E82 Existed
22 49 P

Procedure"
EVC-139
8.CHECK SHIFT SELECTOR GROUND CIRCUIT
2. Check continuity between shift selector harness connector and ground.
+
Shift selector − Continuity
Connector Terminal
5
M57 Ground Existed
24
YES >> GO TO 9.
9.CHECK SHIFT SELECTOR OUTPUT SIGNAL CIRCUIT
2. Disconnect VCM harness connector and shift selector harness connector.
3. Check continuity between VCM harness connector and shift selector harness connector.
+ −
Shift selector VCM Continuity
6 94
7 98
9 99
M57 E83 Existed
18 93
19 97
21 103
YES >> Replace shift selector. Refer to TM-52, "Removal and Installation".
Component Inspection (Park Position Switch) INFOID:0000000011045538
1.CHECK PARK POSITION SWITCH-1

2. Disconnect park position switch harness connector.
3. Check continuity between park position switch terminals.
Park position switch

Condition Continuity
Terminal
Shift lever: P position Existed
1 2
Except P position Not existed
YES >> GO TO 2.
2.CHECK PARK POSITION SWITCH-2
Check continuity between park position switch connector and ground.
EVC-140
+ A
Park position switch − Continuity
Terminal
B
1 Ground Not existed
YES >> INSPECTION END EVC
EVC-141
DTC DETECTION LOGIC

UP/DOWN SHIFT SWITCH A DTC is set if VCM simultaneously detects the OFF signal from the shift
P0827
(Up and down shift switch circuit low) position signal 7 and OFF signal from the shift position signal 8.
UP/DOWN SHIFT SWITCH A DTC is set if VCM simultaneously detects the ON signal from the shift po-
P0828
(Up and down shift switch circuit high) sition signal 7 and ON signal from the shift position signal 8.
POSSIBLE CAUSE
• Harness or connectors (The switch and sensor circuit is open or shorted.)
• Shift selector
FAIL-SAFE
The B range driving prohibited.
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
Is DTC detected?
1.CHECK SHIFT SELECTOR OUTPUT SIGNAL

1. Connect shift selector harness connector.
+
Voltage
Shift selector − Condition
(Approx.)
Connector Terminal
Shift lever: B position 0V
8
Except B position 5V
M57 Ground
Except B position 0V
20
Shift lever: B position 5V
EVC-142
YES >> GO TO 5.
NO >> GO TO 2. A
2.CHECK SHIFT SELECTOR POWER SUPPLY
B
EVC
+
Voltage
Shift selector −
(Approx.)
Connector Terminal D
M57 10 Ground 5V
YES >> GO TO 4. E
NO >> GO TO 3.
3.CHECK SHIFT SELECTOR POWER SUPPLY CIRCUIT F
3. Check continuity between shift selector harness connector and VCM harness connector.
G
+ −
Shift selector VCM Continuity H
M57 10 E82 53 Existed
4. Also check harness for short to ground and short to power. I
J
Procedure"
4.CHECK SHIFT SELECTOR GROUND CIRCUIT K
2. Check continuity between shift selector harness connector and ground.
L
+
Shift selector − Continuity
Connector Terminal M
5
M57 Ground Existed
24
N
YES >> GO TO 5.
NO >> Repair or replace error-detected parts. O
5.CHECK SHIFT SELECTOR OUTPUT SIGNAL CIRCUIT
2. Disconnect VCM harness connector and shift selector harness connector. P
3. Check continuity between VCM harness connector and shift selector harness connector.
EVC-143
+ −
Shift selector VCM Continuity
8 E83 101
20 E83 102
YES >> Replace shift selector. Refer to TM-52, "Removal and Installation".
EVC-144
P0A00 COOLANT TEMPERATURE SENSOR
A

• VCM detects that coolant temperature sensor voltage remains less than
COOLANT TEMPERATURE SENSOR
0.1 V for 2.5 seconds.
P0A00 (Motor electronics coolant temperature sen-
• VCM detects coolant temperature sensor voltage remains more than 4.9
sor circuit) D
V for 2.5 seconds.
POSSIBLE CAUSE
• Harness or connectors (The sensor circuit is open or shorted.) E
• Coolant temperature sensor
FAIL-SAFE
Not applicable F
1.PRECONDITIONING G
CAUTION:
vehicle handling.
I
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE J
With CONSULT
2. Check self-diagnostic result. K
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". L
M
1.CHECK COOLANT TEMPERATURE SENSOR POWER SUPPLY-1
1. Turn power switch OFF. N
2. Disconnect coolant temperature sensor harness connector.
4. Check the voltage between coolant temperature sensor harness connector terminals.
O
Coolant temperature sensor
Voltage
+ −
Connector (Approx.) P
Terminal
E69 1 2 5V
YES >> GO TO 7.
NO >> GO TO 2.
EVC-145
2.CHECK COOLANT TEMPERATURE SENSOR POWER SUPPLY-2
Check the voltage between coolant temperature sensor harness connector and ground.
+
Voltage
Coolant temperature sensor −
(Approx.)
Connector Terminal
E69 1 Ground 5V
YES >> GO TO 3.
NO >> GO TO 5.
3.CHECK COOLANT TEMPERATURE SENSOR GROUND CIRCUIT
3. Check the continuity between VCM harness connector and coolant temperature sensor harness connec-
tor.
+ −
VCM Coolant temperature sensor Continuity
YES >> GO TO 4.
Check the continuity between VCM harness connector and ground.
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
5.CHECK SENSOR POWER SUPPLY CIRCUIT
3. Check the continuity between VCM harness connector and coolant temperature sensor harness connec-
tor.
+ −
VCM Coolant temperature sensor Continuity
EVC-146
YES >> GO TO 6. A
6.CHECK VCM POWER SUPPLY CIRCUIT
B
Check VCM power supply circuit. Refer to EVC-128, "VCM : Diagnosis Procedure".
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". EVC
7.CHECK COOLANT TEMPERATURE SENSOR
Check coolant temperature sensor. Refer to EVC-147, "Component Inspection". D
NO >> Replace coolant temperature sensor. Refer to HCO-14, "Exploded View". E
F
1.CHECK COOLANT TEMPERATURE SENSOR
2. Disconnect coolant temperature sensor harness connector. G
3. Remove coolant temperature sensor.
4. Check resistance between coolant temperature sensor termi-
nals by heating with hot water as shown in the figure.
H
Terminals Condition Resistance

20 (68) 2.35 - 2.73 kΩ I
1 and 2 Temperature [°C (°F)] 50 (122) 0.68 - 1.00 kΩ
90 (194) 0.236 - 0.260 kΩ
J
YES >> INSPECTION END JMBIA0080ZZ
NO >> Replace coolant temperature sensor. Refer to HCO-14,
"Exploded View". K
EVC-147
P0A0B HIGH VOLTAGE CONNECTOR CONNECTION DETECTING CIRCUIT
P0A0B HIGH VOLTAGE CONNECTOR CONNECTION DETECTING CIR-
CUIT
The connection detecting circuit is used to detect the connection status of the PDM (Power Delivery Module)
cover and the bus bar cover of PDM (Power Delivery Module).
The connection detecting circuit consists of two circuits (i.e. power supply circuit and signal input circuit).
When the PDM (Power Delivery Module) cover and the bus bar cover are installed normally, their protrusions
press the internal switch of PDM (Power Delivery Module). Accordingly, the connection detecting circuit is
energized and a voltage signal is input.
DTC DETECTION LOGIC

DTC DTC detecting condition Possible cause
HV SYSTEM INTERLOCK VCM detects that high voltage harness con-
• Harness or connectors
ERROR nector interlock circuit voltage remains ex-
P0A0B • VCM
(High voltage system inter- cessively high for 0.5 seconds or more
• PDM (Power Delivery Module)
lock circuit performance) immediately before M/C relay turns ON.
POSSIBLE CAUSE
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
CAUTION:
vehicle handling.
Is DTC detected?
EVC-148
A
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of B
maintenance.
EVC
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in D
• Be sure to wear insulating protective equipment before beginning work on the high voltage system.
• Never allow workers other than the responsible person to touch the vehicle containing high voltage E
• Refer to EVC-10, "High Voltage Precautions".
CAUTION: F
• Erase DTC after the work is completed. G
1. OVERALL FUNCTION CHECK
With CONSULT
H
1. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “HV INTERLOCK (DC/DC)”.
2. Check that “On” is displayed.
I
NO >> GO TO 2.
2.PRECONDITIONING J
WARNING:
1. Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage". K
>> GO TO 3. L
3.CHECK CONNECTION DETECTING CIRCUIT POWER SUPPLY
1. Disconnect PDM (Power Delivery Module) harness connector.
M
2. Reconnect 12V battery negative terminal.
4. Check the voltage between PDM (Power Delivery Module) harness connector and ground.
N
+
PDM (Power Delivery Module) − Voltage
O
Connector Terminal
12V battery volt-
F18 12 Ground
age
P
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK CONNECTION DETECTING CIRCUIT POWER SUPPLY CIRCUIT
EVC-149
3. Check the harness for short to power, between PDM (Power Delivery Module) harness connector and
VCM harness connector.
+
Connector Terminal
F18 12 Ground 0V
5.CHECK CONNECTION DETECTING CIRCUIT SIGNAL CIRCUIT
VCM harness connector.
+
Connector Terminal
F18 15 Ground 0V
YES >> GO TO 6.
6.REPLACE VCM
2. Reconnect harness connector and parts disconnected.
3. Perform DTC Confirmation Procedure. Refer to EVC-148, "DTC Description".
Is DTC P0A0B detected again?
YES >> Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation".
EVC-150
P0A8D 12V BATTERY POWER SUPPLY
A

14V POWER SUPPLY VCM detects that a voltage of 12V battery power supply remains less than
P0A8D
(14 V power module system voltage low) 10 V for 10 seconds during READY state.
POSSIBLE CAUSE D
• Harness or connectors (The sensor circuit is open or shorted.)
• DC/DC converter
• IPDM E/R E
FAIL-SAFE
• Normal charge prohibited F
• READY OFF
1.PRECONDITIONING
• Turn power switch OFF and wait at least 90 seconds. H
CAUTION:
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the I
vehicle handling.
J
>> GO TO 2.
With CONSULT K
1. Set the vehicle to READY and wait at least 30 seconds.
Is DTC detected? L
1.CHECK SELF-DIAGNOSTIC RESULT IN PDM (POWER DELIVERY MODULE) N
With CONSULT
Check self-diagnostic result in “CHARGER/PD MODULE”.
O
YES >> Perform trouble diagnosis for detected DTC. Refer to VC-31, "DTC Index".
NO >> GO TO 2. P
2.CHECK SELF-DIAGNOSTIC RESULT IN VCM
With CONSULT
Check self-diagnostic result in “EV/HEV”.
Is DTC (excluding P0A8D) related to DC/DC converter detected?
YES >> Perform trouble diagnosis for detected DTC. Refer to EVC-98, "DTC Index".
NO >> GO TO 3.
EVC-151
3.CHECK 12V BATTERY POWER SUPPLY
2. Check the voltage between IPDM E/R harness connector and ground.
+
IPDM E/R − Voltage
Connector Terminal
12V battery volt-
E14 42 Ground
age
YES >> GO TO 6.
NO >> GO TO 4.
4.CHECK FUSE
2. Check the fuse is not fusing.
YES >> GO TO 5.
NO >> Replace the fuse after replacing the applicable circuit.
5.CHECK IPDM E/R
2. Remove IPDM E/R. Refer to PCS-31, "Removal and Installation".
3. Check the continuity between IPDM E/R connector terminals.
IPDM E/R
+ − Continuity
Terminal
2 42 Existed
YES >> GO TO 6.
NO >> Replace IPDM E/R. Refer to PCS-31, "Removal and Installation".
+ −
EVC-152
P0A8E 12V BATTERY POWER SUPPLY
A

14V POWER SUPPLY VCM detects that a voltage of 12V battery power supply remains more than
P0A8E
(14 V power module system voltage high) 16 V for 25.5 seconds during READY state.
POSSIBLE CAUSE D
• 12V battery
• Harness or connectors (The signal circuit is open or shorted.)
• DC/DC converter E
• VCM
FAIL-SAFE
• Quick charge prohibited F
• READY OFF
• High-voltage power supply stop G
1.PRECONDITIONING H
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some I
vehicle handling.
J
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE K
With CONSULT
2. Check self-diagnostic result. L
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". M
N
1.CHECK 12V BATTERY
Check that the correct 12V battery is installed.
O
YES >> GO TO 2.
NO >> Replace 12V battery with a correct one.
P
2.CHECK SELF-DIAGNOSTIC RESULT IN PDM (POWER DELIVERY MODULE)
With CONSULT
NO >> GO TO 3.
EVC-153
With CONSULT
Is DTC (excluding P0A8E) related to DC/DC converter detected?
NO >> GO TO 4.
4.CHECK DC/DC CONVERTER POWER VOLTAGE VARIABLE CONTROL SIGNAL
With CONSULT
1. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “DC/DC CONV REQ VOLT”.
2. Check that the value of “DC/DC CONV REQ VOLT” is less than 16 V.
NO >> Replace VCM. Refer to EVC-404, "Removal and Installation".
EVC-154
P0A8F 12V BATTERY POWER SUPPLY
A

14V POWER SUPPLY When shift is except P range, VCM detects that a voltage of 12V battery
P0A8F
(14 V power module system performance) power supply remains less than 12 V for 10 seconds.
POSSIBLE CAUSE D
• Harness or connectors (The sensor circuit is open or shorted.)
• DC/DC converter
• IPDM E/R E
FAIL-SAFE
Not applicable
F
1.PRECONDITIONING
G
CAUTION:
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the H
vehicle handling.
I
>> GO TO 2.
J
With CONSULT
1. Under the following conditions, and wait at least 30 seconds.
K
Power switch READY
Shift position Except P range
2. Check self-diagnostic result. L
Is DTC detected?
N
1.INTERVIEW THE CUSTOMER
Interview the customer to see if there is a history that all of the following conditions are satisfied for a long O
time.
Power switch ON P
Shift position Except P range
NOTE:
This DTC may be detected if the above state continues for a long time.
YES >> Explain the customer that this is the normal operation.
NO >> GO TO 2.
EVC-155
With CONSULT
NO >> GO TO 3.
With CONSULT
Is any DTC that related DC/DC converter other than P0A8F detected?
NO >> GO TO 4.
+
Connector Terminal
12V battery volt-
E14 42 Ground
age
YES >> GO TO 7.
NO >> GO TO 5.
5.CHECK FUSE
YES >> GO TO 6.
NO >> Replace the fuse after repairing the applicable circuit.
6.CHECK IPDM E/R
2. Remove IPDM E/R.
3. Check the continuity between IPDM E/R connector terminals.
IPDM E/R
+ − Continuity
Terminal
2 42 Existed
YES >> GO TO 7.
EVC-156
+ − A
B
D
EVC-157
P0A94 DC/DC CONVERTER
DTC DETECTION LOGIC

During READY, the following state continues for 2.5 seconds or more:
DC/DC CONVERTER
P0A94 The VCM power supply voltage is less than 12.48 V and VCM detects a
(DC/DC converter performance)
malfunction in the DC/DC converter.
POSSIBLE CAUSE
• DC/DC converter
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
Is DTC detected?
1.CHECK DC/DC CONVERTER STATUS SIGNAL

With CONSULT
1. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “DC/DC CONV STATUS”.
2. Check that the value of “DC/DC CONV STATUS” is other than “3”.
YES >> GO TO 3.
NO >> GO TO 2.
With CONSULT
EVC-158
With CONSULT
1. Erase DTC. A
Is DTC P0A94 detected again?
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". B
EVC
EVC-159
P0AA0 SYSTEM MAIN RELAY
DTC DETECTION LOGIC

• A traction motor inverter input voltage is 240 V or more for 9 seconds or
HYBRID BATT POSITIVE CONTACTOR more while starting the EV system.
P0AA0
(Hybrid battery positive contactor circuit) • A traction motor inverter input voltage is 190 V or more for 1 minute or
more while starting the EV system.
POSSIBLE CAUSE
• Battery J/B
• Electric compressor
• PTC heater
• High voltage harness
• Battery heater relay
• Battery heater
FAIL-SAFE
• READY OFF
• Start not possible
1.CHECK DTC PRIORITY
If DTC P0AA0 is displayed with DTC P0AA2, P0AA5, P31D4, P31DB, P31DC, or P31DD, first perform the
trouble diagnosis for DTC P0AA2, P0AA5, P31D4, P31DB, P31DC, or P31DD.
Is applicable DTC detected?
YES >> Perform diagnosis of applicable. Refer to EVC-98, "DTC Index".
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
Since this DTC may be displayed if a malfunction is detected in other systems, check them for mal-
function before performing this diagnosis.
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
Is DTC “P0AA0” detected?
EVC-160
A
DANGER:
B
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and EVC
maintenance.
WARNING:
• Be sure to wear insulating protective equipment before beginning work on the high voltage system. E
lating sheet except when using them. F
CAUTION:
instructed in the Service Manual. A malfunction may occur if this is not observed. G
• Erase DTC after the work is completed.
1.CHECK DTC PRIORITY H
If DTC P0AA0 is displayed with DTC P0AA2, P0AA5, P31D4, P31DB, P31DC, or P31DD, first perform the
Is applicable DTC detected? I
NO >> GO TO 2.
2.CHECK SYSTEM MAIN RELAY DRIVE POWER VOLTAGE J
2. Disconnect Li-ion battery harness connector.
3. Check the voltage between Li-ion battery harness connector and ground. K
+
Relay Li-ion battery − Voltage
L
Connector Terminal
System main relay 1 17
M
System main relay 2 E128 14 Ground 0V
Pre-charge relay 11
YES >> GO TO 4.
NO >> GO TO 3.
3.CHECK SYSTEM MAIN RELAY DRIVE CIRCUIT O

2. Check harness for short to power, between Li-ion battery harness connector and VCM harness connector. P
EVC-161
+
Li-ion battery − Voltage
Connector Terminal
17
E128 14 Ground 0V
11
4.PRECONDITIONING
WARNING:
>> GO TO 5.
5.CHECK ELECTRIC COMPRESSOR
1. Disconnect electric compressor high voltage harness connector.
2. Check the short circuit between electric compressor terminals.
Electric compressor
+ − Resistance
Terminal
7 8 3 kΩ or more
YES >> GO TO 6.
NO >> Replace electric compressor. And then, GO TO 12. Refer to HA-34, "Removal and Installation".
6.CHECK PTC HEATER
1. Disconnect Li-ion battery harness connector (H36).
2. Check the short circuit between Li-ion battery terminals.
Li-ion battery
Connected to: + − Resistance
Connector
Terminal
PTC heater H36 40 41 3 kΩ or more
YES >> GO TO 7.
NO >> Replace PTC heater. And then, GO TO 12. Refer to HAC-215, "Removal and Installation".
7.CHECK HIGH VOLTAGE HARNESS-1
2. Check the short circuit between Li-ion battery harness connector terminals.
Li-ion battery
Connector
Terminal
PDM (Power Delivery
H17 37 38 3 kΩ or more
Module)
EVC-162
YES-1 >> With battery heater: GO TO 10. A
YES-2 >> Without battery heater: The high voltage harness within Li-ion battery may be shorted. Check the
related circuits. And then, GO TO 12.
NO >> GO TO 8. B
8.CHECK TRACTION MOTOR INVERTER
2. Check the short circuit between traction motor inverter termi- EVC
nals.
Resistance : more than 3 kΩ D
JSCIA0696ZZ
F

YES >> GO TO 9. G
NO >> Replace traction motor inverter. And then, GO TO 12. Refer to TMS-106, "Removal and Installa-
tion".
9.CHECK HIGH VOLTAGE HARNESS-2 H
1. Remove high voltage harness from PDM (Power Delivery Module). Refer to VC-108, "Removal and Instal-
lation".
2. Check the short circuit between high voltage harness connector (Li-ion battery side) and high voltage har- I
ness connector [PDM (Power Delivery Module) side].
PDM (Power Delivery Module) J

Connector
Terminal
K
Li-ion battery H18 38 39 3 kΩ or more
3. Check the short circuit between high voltage harness connector (electric compressor side) and high volt-
age harness connector [PDM (Power Delivery Module) side]. L
PDM (Power Delivery Module)

Connected to: + − Resistance M
Electric compressor H22 43 H23 42 3 kΩ or more
N
YES >> GO TO 12.
NO >> Replace malfunctioning harness. And then, GO TO 12. O
10.CHECK BATTERY HEATER RELAY
1. Remove Li-ion battery. Refer to EVB-788, "Removal and Installation".
2. Remove battery pack upper case. Refer to EVB-797, "BATTERY PACK UPPER CASE : Removal and P
Installation".
3. Disconnect battery heater relay harness connector.
4. Check the short circuit between battery heater relay terminals.
EVC-163
Battery heater relay

Continuity
Connector Terminal
10
LB18 Not existed
11
For the connector numbers of Li-ion battery, Refer to EVB-598, "Circuit Diagram".
YES >> GO TO 11.
NO >> Replace Battery heater relay. And then, GO TO 12. Refer to EVB-810, "LI-ION BATTERY
HEATER RELAY UNIT : Removal and Installation".
11.CHECK BATTERY HEATER
1. Disconnect battery heater harness connector.
2. Check the short circuit between battery heater terminals.
Battery heater
Resistance
Connector Terminal
2
LB19 200 Ω or more
3
YES >> The high voltage harness within Li-ion battery may be shorted. Check the related circuits. And
then, GO TO 12.
NO >> Replace Li-ion battery heater cooling unit. And then, GO TO 12. Refer to EVB-820, "LI-ION BAT-
TERY HEATER & COOLING UNIT : Removal and Installation".
12.REPLACE LI-ION BATTERY JUNCTION BOX
Replace Li-ion battery junction box. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HAR-
NESS : Removal and Installation" (without battery cooler models) or EVB-515, "BATTERY JUNCTION BOX
AND BATTERY HARNESS : Removal and Installation" (with battery cooler models) or EVB-814, "BATTERY
JUNCTION BOX AND BATTERY HARNESS : Removal and Installation" (with battery heater & cooler models).
>> INSPECTION END
EVC-164
P0AA1 SYSTEM MAIN RELAY +
A

WARNING:
• When this DTC is detected, the implementation of the DTC confirmation procedure may damage
other parts. To prevent damage from occurring, perform EVC-166, "Diagnosis Procedure" first. After EVC
repairing malfunctioning part, perform the DTC confirmation procedure.
• To erase DTC, always repair malfunctioning part first.
NOTE:
D
To Clear DTC P0AA1, perform “SPECIFIC DTC CLEAR” in “WORK SUPPORT” of CONSULT.

(Trouble diagnosis content) E
HYBRID BATT POSITIVE CONTACTOR The voltage of the traction motor inverter is 160 V or more and the voltage
P0AA1 (Hybrid battery positive contactor circuit does not decreases 100 V or more even after a lapse of the specified time
stuck closed) after starting diagnosis. F
POSSIBLE CAUSE
• Battery J/B G
• PTC heater
• Traction motor inverter H
• Battery heater
I
FAIL-SAFE
• Normal charge prohibited J
• READY OFF
K
WARNING:
• When this DTC is detected, the implementation of the DTC confirmation procedure may damage L
other parts. To prevent damage from occurring, perform EVC-166, "Diagnosis Procedure" first. After
repairing malfunctioning part, perform the DTC confirmation procedure.
• To erase DTC, always repair malfunctioning part first.
M
If DTC P0AA1 is displayed with DTC P0AA2, P31D4, P31DB, or P31DD, first perform the trouble diagnosis for
DTC P0AA2, P31D4, P31DB, or P31DD. N
NO >> GO TO 2. O
2.PRECONDITIONING
CAUTION:
Since this DTC may be displayed if a malfunction is detected in other systems, check them for mal- P
CAUTION:
vehicle handling.
EVC-165
>> GO TO 3.
With CONSULT
1. Set the vehicle to READY and perform test drive.
Is the DTC detected?
DANGER:
maintenance.
WARNING:
CAUTION:
If DTC P0AA1 is displayed with DTC P0AA2, P31D4, P31DB, or P31DD, first perform the trouble diagnosis for
DTC P0AA2, P31D4, P31DB, or P31DD.
NO >> GO TO 2.
2.CHECK SYSTEM MAIN RELAY DRIVE POWER VOLTAGE
3. Check the voltage between Li-ion battery harness connector and ground.
+
Connector Terminal
Pre-charge relay 11
YES >> GO TO 4.
EVC-166
NO >> GO TO 3.
3.CHECK SYSTEM MAIN RELAY DRIVE CIRCUIT A

2. Check harness for short to power, between Li-ion battery harness connector and VCM harness connector.
B
+
Li-ion battery − Voltage EVC
Connector Terminal
17
E128 14 Ground 0V
D
11
4.PRECONDITIONING F
WARNING:
1. Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage". G
H
>> GO TO 5.
1. Disconnect electric compressor high voltage harness connector. I
Electric compressor J
+ − Resistance
Terminal
K
7 8 3 kΩ or more
YES >> GO TO 6. L
6.CHECK PTC HEATER
1. Disconnect Li-ion battery harness connector (H36). M
Li-ion battery N
Connector
Terminal
O
YES >> GO TO 7. P
EVC-167
Li-ion battery
Connector
Terminal
PDM (Power Delivery
Module)
YES-1 >> With battery heater: GO TO 10.
NO >> GO TO 8.
2. Check the short circuit between traction motor inverter termi-
nals.
Resistance : more than 3 kΩ
JSCIA0696ZZ

YES >> GO TO 9.
tion".
lation".
2. Check the short circuit between high voltage harness connector (Li-ion battery side) and high voltage har-

Connector
Terminal
age harness connector [PDM (Power Delivery Module) side].

YES >> GO TO 12.
NO >> Replace malfunctioning harness. And then, GO TO 12.
EVC-168
2. Remove battery pack upper case. Refer to EVB-797, "BATTERY PACK UPPER CASE : Removal and
Installation". A
B
Continuity
Connector Terminal
10 EVC
LB18 Not existed
11
D
YES >> GO TO 11.
NO >> Replace Battery heater relay. And then, GO TO 12. Refer to EVB-810, "LI-ION BATTERY E
1. Disconnect battery heater harness connector. F
Battery heater G
Resistance
Connector Terminal
2
LB19 200 Ω or more H
3
then, GO TO 12.
NO >> Replace Li-ion battery heater cooling unit. And then, GO TO 12. Refer to EVB-820, "LI-ION BAT- J
Replace Li-ion battery junction box. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HAR- K
JUNCTION BOX AND BATTERY HARNESS : Removal and Installation" (with battery heater & cooler models). L
>> INSPECTION END

M
EVC-169
DTC DETECTION LOGIC

HYBRID BATT POSITIVE CONTACTOR
VCM detects a break in the drive circuit of System main relay 1 or an ex-
P0AA2 (Hybrid battery positive contactor circuit
tremely high resistance for 2.5 seconds or more.
stuck open)
POSSIBLE CAUSE
• Battery J/B
FAIL-SAFE
• READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
1. Turn power switch ON and wait a least 10 seconds.
Is DTC detected?
1.CHECK SYSTEM MAIN RELAY GROUND CIRCUIT

3. Check the continuity between Li-ion battery harness connector and ground.
+
Li-ion battery − Continuity
Connector Terminal
E128 16 Ground Existed
YES >> GO TO 2.
EVC-170
2.CHECK SYSTEM MAIN RELAY CIRCUIT A
Check continuity between Li-ion battery connector terminals.
Li-ion battery B
Continuity
Terminals
16 17 Existed
EVC
YES >> GO TO 3.
NO >> Check the relay circuit of Li-ion battery for malfunction. If no malfunction is found, replace battery
junction box. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HARNESS : D
Removal and Installation" (without battery cooler models) or EVB-515, "BATTERY JUNCTION
BOX AND BATTERY HARNESS : Removal and Installation" (with battery cooler models) or EVB-
814, "BATTERY JUNCTION BOX AND BATTERY HARNESS : Removal and Installation" (with E
battery heater & cooler models).
3.CHECK SYSTEM MAIN RELAY DRIVE CIRCUIT
F
2. Check the continuity between VCM harness connector and Li-ion battery harness connector.
G
+ −
VCM Li-ion battery Continuity
Connector Terminal Connector Terminal H
E83 107 E128 17 Existed
YES >> INSPECTION END I
NO >> Repair harness or connector.
EVC-171
P0AA4 SYSTEM MAIN RELAY -
DTC DETECTION LOGIC

HYBRID BATT NEGATIVE CONTACTOR
During the stop state from READY or charging state, the voltage of the trac-
P0AA4 (Hybrid battery negative contactor circuit
tion monitor inverter is 100 V or more.
stuck closed)
POSSIBLE CAUSE
• Battery J/B
• PTC heater
• Battery heater
FAIL-SAFE
• READY OFF
If DTC P0AA4 is displayed with DTC P0AA5 or P31DC, first perform the trouble diagnosis for DTC P0AA5 or
P31DC.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
Is DTC detected?
EVC-172
NO-2 >> Confirmation after repair: INSPECTION END A
DANGER: B
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are EVC
maintenance.
WARNING: D
CAUTION:
• Never bring the vehicle into the READY status with the service plug removed unless otherwise G
1. CHECK DTC PRIORITY H
If DTC P0AA4 is displayed with DTC P0AA5 or P31DC, first perform the trouble diagnosis for DTC P0AA5 or
P31DC.
I
NO >> GO TO 2.
J
2.CHECK SYSTEM MAIN RELAY DRIVE POWER VOLTAGE
2. Disconnect Li-ion battery harness connector. K
3. Check the voltage between Li-ion battery harness connector and ground.
+ L
Connector Terminal
M
Pre-charge relay 11 N
YES >> GO TO 4.
NO >> GO TO 3. O
3.CHECK SYSTEM MAIN RELAY DRIVE CIRCUIT
1. Disconnect VCM harness connector. P
2. Check harness for short to power, between Li-ion battery harness connector and VCM harness connector.
EVC-173
+
Connector Terminal
17
E128 14 Ground 0V
11
4.PRECONDITIONING
WARNING:
>> GO TO 5.
Electric compressor
+ − Resistance
Terminal
7 8 3 kΩ or more
YES >> GO TO 6.
6.CHECK PTC HEATER
Li-ion battery
Connector
Terminal
YES >> GO TO 7.
Li-ion battery
Connector
Terminal
PDM (Power Delivery
Module)
EVC-174
YES-1 >> With battery heater: GO TO 10. A
NO >> GO TO 8. B
2. Check the short circuit between traction motor inverter termi- EVC
nals.
Resistance : more than 3 kΩ D
JSCIA0696ZZ
F

YES >> GO TO 9. G
tion".
9.CHECK HIGH VOLTAGE HARNESS-2 H
lation".
2. Check the short circuit between high voltage harness connector (Li-ion battery side) and high voltage har- I
PDM (Power Delivery Module) J

Connector
Terminal
K
age harness connector [PDM (Power Delivery Module) side]. L

Connected to: + − Resistance M
N
YES >> GO TO 12.
NO >> Replace malfunctioning harness. And then, GO TO 12. O
2. Remove battery pack upper case. Refer to EVB-797, "BATTERY PACK UPPER CASE : Removal and P
Installation".
EVC-175

Continuity
Connector Terminal
10
LB18 Not existed
11
YES >> GO TO 11.
Battery heater
Resistance
Connector Terminal
2
3
then, GO TO 12.
JUNCTION BOX AND BATTERY HARNESS : Removal and Installation" (with battery heater & cooler models).
>> INSPECTION END
EVC-176
A

HYBRID BATT NEGATIVE CONTACTOR VCM detects a break in the drive circuit of the system main relay or an ex-
P0AA5 (Hybrid battery negative contactor circuit tremely high resistance for 2.5 seconds or more when the F/S relay is ON
stuck open) with the system main relay OFF.
D
POSSIBLE CAUSE
• Battery J/B E
FAIL-SAFE
• READY OFF
1.PRECONDITIONING
CAUTION:
I
vehicle handling.
J
>> GO TO 2.
With CONSULT K
Is DTC detected? L
1.CHECK SYSTEM MAIN RELAY GROUND CIRCUIT N

3. Check the continuity between Li-ion battery harness connector and ground. O
+
P
Connector Terminal
YES >> GO TO 2.
EVC-177
2.CHECK SYSTEM MAIN RELAY CIRCUIT
Check continuity between Li-ion battery connector terminals.
Li-ion battery
Continuity
Terminals
13 14 Existed
YES >> GO TO 3.
junction box. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Removal and Installation" (without battery cooler models) or EVB-515, "BATTERY JUNCTION
814, "BATTERY JUNCTION BOX AND BATTERY HARNESS : Removal and Installation" (with
3.CHECK HARNESS
2. Check the continuity between VCM harness connector and Li-ion battery harness connector.
+ −
VCM Li-ion battery Continuity
E83 110 E128 14 Existed
EVC-178
P0AA6 HIGH VOLTAGE SYSTEM ISOLATION
A
Li-ion battery is equipped with the IR (Insulation resistance) sensing system. VCM receives the IR sensor sig- B
nal sent from Li-ion battery controller and monitors the insulation resistance of the high voltage circuit.
EVC
DTC DETECTION LOGIC
NOTE:
• DTC “P0AA6” is not detected when insulation resistance decreases between quick charge relay and quick D
charge port. In this case, insulation check performed by the quick charger becomes NG, resulting in no
implementation of quick charge.
• DTC “P0AA6” is not detected when insulation resistance decreases between normal charge port and PDM
E
(Power Delivery Module). In this case, the “Fault” lamp of EVSE control box blinks and normal charge does
not start even when trying to perform normal charge.
CONSULT screen terms F

HYBRID BATT VOLT SYS ISOLATION
VCM detects a insulation resistance calculated based on IR sensor signal
P0AA6 (Hybrid battery voltage system isolation G
sent from Li-ion battery is 380 kΩ or less.
fault)
POSSIBLE CAUSE
• High voltage harness or connectors H
• PTC heater
• Traction motor I
• Li-ion battery
• Battery heater J
FAIL-SAFE
• Quick charge prohibited K
• Doing READY again is prohibited.
DTC CONFIRMATION PROCEDURE L
1.PRECONDITIONING
CAUTION: M
vehicle handling. N
>> GO TO 2. O
2.PERFORM DTC CONFIRMATION PROCEDURE-1
With CONSULT P
1. Maintain the following conditions for at least 50 seconds.
Power switch READY

Shift position P range
A/C set temperature OFF
2. Check DTC.
EVC-179
Is the DTC detected?
NO >> GO TO 3.
With CONSULT
1. Maintain the following conditions for at least 30 minutes.
Power switch READY

A/C set temperature Full cold
2. Check DTC.
Is DTC detected?
NO >> GO TO 4.
With CONSULT
1. Maintain the following conditions for at least 30 minutes.
Power switch READY

A/C set temperature Full hot
2. Check DTC.
Is DTC detected?
NO >> GO TO 5.
With CONSULT
1. Shift selector lever in D position.
2. Drive the vehicle at more than 15 km (10 MPH) at least 40 seconds.
CAUTION:
Always drive vehicle at safe speed.
3. Check DTC.
Is DTC detected?
NO >> GO TO 6.
With CONSULT
1. Stop the vehicle and turn power switch OFF.
2. Connect quick charge connector.
3. Perform quick charging (charging status indicator is ON) at least 20 seconds.
4. Check DTC.
Is DTC detected?
DANGER:
EVC-180
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of A
maintenance.
B
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in EVC
• Never allow workers other than the responsible person to touch the vehicle containing high voltage D
CAUTION: E
• Erase DTC after the work is completed. F
1. CHECK HIGH VOLTAGE PART
2. Visually check that there is no damage in each high voltage part. G
YES >> GO TO 2
H
NO >> Repair or replace the error-detected part.
2.IDENTIFY THE MODE USED AT THE OCCURRENCE OF MALFUNCTION
I
On which DTC Confirmation Procedure is the DTC P0AA6 detected?
DTC Confirmation Procedure-1>>GO TO 12.
DTC Confirmation Procedure-2>>GO TO 3. J
DTC Confirmation Procedure-5>>GO TO 10. K
3.PRECONDITIONING
WARNING:
L
M
>> GO TO 4.
4.CHECK INSULATION RESISTANCE OF ELECTRIC COMPRESSOR N
Check insulation resistance of electric compressor. Refer to HAC-192, "Component Inspection".
CAUTION:
• Since testers are polarized, check the polarity of the tester and connect it in the forward direction to
O
the circuit.
• If the inspection results show no continuity, check the parts for proper installation.
P
NO >> GO TO 5.
5.CHECK REFRIGERANT GAS
Interview the customer and check maintenance records to see if there is the possibility that coolant a gas other
than EV specific refrigerant gas is mixed in A/C refrigerant gas.
NOTE:
If A/C refrigerant gas other than EV specific refrigerant gas is used, insulation resistance may decrease.
EVC-181
YES >> Replace electric compressor. Refer to HA-34, "Removal and Installation".
NO >> Change refrigerant gas and compressor oil.
6.PRECONDITIONING
WARNING:
>> GO TO 7.
7.CHECK INSULATION RESISTANCE OF PTC HEATER
Check insulation resistance of PTC heater. Refer to HAC-194, "Component Inspection".
CAUTION:
the circuit.
YES >> Check intermittent incident. Refer to GI-47, "Intermittent Incident".
NO >> Replace PTC heater. Refer to HAC-215, "Removal and Installation".
8.PRECONDITIONING
WARNING:
>> GO TO 9.
9.CHECK INSULATION RESISTANCE OF TRACTION MOTOR INVERTER
Check insulation resistance of traction motor inverter. Refer to TMS-101, "Component Inspection".
CAUTION:
the circuit.
YES >> Replace traction motor inverter. Refer to TMS-106, "Removal and Installation".
NO >> Replace traction motor. Refer to TMS-112, "Removal and Installation".
10.PRECONDITIONING
WARNING:
>> GO TO 11.
11.CHECK INSULATION RESISTANCE OF PDM (POWER DELIVERY MODULE)
Check insulation resistance of PDM (Power Delivery Module). Refer to VC-98, "Diagnosis Procedure".
CAUTION:
the circuit.
NO >> Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation".
EVC-182
12.PRECONDITIONING A
WARNING:
1. Disconnect high voltage circuit. Refer to GI-27, "How to Disconnect High Voltage". B
>> GO TO 13. EVC

13.CHECK INSULATION RESISTANCE OF HIGH VOLTAGE HARNESS
WARNING: D
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 E
1. Disconnect Li-ion battery high voltage harness connector (H17).
2. Check the insulation resistance of high voltage harness with an insulation resistance tester (Multi tester), F
between Li-ion battery and PDM (Power Delivery Module).
CAUTION:
• Use 500 V range of insulation resistance tester to measure insulation resistance.
• Wait for 30 seconds until the value becomes stable. G
+ H
Li-ion battery − Resistance
Connector Terminal
I
37
H17 Ground 5.6 MΩ
38
YES >> GO TO 19.
NO >> GO TO 14.
14.CHECK INSULATION RESISTANCE OF ELECTRIC COMPRESSOR K
Check insulation resistance of electric compressor. Refer to HAC-192, "Component Inspection".

CAUTION:
L
the circuit.
Is the inspection result normal? M
YES >> GO TO 16.
NO >> GO TO 15.
15.CHECK REFRIGERANT GAS N
Interview the customer and check maintenance records to see if there is the possibility that coolant a gas other
than EV specific refrigerant gas is mixed in A/C refrigerant gas. O
NOTE:
P
YES >> Replace electric compressor. Refer to HA-34, "Removal and Installation".
NO >> Change refrigerant gas and compressor oil.
1. Remove high voltage harness, normal charge port, and quick charge port from PDM (Power Delivery
Module). Refer to VC-114, "Disassembly and Assembly".
2. Check insulation resistance of PDM (Power Delivery Module). Refer to VC-98, "Diagnosis Procedure".
CAUTION:
EVC-183
• Since testers are polarized, check the polarity of the tester and connect it in the forward direc-
tion to the circuit.
YES >> GO TO 17.
17.CHECK INSULATION RESISTANCE OF TRACTION MOTOR
Check insulation resistance of traction motor. Refer to TMS-101, "Component Inspection".
CAUTION:
the circuit.
YES >> GO TO 18.
NO >> Replace traction motor. Refer to TMS-106, "Removal and Installation".
18.CHECK INSULATION RESISTANCE OF TRACTION MOTOR INVERTER
Check insulation resistance of traction motor inverter. Refer to TMS-103, "Component Inspection".
CAUTION:
the circuit.
YES >> Replace high voltage harness between PDM (Power Delivery Module) and Li-ion battery.
NO >> Replace traction motor inverter. Refer to TMS-106, "Removal and Installation".
19.CHECK INSULATION RESISTANCE OF PTC HEATER
Check insulation resistance of PTC heater. Refer to HAC-194, "Component Inspection".
CAUTION:
the circuit.
YES-2 >> Without battery heater: GO TO 21.
NO >> Replace PTC heater. Refer to HAC-215, "Removal and Installation".
20.CHECK INSULATION RESISTANCE OF BATTERY HEATER
Check insulation resistance of Battery heater. Refer to EVB-776, "Diagnosis Procedure".
CAUTION:
the circuit.
YES >> GO TO 21.
NO >> Replace Battery heater. Refer to EVB-820, "LI-ION BATTERY HEATER & COOLING UNIT :
21.CHECK INSULATION RESISTANCE OF LI-ION BATTERY
Check insulation resistance of Li-ion battery. Refer to EVB-180, "Component Inspection" (without battery
cooler models) or EVB-459, "Component Inspection" (with battery cooler models) or EVB-752, "Component
Inspection" (with battery heater & cooler models).
CAUTION:
the circuit.
EVC-184
NO >> Repair or replace error-detected parts. A
EVC
EVC-185
P1550, P1551, P1552 BATTERY CURRENT SENSOR
DTC DETECTION LOGIC

BATTERY CURRENT SENSOR The output voltage of the battery current sensor remains within the speci-
P1550
(Battery current sensor) fied range during READY or charging.
P1551 An excessively low voltage from the sensor is sent to VCM.
(Battery current sensor)
P1552 An excessively high voltage from the sensor is sent to VCM.
(Battery current sensor)
POSSIBLE CAUSE
• Harness or connectors (Battery current sensor circuit is open or shorted.)
• Battery current sensor
FAIL-SAFE
Not applicable
If DTC P1550, P1551 or P1552 is displayed with DTC P31E5, first perform the trouble diagnosis for DTC
P31E5.
YES >> Perform diagnosis of applicable. Refer to EVC-351, "DTC Description".
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
Is DTC detected?
NO >> GO TO 4.
CAUTION:
vehicle handling.
2. Maintain the following conditions for at least 60 seconds.
Power switch READY

Selector lever P range
EVC-186
Brake pedal Fully released
A
Ambient air temperature 10°C (50°F) or more
Is DTC detected? B
NO-2 >> Confirmation after repair: INSPECTION END EVC
1.CHECK DTC PRIORITY D

If DTC P1550, P1551 or P1552 is displayed with DTC P31E5, first perform the trouble diagnosis for DTC
P31E5.
Is applicable DTC detected? E
NO >> GO TO 2.
F
2.CHECK BATTERY CURRENT SENSOR POWER SUPPLY-1
2. Disconnect battery current sensor harness connector. G
4. Check the voltage between battery current sensor harness connector terminals.
H
Battery current sensor
Voltage
+ −
Connector (Approx.)
Terminal I
E119 4 2 5V
J
YES >> GO TO 8.
NO >> GO TO 3.
3.CHECK BATTERY CURRENT SENSOR POWER SUPPLY-2 K
Check the voltage between battery current sensor harness connector and ground.
+ L
Voltage
(Approx.)
Connector Terminal
M
E119 4 Ground 5V
YES >> GO TO 4. N
NO >> GO TO 6.
1. Turn power switch OFF. O
P
EVC-187
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
YES >> GO TO 5.
5.CHECK BATTERY CURRENT SENSOR GROUND CIRCUIT
1. Check the continuity between battery current sensor harness connector and VCM harness connector.
+ −
Battery current sensor VCM Continuity
2. Also check harness for short to power.
6.CHECK BATTERY CURRENT SENSOR POWER SUPPLY CIRCUIT
3. Check the continuity between VCM harness connector and battery current sensor harness connector.
− +
YES >> GO TO 7.
Check harness for short to power and short to ground, between the following terminals.
VCM Sensor
E82 45 Accelerator pedal position sensor 2 E101 2
YES >> Perform the trouble diagnosis for power supply circuit. Refer to EVC-128, "VCM : Diagnosis Pro-
cedure".
EVC-188
8.CHECK BATTERY CURRENT SENSOR INPUT SIGNAL CIRCUIT A
B
+ −
Battery current sensor VCM Continuity EVC
D
4. Also check harness for short to ground and to power.
YES >> GO TO 9. E
NO >> Repair or replace error-detected parts
Check the battery current sensor. Refer to EVC-189, "Component Inspection". F
NO >> Replace battery current sensor. Refer to PG-117, "Removal and Installation". G
H
2. Reconnect harness connectors disconnected. I
3. Disconnect battery negative cable.
4. Install jumper cable between battery negative terminal and body
ground.
5. Turn power switch ON. J
6. Check the voltage between VCM harness connector terminals.
JPBIA3286ZZ
VCM
Voltage
+ - N
Connector (Approx.)
Terminal
42
E82 43 2.5 V
(Battery current sensor signal) O
Before measuring the terminal voltage, confirm that the battery is fully charged. Refer to PG-103, "How to Handle 12V Battery".
YES >> INSPECTION END P
NO >> Replace battery current sensor. Refer to PG-117, "Removal and Installation".
EVC-189
P1554 BATTERY CURRENT SENSOR
DTC DETECTION LOGIC

BATTERY CURRENT SENSOR The output voltage of the battery current sensor is lower than the specified
P1554
(Battery current sensor) value while the battery voltage is high enough.
POSSIBLE CAUSE
• Harness or connectors (Battery current sensor circuit is open or shorted.)
• Battery current sensor
FAIL-SAFE
Not applicable
If DTC P1554 is displayed with DTC P31E5, first perform the trouble diagnosis for DTC P31E5.
NO >> GO TO 2.
2.PERFORM COMPONENT FUNCTION CHECK
NOTE:
Use component function check to check the overall function of the battery current sensor circuit. During this
check, a DTC might not be confirmed.
TESTING CONDITION:
• Before performing the following procedure, confirm that battery voltage is more than 12.8 V while
power switch ON.
• Before performing the following procedure, confirm that all load switches and A/C switch are turned
OFF.
VCM
+ - Voltage
Connector
Terminal Terminal
42 Above 2.37 V at
E82 43
(Battery current sensor signal) least once
YES-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident".
YES-2 >> Confirmation after repair: INSPECTION END
NO >> Proceed to EVC-190, "Diagnosis Procedure".

NO >> GO TO 2.
2.CHECK BATTERY CURRENT SENSOR POWER SUPPLY-1
EVC-190
2. Disconnect battery current sensor harness connector. A
4. Check the voltage between battery current sensor harness connector terminals.
B
Voltage
+ −
Connector (Approx.)
Terminal EVC
E119 4 2 5V
D
YES >> GO TO 8.
NO >> GO TO 3.
3.CHECK BATTERY CURRENT SENSOR POWER SUPPLY-2 E
Check the voltage between battery current sensor harness connector and ground.
+ F
Voltage
(Approx.)
Connector Terminal
G
E119 4 Ground 5V
YES >> GO TO 4. H
NO >> GO TO 6.
I
J
+
VCM − Continuity
K
Connector Terminal
4
E81
8 L
Ground Existed
111
E83
112
M
YES >> GO TO 5.
NO >> Repair or replace error-detected parts. N
5.CHECK BATTERY CURRENT SENSOR GROUND CIRCUIT
O
+ −
P
EVC-191
6.CHECK BATTERY CURRENT SENSOR POWER SUPPLY CIRCUIT
3. Check the continuity between VCM harness connector and battery current sensor harness connector.
− +
YES >> GO TO 7.
Check harness for short to power and short to ground, between the following terminals.
VCM Sensor
E82 45 Accelerator pedal position sensor 2 E101 2
cedure".
8.CHECK BATTERY CURRENT SENSOR INPUT SIGNAL CIRCUIT
+ −
4. Also check harness for short to ground and to power.
YES >> GO TO 9.
Check the battery current sensor. Refer to EVC-192, "Component Inspection".

2. Reconnect harness connectors disconnected.
EVC-192
3. Disconnect battery negative cable.
4. Install jumper cable between battery negative terminal and body A
ground.
B
EVC
JPBIA3286ZZ D
VCM E
Voltage
+ -
Connector (Approx.)
Terminal
F
42
E82 43 2.5 V
(Battery current sensor signal)
Before measuring the terminal voltage, confirm that the battery is fully charged. Refer to PG-103, "How to Handle 12V Battery".
G
NO >> Replace battery current sensor. Refer to PG-117, "Removal and Installation". H
EVC-193
P1556, P1557 BATTERY TEMPERATURE SENSOR
DTC DETECTION LOGIC

BATTERY TEMPERATURE SENSOR Signal voltage from Battery temperature sensor remains 0.1 V or less for 5
P1556
(Battery temperature sensor) seconds or more.
BATTERY TEMPERATURE SENSOR Signal voltage from Battery temperature sensor remains 4.84 V or more for
P1557
(Battery temperature sensor) 5 seconds or more.
POSSIBLE CAUSE
• Harness or connectors [Battery current sensor (Battery temperature sensor) circuit is shorted.]
• Battery current sensor (Battery temperature sensor)
FAIL-SAFE
Not applicable
If DTC P1556 or P1557 is displayed with DTC P31E5, first perform the trouble diagnosis for DTC P31E5.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
1. Turn power switch ON at least 10 seconds.
Is DTC detected?

NO >> GO TO 2.
2.CHECK BATTERY TEMPERATURE SENSOR POWER SUPPLY
EVC-194
4. Check the voltage between battery current sensor harness connector and ground. A
+
Voltage B
(Approx.)
Connector Terminal
E119 3 Ground 5V
EVC
YES >> GO TO 4.
NO >> GO TO 3. D
3.CHECK BATTERY TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
2. Disconnect VCM harness connector. E
+ − F
G
Is the inspection result normal? H
cedure".
NO >> Repair or replace error-detected parts. I
4.CHECK BATTERY TEMPERATURE SENSOR GROUND CIRCUIT
J
K
+ −
Connector Terminal Connector Terminal L
YES >> GO TO 5.
N
5.CHECK BATTERY TEMPERATURE SENSOR
Check the battery temperature sensor. Refer to EVC-195, "Component Inspection".
P

3. Check the resistance between battery current sensor connector terminals.
EVC-195

+ − Condition Resistance
Terminal
3 2 Temperature: 25°C (77°F) 1.9 – 2.1 kΩ
NO >> Replace battery current sensor (with battery temperature sensor). Refer to PG-117, "Removal and
Installation".
EVC-196
P155A BATTERY TEMPERATURE SENSOR
A

BATTERY TEMPERATURE SENSOR A ambient temperature of 12V battery remains 50°C (122°F) or more for 10
P155A
(Battery temperature sensor) seconds or more.
POSSIBLE CAUSE D
• Harness or connectors [Battery current sensor (Battery temperature sensor) circuit is shorted.]
• Battery current sensor (Battery temperature sensor)
E
FAIL-SAFE
Not applicable
DTC CONFIRMATION PROCEDURE F
If DTC P155A is displayed with DTC P31E5, first perform the trouble diagnosis for DTC P31E5.
G
NO >> GO TO 2. H
2.PRECONDITIONING
CAUTION: I
vehicle handling. J
>> GO TO 3. K
With CONSULT
1. Drive the vehicle under the following conditions. L
Coolant temperature Less than 20°C (68°F)

M
Vehicle speed 20 km/h (13 MPH) or more
Is DTC detected? N
NO-2 >> Confirmation after repair: INSPECTION END O
1.CHECK DTC PRIORITY P

If DTC P155A is displayed with DTC P31E5, first perform the trouble diagnosis for DTC P31E5.
NO >> GO TO 2.
2.CHECK BATTERY TEMPERATURE SENSOR POWER SUPPLY
EVC-197
4. Check the voltage between battery current sensor harness connector and ground.
+
Voltage
(Approx.)
Connector Terminal
E119 3 Ground 5V
YES >> GO TO 4.
NO >> GO TO 3.
3.CHECK BATTERY TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
+ −
cedure".
4.CHECK BATTERY TEMPERATURE SENSOR GROUND CIRCUIT
+ −
YES >> GO TO 5.
Check the battery temperature sensor. Refer to EVC-198, "Component Inspection".

EVC-198
3. Check the resistance between battery current sensor connector terminals.
A
+ − Condition Resistance
B
Terminal
3 2 Temperature: 25°C (77°F) 1.9 – 2.1 kΩ
NO >> Replace battery current sensor (with battery temperature sensor). Refer to PG-117, "Removal and
Installation". D
EVC-199
P1564 ASCD STEERING SWITCH
DTC DETECTION LOGIC

• An excessively high voltage signal from the ASCD steering switch is sent
to VCM.
ASCD SWITCH
P1564 • VCM detects that input signal from the ASCD steering switch is out of the
(ASCD switch)
specified range.
• VCM detects that the ASCD steering switch is stuck ON.
POSSIBLE CAUSE
• Harness or connectors (The switch circuit is open or shorted.)
• ASCD steering switch
• VCM
FAIL-SAFE
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Press CANCEL switch for at least 10 seconds, then release it and wait at least 10 seconds.
3. Press RESUME/ACCELERATE switch for at least 10 seconds, then release it and wait at least 10 sec-
onds.
4. Press SET/COAST switch for at least 10 seconds, then release it and wait at least 10 seconds.
5. Press ASCD MAIN switch, then release it and wait at least 10 seconds.
6. Wait for at least 60 seconds.
Is DTC detected?
1.CHECK ASCD STEERING SWITCH CIRCUIT

With CONSULT
2. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “ASCD MAIN SW”, “SL MAIN SW”,
“ASCD CANCEL SW”, “RESUME/ACC SW”, “ASCD SET SW”.
3. Check each item indication under the following conditions.
EVC-200
Monitor item Condition Indication A

Pressed On
ASCD MAIN SW ASCD MAIN switch
Released Off
B
Pressed On
SL MAIN SW Speed limiter MAIN switch
Released Off
ASCD CANCEL Pressed On EVC

CANCEL switch
SW Released Off
RESUME/ACCELERATE Pressed On
RESUME/ACC SW
switch
D
Released Off
Pressed On
ASCD SET SW SET/COAST switch
Released Off E
NO >> GO TO 2. F
2.CHECK SPEED LIMITER MAIN SWITCH AND ASCD MAIN SWITCH POWER SUPPLY
1. Turn power switch OFF. G
2. Disconnect spiral cable harness connector.
4. Check the voltage between spiral cable harness connector and ground.
H
+
Spiral cable − Voltage
I
Connector Terminal
M32 21 Ground Battery voltage
YES >> GO TO 4.
NO >> GO TO 3.
3.CHECK SPEED LIMITER MAIN SWITCH AND ASCD MAIN SWITCH POWER SUPPLY CIRCUIT K

2. Pull out #15 fuse. L
3. Check that the fuse is not fusing.
4. Check the continuity between spiral cable harness connector and fuse terminal.
M
+
Spiral cable − Continuity
Connector Terminal N
#15 fuse termi-
M32 21 Existed
nal
5. Also check harness for short to ground. O
YES >> Perform trouble diagnosis for power ON power supply circuit.
NO >> Repair or replace error-detected parts. P
4.CHECK SPEED LIMITER MAIN SWITCH INPUT SIGNAL CIRCUIT
3. Check the continuity between spiral cable harness connector and VCM harness connector.
EVC-201
+ −
Spiral cable VCM Continuity
YES >> GO TO 5.
5.CHECK ASCD MAIN SWITCH INPUT SIGNAL CIRCUIT
+ −
YES >> GO TO 6.
6.CHECK ASCD STEERING SWITCH GROUND CIRCUIT
+ −
YES >> GO TO 7.
7.CHECK ASCD STEERING SWITCH INPUT SIGNAL CIRCUIT
+ −
YES >> GO TO 8.
8.CHECK ASCD STEERING SWITCH
Check ASCD steering switch. Refer to EVC-203, "Component Inspection (ASCD Steering Switch)".
NO >> Replace ASCD steering switch. Refer to SR-21, "Exploded View".
EVC-202
Component Inspection (ASCD Steering Switch) INFOID:0000000010410199
A
2. Disconnect spiral cable harness connector. B
3. Check resistance between spiral cable harness connector terminals under the following conditions.
Combination switch EVC

Condition Continuity
Connector Terminals
Pressed Existed
35 and 36 Speed limiter MAIN switch D
Released Not existed
M303
Pressed Existed
35 and 37 ASCD MAIN switch
Released Not existed E
YES >> GO TO 2.
NO >> Replace ASCD steering switch. Refer to SR-21, "Exploded View". F

Check resistance between spiral cable harness connector terminals under the following conditions. G
Combination switch
Condition Resistance (Ω) H
Connector Terminals
CANCEL switch: Pressed Approx. 249
SET/COAST switch: Pressed Approx. 412
M302 13 and 16 I
RESUME/ACCELERATE switch: Pressed Approx. 825
All ASCD steering switches: Released Approx. 2,490
NO >> Replace ASCD steering switch. Refer to SR-21, "Exploded View".
K
EVC-203
P1572 BRAKE PEDAL POSITION SWITCH
DTC DETECTION LOGIC

When the vehicle speed is above 30 km/h (19 MPH), ON signals from
A the stop lamp switch and the brake pedal position switch are sent to the
ASCD BRAKE SWITCH VCM at the same time.
P1572
(ASCD brake switch)
Brake pedal position switch signal is not sent to VCM for extremely long
B
time while the vehicle is being driven.
POSSIBLE CAUSE
• Harness or connectors (The stop lamp switch circuit is shorted.)
• Harness or connectors (The brake pedal position switch circuit is shorted.)
• Stop lamp switch
• Brake pedal position switch
• Incorrect stop lamp switch installation
• Incorrect brake pedal position switch installation
• VCM
FAIL-SAFE
1.PRECONDITIONING
CAUTION:
vehicle handling.
With ASCD system>>GO TO 2.

Without ASCD system>>GO TO 4.
With CONSULT
1. Turn power switch ON (VDC switch OFF).
2. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “VEHICLE SPEED” and “GEAR
POSITION”.
3. Press ASCD MAIN switch and check that CRUISE indicator illuminates.
4. Drive the vehicle for at least 5 consecutive seconds under the following conditions.
CAUTION:
VEHICLE SPEED More than 30 km/h (19 MPH)

GEAR POSITION D
Is DTC detected?
NO >> GO TO 3.
With CONSULT
EVC-204
1. Drive the vehicle for at least 5 consecutive seconds under the following conditions.
CAUTION: A
NOTE:
This procedure may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a
B
road test is expected to be easier, it is unnecessary to lift the vehicle.
VEHICLE SPEED More than 30 km/h (19 MPH)

EVC
GEAR POSITION D or R
Depress the brake pedal for more than 5
Driving location seconds so as not to come off from the
D
above-mentioned vehicle speed.
Is DTC detected? E
NO >> GO TO 4.
4.PERFORM COMPONENT FUNCTION CHECK F
With CONSULT
2. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “ASCD BRAKE SW” and “STOP G
LAMP SW”.
3. Check the indication under the following conditions.
H
Item Condition Indication
Slightly de-
ASCD BRAKE Off
pressed I
SW
Fully released On
Brake pedal
Slightly de-
STOP LAMP On J
pressed
SW
Fully released Off
Is the inspection result normal? K
L
1.CHECK OVERALL FUNCTION-1 M

With CONSULT
2. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “ASCD BRAKE SW”. N
3. Check “ASCD BRAKE SW” indication under the following conditions.
Monitor item Condition Indication O

Slightly de-
ASCD BRAKE Off
Brake pedal pressed
SW
Fully released On P
YES >> GO TO 7.
NO >> GO TO 2.
2.CHECK BRAKE PEDAL POSITION SWITCH
Check brake pedal position switch. Refer to EVC-208, "Component Inspection (Brake Pedal Position Switch)"
EVC-205
YES >> GO TO 3.
NO >> Replace brake pedal position switch. Refer to BR-444, "Removal and Installation" (LHD models)
or BR-924, "Removal and Installation" (RHD models).
3.CHECK BRAKE PEDAL POSITION SWITCH POWER SUPPLY
2. Disconnect brake pedal position switch harness connector.
4. Check the voltage between brake pedal position switch harness connector and ground.
+
Brake pedal position switch − Voltage
Connector Terminal
E40 1 Ground Battery voltage
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK BRAKE PEDAL POSITION SWITCH POWER SUPPLY CIRCUIT
4. Check the continuity between brake pedal position switch harness connector and fuse terminal.
+
Brake pedal position switch − Continuity
Connector Terminal
#14 fuse termi-
E40 1 Existed
nal
YES >> Perform trouble diagnosis for power ON power supply circuit.
5.CHECK BRAKE PEDAL POSITION SWITCH SIGNAL
2. Install the brake pedal position switch. Refer to BR-444, "Removal and Installation" (LHD models) or BR-
924, "Removal and Installation" (RHD models).
3. Reconnect brake pedal position switch harness connector.
NOTE:
Brake pedal is fully released.
+
VCM − Voltage
Connector Terminal
NO >> GO TO 6.
EVC-206
6.CHECK BRAKE PEDAL POSITION SWITCH INPUT SIGNAL CIRCUIT A
3. Check the continuity between brake pedal position switch harness connector and VCM harness connec-
B
tor.
+ −
EVC
Brake pedal position switch VCM Continuity
E40 2 E81 15 Existed D
E
7.CHECK OVERALL FUNCTION-2 F
With CONSULT
Select “STOP LAMP SW” and check indication under the following conditions.
G
Monitor item Condition Indication
Slightly de-
STOP LAMP On
Brake pedal pressed H
SW
Fully released Off
I
NO >> GO TO 8.
8.CHECK STOP LAMP SWITCH J
Refer to EVC-209, "Component Inspection (Stop Lamp Switch)"
YES >> GO TO 9. K
NO >> Replace stop lamp switch. Refer to BR-444, "Removal and Installation" (LHD models) or BR-924,
"Removal and Installation" (RHD models).
9.CHECK STOP LAMP SWITCH POWER SUPPLY L

2. Disconnect stop lamp switch harness connector.
3. Check the voltage between stop lamp switch harness connector and ground. M
+
N
Stop lamp switch − Voltage
Connector Terminal
E102 3 Ground Battery voltage O
YES >> GO TO 11.
NO >> GO TO 10. P
10.CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
3. Check the continuity between stop lamp switch harness connector and fuse terminal.
EVC-207
+
Stop lamp switch − Continuity
Connector Terminal
#43 fuse termi-
E102 3 Existed
nal
YES >> Perform trouble diagnosis for 12V battery power supply circuit.
11.CHECK STOP LAMP SWITCH SIGNAL
2. Install the stop lamp switch. Refer to BR-444, "Removal and Installation" (LHD models) or BR-924,
3. Reconnect stop lamp switch harness connector.
5. Depress the brake pedal.
+
VCM − Voltage
Connector Terminal
NO >> GO TO 12.
12.CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT
2. Check the continuity between stop lamp switch harness connector and VCM harness connector.
+ −
Stop lamp switch VCM Continuity
Component Inspection (Brake Pedal Position Switch) INFOID:0000000010410203
1.CHECK BRAKE PEDAL POSITION SWITCH-1

3. Check the continuity between brake pedal position switch terminals under the following conditions.
Terminals Condition Continuity

Fully released Existed
1 and 2 Brake pedal Slightly de-
Not existed
pressed
EVC-208
YES >> INSPECTION END A
NO >> GO TO 2.
2.CHECK BRAKE PEDAL POSITION SWITCH-2
B
1. Adjust brake pedal position switch installation. Refer to BR-432, "Inspection and Adjustment" (LHD mod-
els) or BR-912, "Inspection and Adjustment" (RHD models).
2. Check the continuity between brake pedal position switch terminals under the following conditions.
EVC
Fully released Existed
D
1 and 2 Brake pedal Slightly de-
Not existed
pressed
NO >> Replace brake pedal position switch. Refer to BR-444, "Removal and Installation" (LHD models)
or BR-924, "Removal and Installation" (RHD models). F
Component Inspection (Stop Lamp Switch) INFOID:0000000010410204
1.CHECK STOP LAMP SWITCH-1 G

3. Check the continuity between stop lamp switch terminals under the following conditions. H

I
Fully released Not existed
3 and 4 Brake pedal
Slightly depressed Existed
NO >> GO TO 2.
2.CHECK STOP LAMP SWITCH-2 K
1. Adjust stop lamp switch installation. Refer to BR-432, "Inspection and Adjustment" (LHD models) or BR-
912, "Inspection and Adjustment" (RHD models).
2. Check the continuity between stop lamp switch terminals under the following conditions. L

M
3 and 4 Brake pedal
"Removal and Installation" (RHD models). O
EVC-209
P1574 ASCD VEHICLE SPEED SENSOR
The VCM receives two vehicle speed sensor signals via CAN communication. One is sent from the hydraulic
brake actuation module, and the other is from the traction motor inverter (motor speed signal). The VCM uses
these signals for ASCD control. Refer to EVC-52, "AUTOMATIC SPEED CONTROL DEVICE (ASCD) : Sys-
tem Description" for ASCD functions.
DTC DETECTION LOGIC

ASCD VEHICLE SPEED SENSOR The difference between the two vehicle speed signals is out of the specified
P1574
(ASCD vehicle speed sensor) range.
POSSIBLE CAUSE
• Hydraulic brake actuation module
• Traction motor
• VCM
FAIL-SAFE
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Push the VDC OFF switch to stop the VDC control.
3. Drive the vehicle at more than 40 km/h (25 MPH).
CAUTION:
Is DTC detected?
1.CHECK DTC IN TRACTION MOTOR INVERTER

Check DTC in traction motor inverter.
YES >> GO TO 2.
NO >> Check the DTC. Refer to TMS-34, "DTC Index".
EVC-210
2.CHECK DTC IN HYDRAULIC BRAKE ACTUATION MODULE A
Check DTC in hydraulic brake actuation module.
YES >> GO TO 3. B
NO >> Check the DTC. Refer to BR-47, "DTC Index" (LHD models) or BR-527, "DTC Index" (RHD mod-
els).
3.CHECK INTERMITTENT INCIDENT EVC
Check intermittent incident. Refer to GI-47, "Intermittent Incident".
D
EVC-211
P1805 BRAKE SWITCH
P1805 BRAKE SWITCH
DTC DETECTION LOGIC

BRAKE SWITCH Stop lamp signal is not sent to VCM for extremely long time while the vehi-
P1805
(Brake switch) cle is driving.
POSSIBLE CAUSE
• Harness or connectors (Stop lamp switch circuit is open or shorted.)
• Stop lamp switch
FAIL-SAFE
Not applicable
NOTE:
Since this DTC is difficult to be confirmed, check component function to judge the normality.
>> GO TO 2.
With CONSULT
1. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “STOP LAMP SW”.
2. Check “STOP LAMP SW” indication under the following conditions.

Slightly depressed ON
STOP LAMP SW Brake pedal
Fully released OFF

1.CHECK STOP LAMP SWITCH OPERATION

2. Check the stop lamp when depressing and releasing the brake pedal.
Brake pedal Stop lamp

Fully released OFF
Slightly depressed ON
YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK STOP LAMP SWITCH
Check stop lamp switch. Refer to EVC-213, "Component Inspection (Stop Lamp Switch)".
EVC-212
P1805 BRAKE SWITCH
YES >> GO TO 3.
NO >> Replace stop lamp switch. Refer to BR-444, "Removal and Installation" (LHD models) or BR-924, A
3.CHECK STOP LAMP SWITCH POWER SUPPLY
B
2. Check the voltage between stop lamp switch harness connector and ground.
EVC
+
Stop lamp switch − Voltage
Connector Terminal D
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT F

2. Check that the fuse is not fusing. G
3. Check the continuity between stop lamp switch harness connector and fuse terminal.
+ H
Stop lamp switch − Continuity
Connector Terminal
#43 fuse I
E102 3 Existed
terminal
YES >> Perform trouble diagnosis for 12V battery power supply circuit.
K
5.CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT
2. Disconnect VCM harness connector. L
3. Check the continuity between stop lamp switch harness connector and VCM harness connector.
+ − M
Stop lamp switch VCM Continuity
E102 4 E81 18 Existed N

Component Inspection (Stop Lamp Switch) INFOID:0000000010410211 P
1.CHECK STOP LAMP SWITCH-1

3. Check the continuity between stop lamp switch terminals under the following conditions.
EVC-213
P1805 BRAKE SWITCH

3 and 4 Brake pedal
NO >> GO TO 2.
2.CHECK STOP LAMP SWITCH-2
1. Adjust stop lamp switch installation. Refer to BR-432, "Inspection and Adjustment" (LHD models) or BR-
912, "Inspection and Adjustment" (RHD models).
2. Check the continuity between stop lamp switch terminals under the following conditions.

3 and 4 Brake pedal
EVC-214
P2122, P2123 APP SENSOR
A

APP SENSOR D
An excessively low voltage from the accelerator pedal position sensor 1 is
P2122 (Throttle/Pedal position sensor/switch “D”
sent to VCM.
circuit low)
D
APP SENSOR D
An excessively high voltage from the accelerator pedal position sensor 1 is
P2123 (Throttle/Pedal position sensor/switch “D”
sent to VCM.
circuit high)
E
POSSIBLE CAUSE
• Harness or connectors (APP sensor 1 circuit is open or shorted.)
• Accelerator pedal position sensor 1 F
FAIL-SAFE
• Reduced responsiveness during accelerator operation G
YES >> Perform diagnosis of applicable. Refer to EVC-351, "DTC Description". I
NO >> GO TO 2.
2.PRECONDITIONING
J
CAUTION:
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the K
vehicle handling.
L
>> GO TO 3.
3.PERFORM DTC CONFIRMATION PROCEDURE M
With CONSULT
1. Turn power switch ON and wait at least 1 second.
N
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". O
P
NO >> GO TO 2.
EVC-215
2.CHECK APP SENSOR 1 POWER SUPPLY-1
2. Disconnect accelerator pedal position (APP) sensor harness connector.
4. Check the voltage between APP sensor harness connector terminals.
APP sensor
Voltage
+ −
Connector (Approx.)
Terminal
E101 3 5 5V
YES >> GO TO 7.
NO >> GO TO 3.
Check the voltage between APP sensor harness connector and ground.
+
Voltage
APP sensor −
(Approx.)
Connector Terminal
E101 3 Ground 5V
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK APP SENSOR POWER SUPPLY CIRCUIT
3. Check the continuity between APP sensor harness connector and VCM harness connector.
+ −
APP sensor VCM Continuity
4. Also check harness for short to ground and snort to power.
YES >> Check VCM power supply circuit. Refer to EVC-128, "VCM : Diagnosis Procedure".
5.CHECK APP SENSOR GROUND CIRCUIT
+ −
4. Also check harness for snort to power.
YES >> GO TO 6.
EVC-216
6.CHECK VCM GROUND CIRCUIT A

B
+
VCM − Continuity
Connector Terminal EVC
4
E81
8
Ground Existed D
111
E83
112
7.CHECK APP SENSOR SIGNAL CIRCUIT F

3. Check the continuity between APP sensor harness connector and VCM harness connector. G
+ −
H
E101 4 E82 38 Existed I
J
YES >> GO TO 8.
8.CHECK APP SENSOR K
Refer to EVC-217, "Component Inspection (Accelerator Pedal Position Sensor)".
YES >> INSPECTION END L
NO >> Replace Accelerator pedal. Refer to ACC-5, "Removal and Installation".
Component Inspection (Accelerator Pedal Position Sensor) INFOID:0000000010410214
M
1.CHECK ACCELERATOR PEDAL POSITION (APP) SENSOR
2. Reconnect all harness connectors disconnected.
4. Check the voltage VCM harness connector terminals under the following conditions.
O
VCM
+ – Condition Voltage (V)
Connector P
Terminal Terminal
Fully released 0.45 - 1.0
38 (APP sensor 1) 39
Fully depressed 4.4 - 4.8
E82 Accelerator pedal
EVC-217
NO >> Replace accelerator pedal. Refer to ACC-5, "Removal and Installation".
EVC-218
A

APP SENSOR E
P2127 (Throttle/Pedal position sensor/switch “E” An excessively low voltage from the APP sensor 2 is sent to VCM.
circuit low)
D
APP SENSOR E
P2128 (Throttle/Pedal position sensor/switch “E” An excessively high voltage from the APP sensor 2 is sent to VCM.
circuit high)
E
POSSIBLE CAUSE
• Harness or connectors (Accelerator pedal position sensor 2 circuit is shorted.)
• Accelerator pedal position sensor 2 F
FAIL-SAFE
• Reduced responsiveness during accelerator operation G
YES >> Perform diagnosis of applicable. Refer to EVC-351, "DTC Description". I
NO >> GO TO 2.
2.PRECONDITIONING
J
CAUTION:
vehicle handling.
L
>> GO TO 3.
Is DTC detected? N
O
1.CHECK DTC PRIORITY P

NO >> GO TO 2.
EVC-219
2. Disconnect accelerator pedal position (APP) sensor harness connector.
4. Check the voltage between APP sensor harness connector terminals.
APP sensor
Voltage
+ −
Connector (Approx.)
Terminal
E101 2 6 5V
YES >> GO TO 7.
NO >> GO TO 3.
Check the voltage between APP sensor harness connector and ground.
+
Voltage
APP sensor −
(Approx.)
Connector Terminal
E101 2 Ground 5V
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK APP SENSOR POWER SUPPLY CIRCUIT
+ −
Procedure".
5.CHECK APP SENSOR GROUND CIRCUIT
+ −
4. Also check harness for snort to power.
YES >> GO TO 6.
EVC-220
6.CHECK VCM GROUND CIRCUIT A
+ B
VCM − Continuity
Connector Terminal
EVC
4
E81
8
Ground Existed
111 D
E83
112
YES >> INSPECTION END E
7.CHECK APP SENSOR SIGNAL CIRCUIT F
G
+ −
APP sensor VCM Continuity H
I
YES >> GO TO 8. J
8.CHECK APP SENSOR
Check APP sensor. Refer to EVC-221, "Component Inspection (Accelerator Pedal Position Sensor)". K
NO >> Replace Accelerator pedal. Refer to ACC-5, "Removal and Installation". L
M
2. Reconnect all harness connectors disconnected. N
O
VCM
Connector
Terminal Terminal P
EVC-221
EVC-222
P2138 APP SENSOR
P2138 APP SENSOR
A

APP SENSOR
P2138 (Throttle/Pedal position sensor/switch “D” / VCM detects abnormal signal of APP sensor 1 and APP sensor 2 at a time.
“ E” voltage correlation)
D
POSSIBLE CAUSE
• Harness or connectors (APP sensor 1 or 2 circuit is open or shorted.)
• APP sensor E
FAIL-SAFE
TYPE 1 F
READY OFF
TYPE 2
• Traction motor output is limited. G
H
Is applicable DTC detected? I
NO >> GO TO 2.
2.PRECONDITIONING J
CAUTION:
vehicle handling.
• Check that 12V battery voltage is 11 V or more. L
>> GO TO 3.

N
Is DTC detected?
P
NO >> GO TO 2.
EVC-223
P2138 APP SENSOR
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
YES >> GO TO 3.
3.CHECK ACCELERATOR PEDAL POSITION (APP) SENSOR SIGNAL CIRCUIT
1. Disconnect APP sensor harness connector.
2. Check the continuity between APP sensor harness connector terminals.
APP sensor
+ − Continuity
Connector
Terminal
E101 4 1 Not existed
YES >> GO TO 4.
4.CHECK APP SENSOR
Check APP sensor. Refer to EVC-224, "Component Inspection (Accelerator Pedal Position Sensor)".
NO >> Replace Accelerator pedal. Refer to ACC-5, "Removal and Installation".

2. Reconnect all harness connectors disconnected.
VCM
Connector
Terminal Terminal
EVC-224
P2138 APP SENSOR
A
EVC
EVC-225
P3100 EV SYSTEM CAN COMMUNICATION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
DTC DETECTION LOGIC

COMMUNICATION ERROR VCM cannot receive EV system CAN communication signal from LBC and
P3100
(Communication error) traction motor inverter for 5 seconds or more when VCM starts-up.
POSSIBLE CAUSE
• LBC
• VCM
FAIL-SAFE
• READY OFF
If DTC P3100 is displayed with DTC P3191 or P3193, first perform the trouble diagnosis for DTC P3191 or
P3193.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
2. Check DTC.
Is DTC detected?
NO >> GO TO 4.
EVC-226
With CONSULT
1. Turn power switch OFF. A
2. Check that the charging status indicator is not illuminating, and wait at least 90 seconds.
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some B
vehicle handling.
3. Connect EVSE (with AC power input) and wait at least 20 seconds.
4. Turn power switch ON. EVC
5. Check DTC.
Is DTC detected?
YES >> Proceed to EVC-227, "Diagnosis Procedure". D
E

F
If DTC P3100 is displayed with DTC P3191 or P3193, first perform the trouble diagnosis for DTC P3191 or
P3193.
G
NO >> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE AGAIN H
With CONSULT
1. Erase DTC.
2. Perform DTC confirmation procedure again. Refer to EVC-226, "DTC Description". I
Is DTC“ P3100” detected again?
NO >> INSPECTION END J
EVC-227
P3101 VCM
P3101 VCM
DTC DETECTION LOGIC

VCM
P3101 VCM calculation function is malfunctioning.
(Vehicle control module)
POSSIBLE CAUSE
VCM
FAIL-SAFE
TYPE 1
READY OFF
TYPE 2
• READY OFF
TYPE 3
Not applicable
TYPE 4
• READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
NOTE:
If the vehicle does not enter the READY state, proceed to the next step with the power switch ON.
3. Shift selector lever to the entire position from “P” to “D”.
CAUTION:
vehicle handling.
CAUTION:
vehicle handling.
EVC-228
P3101 VCM
8. Check self-diagnostic result. A
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". B
EVC
1. Erase DTC.
D
E
EVC-229
P3102 LI-ION BATTERY
Li-ion Battery ID Registration must be performed if the Li-ion battery controller or VCM is replaced.
DTC DETECTION LOGIC

CAUTION:
This DTC may be detected when the Li-ion battery is replaced. If this DTC is detected, check that the
Li-ion battery is replaced by using the correct parts and method.

INVALID BATTERY
P3102 Detects invalid Li-ion battery ID.
(Invalid battery)
POSSIBLE CAUSE
• Improper replacement of Li-ion battery or Li-ion battery controller.
• Li-ion battery
• Li-ion battery controller
FAIL-SAFE
Traction motor output is limited.
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
CAUTION:
vehicle handling.
3. Check DTC.
Is DTC detected?
1.CHECK SELF-DIAGNOSTIC RESULT OF LI-ION BATTERY CONTROLLER

With CONSULT
2. Check self-diagnostic result of the “HV BAT”.
EVC-230
YES >> Check the DTC. Refer to EVB-55, "DTC Index" (without battery cooler models) or EVB-329, "DTC A
Index" (with battery cooler models) or EVB-617, "DTC Index" (with battery heater & cooler mod-
els).
NO >> GO TO 2. B
2.LI-ION BATTERY VISUALLY CHECK
CAUTION:
This DTC may be detected when the Li-ion battery is replaced. If this DTC is detected, check that the EVC
Li-ion battery is replaced by using the correct parts and method.
Visually check Li-ion battery for malfunction.
YES >> Perform Li-ion Battery ID Registration. Refer to “Li-ion Battery Registration Operation Manual”.
NO >> Replace Li-ion battery. Refer to EVB-213, "Removal and Installation" (without battery cooler mod-
els) or EVB-492, "Removal and Installation" (with battery cooler models) or EVB-788, "Removal E
and Installation" (with battery heater & cooler models).
EVC-231
P3117 A/C SYSTEM
P3117 A/C SYSTEM
This DTC shows a decrease in insulation resistance of the high voltage circuit.
When detecting a decrease in insulation resistance of the high voltage circuit during use of air-conditioner,
VCM turns ON/OFF the electric compressor and the PTC heater to check changes in insulation resistance and
identifies a decrease in insulation resistance of the air-conditioning system.
DTC DETECTION LOGIC

A/C SYSTEM
P3117 When VCM detects a decrease in insulation resistance of A/C system.
(Air conditioner system)
POSSIBLE CAUSE
• A/C refrigerant gas
• PTC heater
FAIL-SAFE
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
1. Set the vehicle as the following condition and wait at least 30 minutes.
Power switch READY

Vehicle speed 0 km/h (0 MPH)
A/C switch ON
A/C set temperature Full cold
2. Check DTC.
Is DTC detected?
YES >> Proceed to EVC-233, "Diagnosis Procedure"
NO >> GO TO 3.
With CONSULT
1. Set the vehicle as the following condition and wait at least 30 minutes.
EVC-232
P3117 A/C SYSTEM
Power switch READY A

Vehicle speed 0 km/h (0 MPH)
A/C switch ON
B
A/C set temperature Full hot
2. Check DTC.
Is DTC detected? EVC
YES >> Proceed to EVC-233, "Diagnosis Procedure"
NO-2 >> Confirmation after repair: INSPECTION END D
1.CHECK A/C REFRIGERANT GAS E
Interview the customer and check maintenance records to see if there is possibility that a refrigerant gas other
than EV specific refrigerant gas is mixed in A/C refrigerant gas.
NOTE: F
YES-1 (DTC P3117 is detected during Step 1 of DTC CONFIRMATION PROCEDURE)>>Replace electric G
compressor. Refer to HA-34, "Removal and Installation".
YES-2 (DTC P3117 is detected during Step 2 of DTC CONFIRMATION PROCEDURE)>>Replace PTC
heater. Refer to HAC-215, "Removal and Installation". H
NO >> Change A/C refrigerant gas and compressor oil.
EVC-233
P311C HIGH VOLTAGE CIRCUIT
DTC DETECTION LOGIC

Remains all of following condition for 0.2 seconds.
• Li-ion battery current: 5.5 A or more
• Input voltage to traction motor inverter: 24 V or less
• Pre-charge impossible
HIGH VOLTAGE SYSTEM • Li-ion battery current: less than 5.5 A
P311C
(High voltage system) • Input voltage to traction motor inverter: 24 V or less
• Difference between Li-ion battery voltage and input voltage to traction
motor inverter 100 V or more.
POSSIBLE CAUSE
• High voltage circuit and connector
• Li-ion battery J/B
• PTC heater
• Battery heater
FAIL-SAFE
Not applicable
If DTC P311C is displayed with DTC P0AA2, P0AA5, P31D4, P31DB, P31DC, or P31DD, first perform the
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
2. Check DTC.
EVC-234
Is DTC detected?
YES >> Proceed to EVC-235, "Diagnosis Procedure". A
B
DANGER:
EVC
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and D
maintenance.
WARNING:
E
• Be sure to wear insulating protective equipment before beginning work on the high voltage system. F
G
CAUTION:
instructed in the Service Manual. A malfunction may occur if this is not observed. H
I
If DTC P311C is displayed with DTC P0AA2, P0AA5, P31D4, P31DB, P31DC, or P31DD, first perform the
J
NO >> GO TO 2.
2.CHECK SELF-DIAGNOSTIC RESULT IN TRACTION MOTOR INVERTER K
With CONSULT
Check self-diagnostic result in “MOTOR”.
Is any DTC detected? L
YES >> Check the DTC. Refer to TMS-34, "DTC Index".
NO >> GO TO 3.
3.PRECONDITIONING M
WARNING:
Follow the instructions below before starting the procedure. N
O
>> GO TO 4.
4.CHECK HIGH VOLTAGE HARNESS CONNECTOR INSTALLATION
Check high voltage harness connectors installation condition visually and tactually. P
CAUTION:
When reconnecting the high voltage harness connector, insert it slowly and directly.
YES >> GO TO 5.
5.CHECK HIGH VOLTAGE HARNESS CONNECTOR
EVC-235
1. Disconnect high voltage harness connector from Li-ion battery.
2. Check high voltage harness connector visually and tactually.
YES >> GO TO 6.
NO >> Replace error-detected parts.
6.CHECK HIGH VOLTAGE CIRCUIT
1. Remove the bus bar cover. Refer to VC-105, "Exploded View".
2. Check the continuity between Li-ion battery harness connector
and bus bar as shown in the figure.
:Vehicle front
Li-ion battery Bus bar

Continuity
Connector Terminals Terminals
37
H17 Existed
38 JSCIA1366GB

YES >> GO TO 7.
Electric compressor
+ − Resistance
Terminal
7 8 3 kΩ or more
YES >> GO TO 8.
8.CHECK PTC HEATER
2. Check the short circuit between PTC heater terminals.
Li-ion battery
Connector
Terminal
YES >> GO TO 9.
Check the short circuit between Li-ion battery harness connector terminals.
EVC-236
Li-ion battery A
Connector
Terminal
B
PDM (Power Delivery
Module)
D
NO >> GO TO 10.
1. Remove PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation". E
nals.
F
H
JSCIA0696ZZ

YES >> GO TO 11.
tion". J
1. Remove high voltage harness from PDM (Power Delivery Module). Refer to VC-114, "Disassembly and
Assembly". K
L
Connector M
Terminal
3. Check the short circuit between high voltage harness connector (electric compressor side) and high volt- N
PDM (Power Delivery Module) O

Electric compressor H22 43 H23 42 3 kΩ or more P
YES >> GO TO 12.
12.CHECK PDM (POWER DELIVERY MODULE)
Check the short circuit between PDM (Power Delivery Module) harness connector terminals.
EVC-237

+ − Resistance
Terminal
38 39 3 kΩ or more
YES >> GO TO 13.
NO >> Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation". And then,
GO TO 16.
13.CHECK SERVICE PLUG FUSE
2. Disconnect service plug.
3. Check service plug fuse fusing.
Is the fuse is fusing?
YES >> Replace service plug. And then, GO TO 16.
NO >> GO TO 16.
Installation".

Continuity
Connector Terminal
10
LB18 Not existed
11
YES >> GO TO 15.
Battery heater
Resistance
Connector Terminal
2
3
then, GO TO 16.
EVC-238
JUNCTION BOX AND BATTERY HARNESS : Removal and Installation" (with battery heater & cooler models). A
>> INSPECTION END

B
EVC
EVC-239
P312A EV SYSTEM CAN COMMUNICATION
DTC DETECTION LOGIC

COMMUNICATION ERROR CAN communication of the EV system CAN connecting unit does not stop
P312A
(Communication error) for 25.5 seconds or more immediately before the VCM self-shutoff.
*: Used only in models with TELEMATICS system
POSSIBLE CAUSE
• LBC
• On board charger
• A/C auto amp.
• TCU (Used only in models with TELEMATICS system)
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
NOTE:
Disconnect CONSULT if it is connected.
>> GO TO 2.
With CONSULT
2. Turn power switch OFF and wait at least 1 minutes.
4. Check DTC.
Is DTC detected?
NO >> GO TO 3.
With CONSULT
EVC-240
CAUTION: A
vehicle handling.
B
4. Disconnect EVSE and wait at least 1 minutes.
6. Check DTC. EVC
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". D
E
1.CHECK VCM POWER SUPPLY-1
F
+
G
Connector Terminal
12V battery volt- H
E15 57 Ground
age
YES >> GO TO 3. I
NO >> GO TO 2.
2.CHECK FUSE J
K
YES >> Replace IPDM E/R. Refer to PCS-31, "Removal and Installation".
L
2. Disconnect VCM harness connector. M
N
+
VCM − Voltage
Connector Terminal O
12V battery volt-
E81 21 Ground
age
P
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK VCM POWER SUPPLY CIRCUIT
3. Check the continuity between VCM harness connector and IPDM E/R harness connector.
EVC-241
+ −
5.CHECK TRACTION MOTOR INVERTER POWER SUPPLY (POWER ON) CIRCUIT
1. Reconnect VCM harness connector.
2. Disconnect traction motor inverter harness connector (F17).
3. Turn power switch ON and erase DTC.
4. Perform confirmation procedure. Refer to EVC-240, "DTC Description".
Is DTC “P312A” detected?
YES >> GO TO 6.
NO >> Check traction motor inverter power supply (POWER ON) circuit for short to power.
6.CHECK LBC POWER SUPPLY (POWER ON) CIRCUIT
2. Reconnect traction motor inverter harness connector.
3. Disconnect LBC harness connector (E128).
YES >> GO TO 7.
NO >> Check LBC power supply (POWER ON) circuit for short to power.
7.CHECK PDM (POWER DELIVERY MODULE) POWER SUPPLY (POWER ON) CIRCUIT
2. Reconnect LBC harness connector.
3. Disconnect PDM (Power Delivery Module) harness connector (F18).
YES >> GO TO 8.
NO >> Check on board charger power supply (POWER ON) circuit for short to power.
8.CHECK A/C AUTO AMP. POWER SUPPLY (POWER ON) CIRCUIT
2. Reconnect PDM (Power Delivery Module) harness connector.
3. Disconnect A/C auto amp. harness connector (M50).
YES-1 (With TCU)>>GO TO 9.
YES-2 (Without TCU)>>Replace VCM. Refer to EVC-404, "Removal and Installation".
NO >> Check A/C auto amp. power supply (POWER ON) circuit for short to power.
9.CHECK TCU POWER SUPPLY (POWER ON) CIRCUIT
2. Reconnect A/C auto amp. harness connector.
3. Disconnect TCU harness connector (M2).
EVC-242
NO >> Check TCU power supply (POWER ON) circuit for short to power.
A
EVC
EVC-243
P312B EV SYSTEM RESTART ERROR
DTC DETECTION LOGIC

The traction motor inverter and the PDM (Power Delivery Module) cannot
RESTART ERROR
P312B be activated for 30 seconds or more at a restart before the completion of
(Restart error)
VCM self shut off.
POSSIBLE CAUSE
• VCM
FAIL-SAFE
• READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Turn OFF the power switch. Between 5 seconds later and within 10 seconds, turn ON the power switch
again. Wait at least 1 minute.
3. Check DTC.
Is DTC detected?
NO >> GO TO 3.
With CONSULT
CAUTION:
vehicle handling.
6. Check DTC.
Is DTC detected?
EVC-244
NO >> GO TO 4. A
With CONSULT B
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some EVC
vehicle handling.
3. Connect quick charge connector. D
4. Start quick charge and wait at least 60 seconds.
6. Stop quick charge and wait at least 60 seconds.
7. Check DTC. E
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". F
G
1.PERFORM SELF-DIAGNOSIS OF TRACTION MOTOR INVERTER
With CONSULT H
Perform self-diagnosis of traction motor inverter.
Is DTC detected?
YES >> Check the DTC. Refer to TMS-34, "DTC Index". I
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS OF PDM (POWER DELIVERY MODULE)
J
Perform self-diagnosis of PDM (Power Delivery Module).
Is DTC detected?
YES >> Check the DTC. Refer to VC-31, "DTC Index". K
NO >> GO TO 3.
1. Erase DTC. L
Is DTC “P312B” detected again?
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". M
EVC-245
P312C, P3130 TRACTION MOTOR INVERTER CONDENSER DISCHARGE ER-
ROR
P312C, P3130 TRACTION MOTOR INVERTER CONDENSER DISCHARGE
ERROR
DTC DETECTION LOGIC

P312C INVERTER DISCHARGE ERROR Traction motor inverter voltage is 54 V or more for 14 seconds during stop
P3130 (Inverter discharge error) of READY or charge.
POSSIBLE CAUSE
• VCM
FAIL-SAFE
• READY OFF
If DTC P312C or P3130 is displayed with DTC P0AA0 or P0AA1, first perform the trouble diagnosis for DTC
P0AA0 or P0AA1.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
CAUTION:
vehicle handling.
3. Turn power switch ON and wait at least 1 minutes.
4. Check DTC.
Is DTC detected?
EVC-246
P312C, P3130 TRACTION MOTOR INVERTER CONDENSER DISCHARGE ER-
ROR
A
If DTC P312C or P3130 is displayed with DTC P0AA0 or P0AA1, first perform the trouble diagnosis for DTC
P0AA0 or P0AA1. B
NO >> GO TO 2. EVC

With CONSULT D
Is DTC detected?
YES >> Check the DTC. Refer to TMS-34, "DTC Index". E
NO >> GO TO 3.
F
Perform confirmation procedure again. Refer to EVC-246, "DTC Description"
Is DTC “P312C” or “P3130” detected?
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". G
EVC-247
P312D QUICK CHARGE ERROR
DTC DETECTION LOGIC

QUICK CHARGE RELAY Immediately before starting quick charge, the quick charger cannot be
P312D
(Quick charge relay) ready for 60 seconds.
POSSIBLE CAUSE
• Harness or connector
• VCM
FAIL-SAFE
• READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
1. Check that the charging status indicator is not illuminating.
3. Start the quick charging and wait at least 2 minutes.
5. Check DTC.
Is DTC detected?

With CONSULT
Is DTC detected?
YES >> Check the DTC. Refer to VC-31, "DTC Index".
NO >> GO TO 2.
With CONSULT
1. Erase DTC.
EVC-248
Is DTC detected?
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". A
EVC
EVC-249
P312E READY OFF ERROR
DTC DETECTION LOGIC

• During the shutdown from READY, battery current remains 5.5 A or more
READY OFF ERROR for 25.5 seconds or more.
P312E
(Ready off error) • During the shutdown from READY, traction motor inverter is not ready for
discharge for 25.5 seconds or more.
POSSIBLE CAUSE
• LBC
• A/C auto amp.
• VCM
FAIL-SAFE
• READY OFF
If DTC P312E is displayed with DTC P317A, P3191, P31A7, or P319C, first perform the trouble diagnosis for
DTC P317A, P3191, P31A7, or P319C.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
2. Operate the automatic air conditioning system (A/C switch ON).
3. Turn power switch OFF as automatic air conditioning system ON condition
4. Wait at least 30 seconds.
6. Check DTC.
Is DTC detected?
EVC-250
A
If DTC P312E is displayed with DTC P317A, P3191, P31A7, or P319C, first perform the trouble diagnosis for
DTC P317A, P3191, P31A7, or P319C. B
NO >> GO TO 2. EVC

With CONSULT D
Is DTC detected?
YES >> Check the DTC. Refer to VC-31, "DTC Index". E
NO >> GO TO 3.
3.PERFORM SELF-DIAGNOSIS OF A/C AUTO AMP.
F
With CONSULT
Perform self-diagnosis of A/C auto amp.
Is DTC detected? G
YES >> Check the DTC. Refer to HAC-76, "DTC Index".
NO >> GO TO 4.
4.PERFORM SELF-DIAGNOSIS OF TRACTION MOTOR INVERTER H
With CONSULT
Is DTC detected? I
NO >> GO TO 5.
J
5.PERFORM SELF-DIAGNOSIS OF LBC
With CONSULT
Perform self-diagnosis of LBC. K
Is DTC detected?
YES >> Check the DTC. Refer to EVB-55, "DTC Index" (without battery cooler models) or EVB-329, "DTC
Index" (with battery cooler models) or EVB-617, "DTC Index" (with battery heater & cooler mod- L
els).
NO >> GO TO 6.
6.PERFORM DTC CONFIRMATION PROCEDURE AGAIN M
With CONSULT
1. Erase DTC.
2. Perform DTC confirmation procedure again. Refer to EVC-250, "DTC Description". N
Is DTC “P312E” detected again?
NO >> INSPECTION END O
EVC-251
P312F CHARGE OFF ERROR
DTC DETECTION LOGIC

During the shutdown from charging, 10 seconds pass without satisfying the
following conditions:
CHARGE OFF ERROR
P312F • Battery current is 5.5 A or less
(Charge off error)
• Traction motor inverter is ready for discharge.
• Quick charge relay OFF
POSSIBLE CAUSE
• LBC
• A/C auto amp.
• VCM
FAIL-SAFE
• READY OFF
If DTC P312F is displayed with DTC P317A, P3191, P3196, P319C, P31A1, P31A7, or P31AE, first perform
the trouble diagnosis for DTC P317A, P3191, P3196, P319C, P31A1, P31A7, or P31AE.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
1. Check that the charging status indicator is not illuminating.
3. Disconnect EVSE and wait at lease 30 seconds.
5. Check DTC.
Is DTC detected?
NO-1 (with quick charge port)>>GO TO 4.
NO-2 (without quick charge port)>>INSPECTION END
EVC-252
With CONSULT
1. Turn power switch OFF. A
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some B
vehicle handling.
4. Start quick charging and wait at least 60 seconds. EVC
5. Stop quick charge and wait at lease 30 seconds.
7. Check DTC. D
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". E
F
If DTC P312F is displayed with DTC P317A, P3191, P3196, P319C, P31A1, P31A7, or P31AE, first perform
the trouble diagnosis for DTC P317A, P3191, P3196, P319C, P31A1, P31A7, or P31AE. G
NO >> GO TO 2. H
2.PERFORM SELF-DIAGNOSIS OF A/C AUTO AMP.

With CONSULT I
Perform self-diagnosis of A/C auto amp.
Is DTC detected?
YES >> Check the DTC. Refer to HAC-76, "DTC Index". J
NO >> GO TO 3.
3.PERFORM SELF-DIAGNOSIS OF POWER DELIVERY MODULE
K
With CONSULT
Is DTC detected? L
NO >> GO TO 4.
4.PERFORM SELF-DIAGNOSIS OF TRACTION MOTOR INVERTER M
With CONSULT
Is DTC detected? N
NO >> GO TO 5.
5.PERFORM SELF-DIAGNOSIS OF LBC O
With CONSULT
Perform self-diagnosis of LBC. P
Is DTC detected?
els).
NO >> GO TO 6.
EVC-253
With CONSULT
1. Erase DTC.
Is DTC “P312F” detected again?
EVC-254
P3131 SYSTEM SHUTOFF ERROR
A

When before shutdown, all of the following conditions are fulfilled for 31
SYSTEM SHUTOFF TIMEOUT minutes or more.
P3131
(System shut-off time out) • VCM does not receive a EV system activation request signal.
• Either of EV system CAN connection unit is not shutdown D
POSSIBLE CAUSE
• Harness or connectors E
• LBC
• A/C auto amp. F
• TCU (Used only in models with TELEMATICS system)
• VCM
G
FAIL-SAFE
TYPE 1
• Quick charge prohibited H
• READY OFF
I
TYPE 2
Not applicable
DTC CONFIRMATION PROCEDURE J
1.PRECONDITIONING
• Turn power switch OFF and wait at least 90 seconds. K
CAUTION:
vehicle handling. L
NOTE:
Disconnect the CONSULT if it is connected. M
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE-1 N
With CONSULT
O
2. Turn power switch OFF and wait at least 35 minutes.
NOTE:
After the completion of the self shutoff of VCM, the next step can be performed without waiting for 35 min-
utes. To confirm the completion of self shutoff, check that the power supply terminal voltage of the battery P
current sensor changes to approximately 0 V.
4. Check DTC.
Is DTC detected?
NO >> GO TO 3.
EVC-255
CAUTION:
vehicle handling.
NOTE:
After the completion of the self shutoff of VCM, the next step can be performed without waiting for 35 min-
utes. To confirm the completion of self shutoff, check that the power supply terminal voltage of the battery
current sensor changes to approximately 0 V.
5. Check DTC.
Is DTC detected?

+
Connector Terminal
12V battery volt-
E15 57 Ground
age
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK FUSE
+
VCM − Voltage
Connector Terminal
12V battery volt-
E81 21 Ground
age
YES >> GO TO 5.
EVC-256
NO >> GO TO 4.
4.CHECK VCM POWER SUPPLY CIRCUIT A

B
3. Check the continuity between VCM harness connector and IPDM E/R harness connector.
+ −
EVC
E15 57 E81 21 Existed D
NO >> Repair or replace error-detected parts. E
5.CHECK TRACTION MOTOR INVERTER POWER SUPPLY (POWER ON) CIRCUIT

1. Reconnect VCM harness connector. F
2. Disconnect traction motor inverter harness connector (F17).
G
Is DTC “P3131” detected?
YES >> GO TO 6.
NO >> Check traction motor inverter power supply (POWER ON) circuit for short to power.
H
6.CHECK LBC POWER SUPPLY (POWER ON) CIRCUIT
2. Reconnect traction motor inverter harness connector. I
3. Disconnect LBC harness connector (E128).
5. Perform confirmation procedure. Refer to EVC-255, "DTC Description". J
YES >> GO TO 7.
NO >> Check LBC power supply (POWER ON) circuit for short to power. K
7.CHECK PDM (POWER DELIVERY MODULE) POWER SUPPLY (POWER ON) CIRCUIT
2. Reconnect LBC harness connector. L
3. Disconnect PDM (Power Delivery Module) harness connector (F18).
5. Perform confirmation procedure. Refer to EVC-255, "DTC Description". M
YES >> GO TO 8.
NO >> Check on board charger power supply (POWER ON) circuit for short to power. N
8.CHECK A/C AUTO AMP. POWER SUPPLY (POWER ON) CIRCUIT
2. Reconnect PDM (Power Delivery Module) harness connector. O
3. Disconnect A/C auto amp. harness connector (M50).
5. Perform confirmation procedure. Refer to EVC-255, "DTC Description". P
YES-1 (With TCU)>>GO TO 9.
YES-2 (Without TCU)>>Replace VCM. Refer to EVC-404, "Removal and Installation".
NO >> Check A/C auto amp. power supply (POWER ON) circuit for short to power.
9.CHECK TCU POWER SUPPLY (POWER ON) CIRCUIT
EVC-257
2. Reconnect A/C auto amp. harness connector.
3. Disconnect TCU harness connector (M2).
NO >> Check TCU power supply (POWER ON) circuit for short to power.
EVC-258
P3135 SLIGHT COLLISION DETECTION
A

SLIGHT COLLISION DETECTION VCM received slight collision detection signal from air bag diagnosis sensor
P3135
(Slight collision detection) unit
POSSIBLE CAUSE D
• Air bag inflated
• CAN communication signal
• Air bag diagnosis sensor unit E
• VCM
FAIL-SAFE
Not applicable F

1.CHECK AIR BAG MODULE G
Check that the air bag modules are not inflating.
Is air bag module inflating?
H
YES >> Refer to SR-14, "FOR FRONTAL COLLISION : When SRS is activated in a collision" (for frontal
collision), SR-16, "FOR SIDE AND ROLLOVER COLLISION : When SRS is activated in a colli-
sion" (for side and rollover collision).
NO >> GO TO 2. I
2.PRECONDITIONING
• Turn power switch OFF and wait at least 90 seconds. J
CAUTION:
vehicle handling. K
>> GO TO 3. L

Turn power switch ON and wait at least 5 seconds. M
Is DTC detected?
O
1.CHECK THE IMPLEMENTATION OF AIR BAG MODULE REPLACEMENT
Check to see if there is a record of air bag module replacement.
P
Is there a record of air bag module replacement?
YES >> GO TO 2.
NO >> GO TO 3.
1. Erase DTC.
EVC-259
Is DTC “P3135” detected again?
YES >> GO TO 3.
3.CHECK SLIGHT COLLISION DETECTION SIGNAL
With CONSULT
On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “LIGHT CRASH JUDGMENT”.
Is indicated “0”?
NO >> Replace air bag diagnosis sensor unit. Refer to SR-40, "Removal and Installation".
EVC-260
P3137 CAR CRASH DETECTION
A

CAR CLASH VCM received car crash information signal from air bag diagnosis sensor
P3137
(Car crash) unit
POSSIBLE CAUSE D
• Air bag inflated
• CAN communication signal
• Air bag diagnosis sensor unit E
• VCM
FAIL-SAFE
• Quick charge prohibited F
• READY OFF
• High-voltage power supply stop G
H
1.CHECK AIR BAG MODULE
Check that the air bag modules are not inflating.
Is air bag module inflating? I
YES >> Refer to SR-14, "FOR FRONTAL COLLISION : When SRS is activated in a collision".
NO >> GO TO 2.
2.PRECONDITIONING J
CAUTION:
vehicle handling.
• Check that 12V battery voltage is 11 V or more. L
>> GO TO 3.
Turn power switch ON and wait at least 5 seconds.

Is DTC detected? N
O
1.CHECK THE IMPLEMENTATION OF AIR BAG MODULE REPLACEMENT P

Check to see if there is a record of air bag module replacement.
Is there a record of air bag module replacement?
YES >> GO TO 2.
NO >> GO TO 3.
EVC-261
1. Erase DTC.
YES >> GO TO 3.
3.CHECK CAR CRASH INFORMATION SIGNAL
With CONSULT
On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “CLASH DETECT INFO”.
Is indicated “##”?
NO >> Replace air bag diagnosis sensor unit. Refer to SR-40, "Removal and Installation".
EVC-262
P3141 PDM (POWER DELIVERY MODULE)
A
If the situation is not improved under the operation of the Charge Insulation Resistance Loss Protection Con- B
trol, VCM stops charging and detects DTC P3141. For details of the protection control, refer to EVC-403,
"Description".
DTC Description INFOID:0000000010410254 EVC
DTC DETECTION LOGIC

D
PDM (POWER DELIVERY MODULE) The Charge Insulation Resistance Loss Protection Control is repeated E
P3141
[PDM (Power Delivery Module)] more than the specified number of times.
POSSIBLE CAUSE
PDM (Power Delivery Module) F
FAIL-SAFE
Normal charge prohibited
G
H
If DTC P3141 is displayed with other DTC, first perform the trouble diagnosis for other DTC.
YES >> Perform diagnosis of applicable. Refer to EVC-98, "DTC Index". I
NO >> GO TO 2.
NOTE: J
Since this DTC is difficult to be confirmed, check component function to judge the normality.
>> GO TO 3. K

With CONSULT L
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some M
vehicle handling.
2. Perform normal charging at least 15 seconds.
CAUTION: N
Never turn ON the power switch during normal charging.
3. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “PRTCTN CNT OPERAT HIST 1”.
4. Check that “0” is indicated. O
YES-2 >> Confirmation after repair: INSPECTION END P

If DTC P3141 is displayed with other DTC, first perform the trouble diagnosis for other DTC.
EVC-263
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS
With CONSULT
Perform self-diagnosis of VCM.
Is DTC other than P3141 detected?
NO >> GO TO 3.
3.REPLACE PDM (POWER DELIVERY MODULE)
1. Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation".
3. Erase self-diagnostic result.
5. Perform normal charge at least 15 seconds.
CAUTION:
Never turn the power switch to ON during normal charge.
6. Check that normal charge operates normally.
7. Stop normal charge.
8. Check self-diagnostic result of VCM and PDM (Power Delivery Module).
YES >> Check the DTC. Refer to EVC-98, "DTC Index" (VCM), VC-31, "DTC Index" [PDM (Power Deliv-
ery Module)].
EVC-264
P315C CHARGE RELAY
P315C CHARGE RELAY
A

CHARGE RELAY
P315C VCM detects DTC P31CA or P31CB.
(Charge relay)
POSSIBLE CAUSE D
• Normal charge relay
• PDM (Power Delivery Module) E
FAIL-SAFE
• READY OFF
1.INSPECTION START
NOTE: H
This DTC is displayed when DTC P31CA or P31CB is detected. If this DTC is displayed, perform trouble diag-
nosis for DTC P31CA or P31CB.
I
>> Proceed to EVC-265, "Diagnosis Procedure".
J
Perform trouble diagnosis for P31CA or P31CB. Refer to EVC-318, "DTC Description".
EVC-265
P315E ABS/VDC
P315E ABS/VDC
DTC DETECTION LOGIC

VDC SYSTEM
P315E VCM detected torque request signal error for 2 seconds
(VDC system)
POSSIBLE CAUSE
• ABS actuator and electric unit (control unit)
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
3. Check DTC.
Is DTC detected?
1.PERFORM SELF-DIAGNOSIS OF VCM

Is DTC detected other than P315E?
NO >> GO TO 2.
2.REPLACE ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
1. Replace ABS actuator and electric unit (control unit). Refer to BRC-189, "LHD : Removal and Installation"
(LHD models) or BRC-192, "RHD : Removal and Installation" (RHD models).
2. Erase DTC.
3. Perform DTC confirmation procedure. Refer to EVC-266, "DTC Description".
Is DTC “P315E” detected again?
EVC-266
P316A MOTOR SPEED
P316A MOTOR SPEED
A

MOTOR SPEED
P316A VCM received motor speed invalid value from traction motor inverter.
(Motor speed)
POSSIBLE CAUSE D
FAIL-SAFE E
READY OFF
1.PRECONDITIONING F

CAUTION:
G
vehicle handling.
• Check that 12V battery voltage is 11 V or more. H
>> GO TO 2.
I
With CONSULT
1. Set the vehicle to READY and wait at least 60 seconds. J
2. Check DTC.
Is DTC detected?
YES >> Proceed to EVC-267, "Diagnosis Procedure". K
NO >> GO TO 3.
L
With CONSULT
1. Perform test drive.
2. Check DTC.
Is DTC detected? M
NO-2 >> Confirmation after repair: INSPECTION END N
1.PERFORM SELF-DIAGNOSIS OF TRACTION MOTOR INVERTER O
With CONSULT
Perform self-diagnosis of traction motor. P
>> Perform diagnosis procedure of detected DTC. Refer to TMS-34, "DTC Index".
EVC-267
P316C, P316D, P316E PDM (POWER DELIVERY MODULE)
P316C, P316D, P316E PDM (POWER DELIVERY MODULE)
DTC DETECTION LOGIC

P316C
PD MODULE SYSTEM VCM receives a DTC detection signal sent from PDM (Power Delivery
P316D
(Power Delivery Module system) Module).
P316E
POSSIBLE CAUSE
FAIL-SAFE
P316C
Quick charge prohibited
P316D
READY OFF
P316E
Not applicable
1.INSPECTION START
NOTE:
This DTC is displayed when PDM (Power Delivery Module) detects a DTC. If the DTC is displayed, perform
trouble diagnosis for a DTC that detected by PDM (Power Delivery Module).

Perform the self-diagnosis of PDM (Power Delivery Module).
EVC-268
P316F PDM (POWER DELIVERY MODULE)
A

PD MODULE SYSTEM The charge electricity of the PDM (Power Delivery Module) is less than
P316F
(Power Delivery Module system) 0.1KW
POSSIBLE CAUSE D
• VCM E
FAIL-SAFE

1.PRECONDITIONING G
CAUTION:
vehicle handling.
• Check that 12V battery voltage is 11 V or more. I
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE-1 J
1. Perform normal charging and wait at least 10 minutes.
3. Check DTC. K
Is DTC detected?
NO (Without quick charge port)>>INSPECTION END L
NO (With quick charge port)>>GO TO 3.
3.PERFORM DTC CONFIRMATION PROCEDURE-2 M
2. Perform quick charging and wait at least 10 minutes.
4. Check DTC. N
Is DTC detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". O
P
1.CHECK PDM (POWER DELIVERY MODULE) OUTPUT POWER-1

With CONSULT
2. Perform normal charging.
4. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “OBC OUT PWR”.
EVC-269
Is value 0 kW?
YES >> GO TO 3.
NO-2 (without quick charge port)>>Replace VCM. Refer to EVC-404, "Removal and Installation".
2.CHECK PDM (POWER DELIVERY MODULE) OUTPUT POWER-2
With CONSULT
2. Perform quick charging.
4. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “OBC OUT PWR”.
Is value 0 kW?
YES >> INSPECTION END (quick charger malfunction)
NO >> Check to see if there is a factor causing a situation that battery charge does not start. Refer to
EVC-390, "Symptom Index".
EVC-270
P3170, P3171 PDM (POWER DELIVERY MODULE)
A

P3170 PD MODULE SYSTEM VCM receives a DTC detection signal sent from PDM (Power Delivery
P3171 (Power Delivery module system) Module).
D
POSSIBLE CAUSE
FAIL-SAFE E
P3170
Normal charge prohibited
F
P3171
Not applicable
1.INSPECTION START
NOTE: H
I
J
EVC-271
DTC DETECTION LOGIC

P3172 PD MODULE SYSTEM VCM detects an error signal that is received from PDM (Power Delivery
P3173 (Power Delivery Module system) Module) via EV system CAN communication.
POSSIBLE CAUSE
FAIL-SAFE
P3172
Not applicable
P3173
1.INSPECTION START
NOTE:

EVC-272
P3176 TRACTION MOTOR INVERTER CONDENSER
A

INVERTER CONDENSER Immediately before READY or the start of charge, pre-charging cannot be
P3176
(Inverter condenser) performed for 5 seconds or more.
POSSIBLE CAUSE D
• LBC
• PDM (Power Delivery Module) E
• VCM
F
• Battery heater
FAIL-SAFE
• Quick charge prohibited G
• READY OFF
H
I
If DTC P3176 is displayed with DTC P0A94, P311C, P317A, P3191, P319C, P31A7, P31D4, P31D7, or
P31DD, first perform the trouble diagnosis for DTC P0A94, P311C, P317A, P3191, P319C, P31A7, P31D4,
P31D7, or P31DD.
Is applicable DTC detected? J
NO >> GO TO 2.
K
2.PRECONDITIONING
CAUTION: L
vehicle handling.
• Check that 12V battery voltage is 11 V or more. M
>> GO TO 3.
N
With CONSULT
1. Set the vehicle to READY and wait at least 10 seconds. O
2. Check DTC.
Is DTC detected?
YES >> Proceed to EVC-273, "Diagnosis Procedure". P
DANGER:
EVC-273
maintenance.
WARNING:
CAUTION:
If DTC P3176 is displayed with DTC P0A94, P311C, P317A, P3191, P319C, P31A7, P31D4, P31D7, or
P31DD, first perform the trouble diagnosis for DTC P0A94, P311C, P317A, P3191, P319C, P31A7, P31D4,
P31D7, or P31DD.
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS OF VCM
With CONSULT
Is DTC detected other than P3176?
NO >> GO TO 3.
3.PRECONDITIONING
WARNING:
>> GO TO 4.
Electric compressor
+ − Resistance
Terminal
7 8 3 kΩ or more
YES >> GO TO 5.
5.CHECK PTC HEATER
EVC-274
A
Li-ion battery
Connector B
Terminal
YES >> GO TO 6.
6.CHECK HIGH VOLTAGE HARNESS-1 D
1. Disconnect Li-ion battery high voltage harness connector (H17).

2. Check the short circuit between high voltage harness terminals.
E
Li-ion battery
Connector F
Terminal
PDM (Power Delivery Module) H17 37 38 3 kΩ or more
related circuits. And then, GO TO 12. H
NO >> GO TO 7.
I
nals.
J
JSCIA0696ZZ
M
YES >> GO TO 8.
tion". N
1. Remove high voltage harness from PDM (Power Delivery Module). Refer to VC-108, "Removal and Instal- O
lation".
P
Connector
Terminal
EVC-275

YES >> GO TO 9.
Check the short circuit between PDM (Power Delivery Module) terminals.

+ − Resistance
Terminal
38 39 3 kΩ or more
NO >> Replace PDM (Power Delivery Module). And then, GO TO 12. Refer to VC-108, "Removal and
Installation".
Installation".

Continuity
Connector Terminal
10
LB18 Not existed
11
YES >> GO TO 11.
Battery heater
Resistance
Connector Terminal
2
3
then, GO TO 12.
EVC-276
TERY HEATER & COOLING UNIT : Removal and Installation". A
12.REPLACE BATTERY JUNCTION BOX
Replace battery junction box. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
B
Removal and Installation" (without battery cooler models) or EVB-515, "BATTERY JUNCTION BOX AND BAT-
TERY HARNESS : Removal and Installation" (with battery cooler models) or EVB-814, "BATTERY JUNCTION
BOX AND BATTERY HARNESS : Removal and Installation" (with battery heater & cooler models).
EVC
>> INSPECTION END
EVC-277
P3177 ECU ACTIVATION ERROR
DTC DETECTION LOGIC

ECU ACTIVATION ERROR When EV system starts up, PDM (Power Delivery Module) or traction motor
P3177
(ECU activation error) inverter does not permit EV system activation.
POSSIBLE CAUSE
• Charging system
• Traction motor system
• EVSE
• Quick charger
• External input
FAIL-SAFE
• READY OFF
If DTC P3177 is displayed with DTC P316C, P316D, P316E, P3170, P3171, P3173, P317A, or P3191, first
perform the trouble diagnosis for DTC P316C, P316D, P316E, P3170, P3171, P3173, P317A, or P3191.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
2. Check DTC.
Is DTC detected?
YES >> Proceed to EVC-279, "TYPE 1 : Diagnosis Procedure".
NO-2 (without quick charge port)>>GO TO 5.
With CONSULT
CAUTION:
EVC-278
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the A
vehicle handling.
4. Start quick charging and wait at least 200 seconds.
B
6. Check DTC.
Is DTC detected?
EVC
NO >> GO TO 5.
5.PERFORM DTC CONFIRMATION PROCEDURE-3 D
With CONSULT
2. Check that the charging status indicator is not illuminating, and wait at least 90 seconds. E
CAUTION:
vehicle handling. F
3. Connect normal charge connector (with AC power input) and wait at least 200 seconds.
CAUTION:
When performing the DTC Confirmation Procedure before Diagnosis Procedure, use the EVSE G
used at the occurrence of malfunction.
4. Check DTC.
Is DTC detected? H
NO-1 (before performing diagnosis procedure)>>Proceed to EVC-280, "TYPE 3 : Diagnosis Procedure".
NO-2 (after performing diagnosis procedure)>>INSPECTION END
I
TYPE 1
TYPE 1 : Diagnosis Procedure INFOID:0000000010410276
J
perform the trouble diagnosis for DTC P316C, P316D, P316E, P3170, P3171, P3173, P317A, or P3191. K
L
NO >> GO TO 2.
2.CHECK DTC
With CONSULT M
Check DTC.
Is any DTC other than P3177 detected?
YES >> Check the DTC. Refer to EVC-98, "DTC Index". N
NO >> GO TO 3.
3.CHECK SELF-DIAGNOSTIC RESULT IN TRACTION MOTOR INVERTER
O
With CONSULT
Is any DTC detected? P
NO >> GO TO 4.
With CONSULT
EVC-279
NO >> Check intermittent incident. Refer to GI-47, "Intermittent Incident".
TYPE 2

NO >> GO TO 2.
2.CHECK CONDITION
Check and study the quick charger to see that it is within the specification.
YES >> GO TO 3.
NO >> Erase DTC. (Quick charger malfunction)
3.CHECK DTC
With CONSULT
Check DTC.
NO >> GO TO 4.
With CONSULT
NO >> GO TO 5.
With CONSULT
NO >> Check intermittent incident. Refer to GI-47, "Intermittent Incident".
TYPE 3

NO >> GO TO 2.
2.PERFORM NORMAL CHARGING
1. Erase DTC of all ECU.
CAUTION:
EVC-280
vehicle handling.
4. Connect normal charge connector (with AC power input) and wait at least 200 seconds.
CAUTION:
B
• Use an EVSE other than the one used for the previous DTC confirmation procedure.
• Use NISSAN genuine EVSE or an equivalent.
5. Check DTC.
Is DTC P3177 detected again? EVC
YES >> GO TO 4.
NO >> GO TO 3.
D
3.CHECK CONDITION
Check adherence to the following conditions at the occurrence of the malfunction:
• No interruption in the indoor power and EVSE. E
• Use of the specified EVSE.
• Proper connection of EVSE.
• EVSE LED (FAULT) is not ON or blinking.
Is the inspection result normal? F
G
4.CHECK DTC
With CONSULT
Check DTC. H
NO >> GO TO 5. I
With CONSULT J
YES >> Check the DTC. Refer to VC-31, "DTC Index". K
NO >> GO TO 6.
With CONSULT L
M
NO >> GO TO 7.
7.CHECK CONDITION N
Check and study the following items:
• No interruption in the indoor power and EVSE.
• Use of the specified EVSE.
O
• Proper connection of EVSE.
• PDM (Power Delivery Module) remains cold.
P
EVC-281
DTC DETECTION LOGIC

ECU ACTIVATION ERROR When EV system starts up, Li-ion battery or traction motor inverter does not
P3178
(ECU activation error) permit EV system activation.
POSSIBLE CAUSE
• Li-ion battery system
• Traction motor system
FAIL-SAFE
• READY OFF
If DTC P3178 is displayed with DTC P0AA0, P317A, P3191, P3193, P319C, P319E, P31A7, or P31A9, first
perform the trouble diagnosis for DTC P0AA0, P317A, P3191, P3193, P319C, P319E, P31A7, or P31A9.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
2. Check DTC.
Is DTC detected?

If DTC P3178 is displayed with DTC P0AA0, P317A, P3191, P3193, P319C, P319E, P31A7, or P31A9, first
perform the trouble diagnosis for DTC P0AA0, P317A, P3191, P3193, P319C, P319E, P31A7, or P31A9.
NO >> GO TO 2.
EVC-282
2.CHECK SELF-DIAGNOSTIC RESULT IN VCM A
With CONSULT
Is DTC other than P3178 detected? B
NO >> GO TO 3.
3.CHECK SELF-DIAGNOSTIC RESULT IN TRACTION MOTOR INVERTER EVC
With CONSULT
D
NO >> GO TO 4.
E
4.CHECK SELF-DIAGNOSTIC RESULT IN LI-ION BATTERY CONTROLLER
With CONSULT
Check self-diagnostic result in “HV BAT”. F
Index" (with battery cooler models) or EVB-617, "DTC Index" (with battery heater & cooler mod- G
els).
NO >> Check high voltage harness connector installation condition of Li-ion battery and traction motor
inverter. H
EVC-283
P3179, P317A, P317B TRACTION MOTOR INVERTER
P3179, P317A, P317B TRACTION MOTOR INVERTER
DTC DETECTION LOGIC

P3179
MOTOR SYSTEM VCM detects an error signal that is received from traction motor inverter via
P317A
(Motor system) CAN communication for 0.01 seconds or more.
P317B
POSSIBLE CAUSE
FAIL-SAFE
P3179
Not applicable
P317A
READY OFF
P317B
• READY OFF
1.INSPECTION START
NOTE:
This DTC is displayed when the traction motor inverter detects a DTC. If this DTC is displayed, perform trouble
diagnosis for a DTC that detected by traction motor inverter.

Perform the self-diagnosis of traction motor inverter.
EVC-284
P317D TRACTION MOTOR INVERTER
A

• The estimated torque value from the traction motor inverter to VCM re-
mains greater/smaller than the torque command value from VCM to the
traction motor inverter for the specified time.
MOTOR SYSTEM D
P317D • The difference between the estimated power consumption calculated
(Motor system)
based on a torque value from VCM to the traction motor inverter and the
actual power consumption calculated based on a high voltage battery
voltage and current is 54 kW or more.
E
POSSIBLE CAUSE
• VCM F
FAIL-SAFE
READY OFF
G
1.PRECONDITIONING
H
CAUTION:
vehicle handling.
J
>> GO TO 2.
K
With CONSULT
CAUTION:
L
NOTE:
DTC can be reproduced more easily when vehicle speed is higher.
2. Check DTC. M
Is DTC detected?
O
1.CHECK TRACTION MOTOR TORQUE
With CONSULT P
1. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “TRG MOTOR TORQ 1” and “CUR-
RENT MOTOR TORQ”.
2. Shift selector lever in P range.
4. Check that the difference between values indicated by “TRG MOTOR TORQ 1” and “CURRENT MOTOR
TORQ” is within 20 N·m.
EVC-285
YES >> GO TO 2.
NO >> Replace traction motor inverter. Refer to TMS-106, "Removal and Installation".
2.REPLACE VCM
Is DTC “P317D” detected again?
EVC-286
P317E, P3180, P3182 LI-ION BATTERY
P317E, P3180, P3182 LI-ION BATTERY
A

P317E
HV BATTERY SYSTEM VCM detects an error signal that is received from LBC via CAN communi-
P3180
(High voltage battery system) cation for 0.02 seconds or more.
P3182 D
POSSIBLE CAUSE
Li-ion battery system E
FAIL-SAFE
P317E
F
P3180 G
Not applicable
P3182
• Quick charge prohibited H
• READY OFF
I
1.INSPECTION START
J
NOTE:
This DTC is displayed when LBC detects a DTC. If this DTC is displayed, perform trouble diagnosis for a DTC
that detected by LBC.
K
Diagnosis Procedure INFOID:0000000010410286 L
Perform the self-diagnosis of LBC.

M
EVC-287
DTC DETECTION LOGIC

After a lapse of 0.3 seconds from M/C RELAY ON, the following state re-
HV BATTERY SYSTEM
P3183 mains for 2.8 seconds or more: LBC's calculation result to the VCM-set ex-
(High voltage battery system)
ample question is incorrect.
POSSIBLE CAUSE
• LBC
• VCM
FAIL-SAFE
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?
1.REPLACE LBC
1. Replace LBC. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal and Installation" (without
battery cooler models) or EVB-511, "LI-ION BATTERY CONTROLLER : Removal and Installation" (with
EVC-288
P318D CAN COMMUNICATION
P318D CAN COMMUNICATION
A

COMMUNICATION ERROR When VCM is not transmitting CAN communication signal for 2 seconds or
P318D
(Communication error) more.
POSSIBLE CAUSE D
VCM
FAIL-SAFE E
Not applicable
1.PRECONDITIONING F

CAUTION:
G
vehicle handling.
>> GO TO 2.
I
2. Check DTC. J
Is DTC detected?
L
1. Erase DTC.
2. Perform confirmation procedure again. Refer to EVC-289, "DTC Description". M
Is DTC “P318D” detected again?
NO >> INSPECTION END N
EVC-289
P3191, P319C, P31A7 EV SYSTEM CAN COMMUNICATION
DTC DETECTION LOGIC

P3191
COMMUNICATION ERROR When VCM detects an error signal that is received from traction motor in-
P319C
(Communication error) verter via CAN communication
P31A7
POSSIBLE CAUSE
• VCM
FAIL-SAFE
P3191
TYPE 1
• READY OFF
TYPE 2
• Not applicable
P319C, P31A7
READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?
1.PERFORM TROUBLE DIAGNOSIS FOR CAN COMMUNICATION

Perform trouble diagnosis for CAN communication. Refer to LAN-21, "Trouble Diagnosis Flow Chart".
YES >> GO TO 2.
EVC-290
With CONSULT
Check self-diagnostic result in “EV/HEV”. A
Is any EV system CAN error (U1000 excluded) other than DTC P3191, P319C, and P31A7 detected?
YES >> GO TO 3.
NO >> GO TO 4. B
3.REPLACE VCM
With CONSULT EVC
Is DTC P3191, P319C, or P31A7 detected again? D
4.REPLACE TRACTION MOTOR INVERTER E
With CONSULT
1. Replace traction motor inverter. Refer to TMS-106, "Removal and Installation".
2. Perform DTC confirmation procedure again. Refer to EVC-290, "DTC Description". F
Is DTC P3191, P319C, or P31A7 detected again?
NO >> INSPECTION END G
EVC-291
P3193, P319E, P31A9 EV SYSTEM CAN COMMUNICATION
DTC DETECTION LOGIC

P3193
COMMUNICATION ERROR When VCM detects an error signal that is received from LBC via CAN com-
P319E
(Communication error) munication
P31A9
POSSIBLE CAUSE
• LBC
• VCM
FAIL-SAFE
P3193
TYPE 1
TYPE 2
• Not applicable
P319E, P31A9
• Only driving in creep is possible.
READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?

EVC-292
YES >> GO TO 2.
With CONSULT B
Is any EV system CAN error (U1000 excluded) other than DTC P3193, P319E, and P31A9 detected?
YES >> GO TO 3. EVC
NO >> GO TO 4.
3.REPLACE VCM
With CONSULT D
Is DTC P3193, P319E, or P31A9 detected again? E
YES >> Replace LBC. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal and Installation"
(without battery cooler models) or EVB-511, "LI-ION BATTERY CONTROLLER : Removal and
Installation" (with battery cooler models) or EVB-807, "LI-ION BATTERY CONTROLLER : F
Removal and Installation" (with battery heater & cooler models).
4.REPLACE LBC G
With CONSULT
1. Replace LBC. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal and Installation" (without
battery cooler models) or EVB-511, "LI-ION BATTERY CONTROLLER : Removal and Installation" (with H
Is DTC P3193, P319E, or P31A9 detected again?
EVC-293
P3194, P319F, P31AA CAN COMMUNICATION
DTC DETECTION LOGIC

P3194
COMMUNICATION ERROR When VCM detects an error signal that is received from ABS actuator and
P319F
(Communication error) electric unit (control unit) via CAN communication
P31AA
POSSIBLE CAUSE
• ABS actuator and electric unit (control unit)
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?

YES >> GO TO 2.
With CONSULT
Is any CAN error (U1000 excluded) other than DTC P3194, P319F, and P31AA detected?
YES >> GO TO 3.
NO >> GO TO 4.
3.REPLACE VCM
EVC-294
With CONSULT
1. Replace VCM. Refer to EVC-404, "Removal and Installation". A
Is DTC P3194, P319F, or P31AA detected again?
YES >> Replace ABS actuator and electric unit (control unit). Refer to BRC-189, "LHD : Removal and B
Installation" (LHD models) BRC-192, "RHD : Removal and Installation" (RHD models).
4.REPLACE ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) EVC
With CONSULT
1. Replace ABS actuator and electric unit (control unit). Refer to BRC-189, "LHD : Removal and Installation"
(LHD models) BRC-192, "RHD : Removal and Installation" (RHD models). D
Is DTC P3194, P319F, or P31AA detected again?
E
EVC-295
P3195, P31A0, P31AB CAN COMMUNICATION
DTC DETECTION LOGIC

P3195
COMMUNICATION ERROR When VCM detects an error signal that is received from hydraulic brake ac-
P31A0
(Communication error) tuation module via CAN communication
P31AB
POSSIBLE CAUSE
• Hydraulic brake actuation module
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
2. Check DTC.
Is DTC detected?

YES >> GO TO 2.
With CONSULT
Is any CAN error (U1000 excluded) other than DTC P3195, P31A0, and P31AB detected?
YES >> GO TO 3.
NO >> GO TO 4.
3.REPLACE VCM
With CONSULT
EVC-296
2. Perform DTC confirmation procedure again. Refer to EVC-296, "DTC Description". A
Is DTC P3195, P31A0, or P31AB detected again?
YES >> Replace hydraulic brake actuation module. Refer to BR-455, "Removal and installation" (LHD
models) or BR-935, "Removal and installation" (RHD models). B
4.REPLACE HYDRAULIC BRAKE ACTUATION MODULE UNIT
EVC
With CONSULT
1. Replace hydraulic brake actuation module. Refer to BR-455, "Removal and installation" (LHD models) or
BR-935, "Removal and installation" (RHD models).
2. Perform DTC confirmation procedure again. Refer to EVC-296, "DTC Description". D
Is DTC P3195, P31A0, or P31AB detected again?
NO >> INSPECTION END E
EVC-297
P3196, P31A1, P31AE EV SYSTEM CAN COMMUNICATION
DTC DETECTION LOGIC

P3196
COMMUNICATION ERROR When VCM detects an error signal that is received from PDM (Power De-
P31A1
(Communication error) livery Module) via CAN communication
P31AE
POSSIBLE CAUSE
• VCM
FAIL-SAFE
TYPE 1
TYPE 2
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?

YES >> GO TO 2.
With CONSULT
EVC-298
Is any EV system CAN error (U1000 excluded) other than DTC P3196, P31A1, and P31AE detected?
YES >> GO TO 3. A
NO >> GO TO 4.
3.REPLACE VCM
B
With CONSULT
EVC
Is DTC P3196, P31A1, or P31AE detected again?
D
4.REPLACE PDM (POWER DELIVERY MODULE)
With CONSULT
1. Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation". E
Is DTC P3196, P31A1, or P31AE detected again?
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". F
EVC-299
P31AF, P31B3 EV SYSTEM CAN COMMUNICATION
DTC DETECTION LOGIC

P31AF COMMUNICATION ERROR When VCM detects an error signal that is received from A/C auto amp. via
P31B3 (Communication error) CAN communication
POSSIBLE CAUSE
• A/C auto amp.
• VCM
FAIL-SAFE
P31AF
Not applicable
P31B3
TYPE 1
• When the power is turned on and the vehicle is charging, the cooling fan is operated at a constant speed.
TYPE 2
• Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?

YES >> GO TO 2.
With CONSULT
EVC-300
Is any EV system CAN error (U1000 excluded) other than DTC P31AF and P31B3 detected? A
YES >> GO TO 3.
NO >> GO TO 4.
3.REPLACE VCM B
With CONSULT
1. Replace VCM. Refer to EVC-404, "Removal and Installation". EVC
Is DTC P31AF or P31B3 detected again?
YES >> Replace A/C auto amp. Refer to HAC-202, "Removal and Installation". D
4.REPLACE A/C AUTO AMP.
With CONSULT E
1. Replace A/C auto amp. Refer to HAC-202, "Removal and Installation".
Is DTC P31AF or P31B3 detected again? F
G
EVC-301
P31B0, P31B4 CAN COMMUNICATION
DTC DETECTION LOGIC

P31B0 COMMUNICATION ERROR When VCM detects an error signal that is received from AV control unit via
P31B4 (Communication error) CAN communication
POSSIBLE CAUSE
• AV control unit
• VCM
FAIL-SAFE
P31B0
TYPE 1
• VCM inhibits the timer charge.
TYPE 2
TYPE 3
• Not applicable
P31B4
TYPE 1
• VCM inhibits the timer charge.
TYPE 2
• VCM inhibits the remote climate control.
TYPE 3
• Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?
EVC-302
A
B
YES >> GO TO 2.
EVC
With CONSULT
Check self-diagnostic result in “EV/HEV”. D
Is any CAN error (U1000 excluded) other than DTC P31B0 and P31B4 detected?
YES >> GO TO 3.
NO >> GO TO 4. E
3.REPLACE VCM
With CONSULT F
Is DTC P31B0 or P31B4 detected again? G
YES >> Replace AV control unit. Refer to AV-187, "Removal and Installation".
4.REPLACE AV CONTROL UNIT H
With CONSULT
1. Replace AV control unit. Refer to AV-187, "Removal and Installation".
Is DTC P31B0 or P31B4 detected again?
EVC-303
DTC DETECTION LOGIC

P31B2
COMMUNICATION ERROR VCM detects an error signal that is received from combination meter via
P31B5 CAN communication
POSSIBLE CAUSE
• Combination meter
• VCM
FAIL-SAFE
P31B2
Not applicable
P31B5
TYPE 1
• ASCD operation prohibited
NOTE:
The ECO indicator value also becomes extremely poor.
TYPE 2
• Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
3. Check DTC.
Is DTC detected?

YES >> GO TO 2.
EVC-304
With CONSULT
Check self-diagnostic result in “EV/HEV”. B
Is any CAN error (U1000 excluded) other than DTC P31B2 and P31B5 detected?
YES >> GO TO 3.
NO >> GO TO 4. EVC
3.REPLACE VCM
With CONSULT
1. Replace VCM. Refer to EVC-404, "Removal and Installation". D
YES >> Replace combination meter. Refer to MWI-135, "Removal and Installation". E
4.REPLACE COMBINATION METER F
With CONSULT
1. Replace combination meter. Refer to MWI-135, "Removal and Installation".
2. Perform DTC confirmation procedure again. Refer to EVC-304, "DTC Description". G
NO >> INSPECTION END H
EVC-305
P31B6 CAN COMMUNICATION
DTC DETECTION LOGIC

COMMUNICATION ERROR When VCM detects an error signal that is received from IPDM E/R via CAN
P31B6
(Communication error) communication
POSSIBLE CAUSE
• IPDM E/R
• VCM
FAIL-SAFE
VCM sets the DC/DC converter output power to a constant 14 V.
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?

YES >> GO TO 2.
With CONSULT
Is any CAN error (U1000 excluded) other than DTC P31B6 detected?
YES >> GO TO 3.
NO >> GO TO 4.
3.REPLACE VCM
With CONSULT
EVC-306
Is DTC P31B6 detected again? A
4.REPLACE IPDM E/R B
With CONSULT
1. Replace IPDM E/R. Refer to PCS-31, "Removal and Installation". EVC
Is DTC P31B6 detected again?
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". D
EVC-307
DTC DETECTION LOGIC

COMMUNICATION ERROR When VCM detects an error signal that is received from air bag diagnosis
P31B7
(Communication error) sensor unit via CAN communication
POSSIBLE CAUSE
• Air bag diagnosis sensor unit
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?

YES >> GO TO 2.
With CONSULT
Is any CAN error (U1000 excluded) other than DTC P31B7 detected?
YES >> GO TO 3.
NO >> GO TO 4.
3.REPLACE VCM
With CONSULT
EVC-308
Is DTC P31B7 detected again? A
YES >> Replace air bag diagnosis sensor unit. Refer to SR-40, "Removal and Installation".
4.REPLACE AIR BAG DIAGNOSIS SENSOR UNIT B
With CONSULT
1. Replace air bag diagnosis sensor unit. Refer to SR-40, "Removal and Installation". EVC
EVC-309
P31B8 EV SYSTEM CAN COMMUNICATION
DTC DETECTION LOGIC

COMMUNICATION ERROR When VCM detects an error signal that is received from TCU via CAN com-
P31B8
POSSIBLE CAUSE
• TCU
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?
1.CHECK TCU CONDITION

Check that the TCU activation is performed normally. Refer to AV-347, "ADDITIONAL SERVICE WHEN
USING TELEMATICS SYSTEM FOR THE FIRST TIME/RE-SUBSCRIPTION : Description".
Is TCU activation performed normally?
YES >> GO TO 2.
NO >> Perform TCU activation. Refer to AV-347, "ADDITIONAL SERVICE WHEN USING TELEMATICS
SYSTEM FOR THE FIRST TIME/RE-SUBSCRIPTION : Work Procedure".
YES >> GO TO 3.
With CONSULT
EVC-310
Is any EV system CAN error (U1000 excluded) other than DTC P31B8 detected? A
YES >> GO TO 4.
NO >> GO TO 5.
4.REPLACE VCM B
With CONSULT
1. Replace VCM. Refer to EVC-404, "Removal and Installation". EVC
YES >> Replace TCU. Refer to AV-369, "Removal and Installation". D
5.REPLACE TCU
With CONSULT E
1. Replace TCU. Refer to AV-369, "Removal and Installation".
Is DTC P31B8 detected again? F
G
EVC-311
P31BA CAN COMMUNICATION
DTC DETECTION LOGIC

COMMUNICATION ERROR When VCM detects an error signal that is received from BCM via CAN com-
P31BA
POSSIBLE CAUSE
• BCM
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?

YES >> GO TO 2.
With CONSULT
Is any CAN error (U1000 excluded) other than DTC P31BA detected?
YES >> GO TO 3.
NO >> GO TO 4.
3.REPLACE VCM
With CONSULT
EVC-312
Is DTC P31BA detected again? A
YES >> Replace BCM. Refer to BCS-121, "Removal and Installation".
4.REPLACE BCM B
With CONSULT
1. Replace BCM. Refer to BCS-121, "Removal and Installation". EVC
Is DTC P31BA detected again?
EVC-313
P31C5, P31C6 VCM
P31C5, P31C6 VCM
DTC DETECTION LOGIC

P31C5 VCM
VCM malfunction is detected
P31C6 (VCM)
POSSIBLE CAUSE
VCM
FAIL-SAFE
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?
NO >> GO TO 3.
With CONSULT
CAUTION:
vehicle handling.
3. Check DTC.
Is DTC detected?
1.CHECK VCM-1
With CONSULT
1. Erase DTC.
EVC-314
P31C5, P31C6 VCM
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some A
vehicle handling.
3. Disconnect 12V battery negative terminal and wait at least 1 minute. Refer to EVC-9, "Precautions for
B
Removing Battery Terminal".
6. Check DTC. EVC
Is DTC “P31C5” or P31C6” detected again?
NO >> GO TO 2. D
2.CHECK VCM-2
With CONSULT E
CAUTION:
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the F
vehicle handling.
3. Check DTC. G
Is DTC “P31C5” or P31C6” detected again?
NO >> INSPECTION END H
EVC-315
P31C7 VCM
P31C7 VCM
DTC DETECTION LOGIC

VCM
P31C7 VCM malfunction is detected
(VCM)
POSSIBLE CAUSE
VCM
FAIL-SAFE
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?
NO >> GO TO 3.
With CONSULT
1. Set timer charge start time to 5 minutes later.
3. Connect EVSE (With AC power input) and wait until battery charge starts.
4. Wait at least 10 minutes after starting timer charge.
5. Turn the power switch ON while charging.
6. Check DTC.
Is DTC detected?
1.CHECK VCM
With CONSULT
1. Erase DTC.
CAUTION:
EVC-316
P31C7 VCM
vehicle handling.
3. Disconnect 12V battery negative terminal and wait at least 1 minute. Refer to EVC-9, "Precautions for
Removing Battery Terminal".
B
6. Check DTC.
Is DTC “P31C7” detected again? EVC
NO >> GO TO 2.
D
With CONSULT
Perform confirmation procedure again. Refer to EVC-316, "DTC Description". E
Is DTC “P31C7” detected again?
NO >> INSPECTION END F
EVC-317
P31CA, P31CB QUICK CHARGE RELAY
DTC DETECTION LOGIC

VCM received quick charge relay (-) stuck signal from PDM (Power Deliv-
P31CA
PD MODULE ery Module).
(Power Delivery Module) VCM received quick charge relay (+) stuck signal from PDM (Power Deliv-
P31CB
ery Module).
POSSIBLE CAUSE
• Quick charge relay
FAIL-SAFE
If DTC P31CA or P31CB is displayed with DTC P3101, first perform the trouble diagnosis for DTC P3101.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
1. Start quick charge and wait at least 30 seconds.
2. Stop quick charge and wait at least 30 seconds.
4. Check DTC.
Is DTC detected?
DANGER:
maintenance.
EVC-318
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- A
B
lating sheet except when using them. EVC
CAUTION:
• Never bring the vehicle into the READY status with the service plug removed unless otherwise D
1.CHECK DTC PRIORITY E
If DTC P31CA or P31CB is displayed with DTC P3101, first perform the trouble diagnosis for DTC P3101.
YES >> Perform diagnosis of applicable. Refer to EVC-228, "DTC Description". F
NO >> GO TO 2.
G
With CONSULT
1. Erase DTC.
2. Perform the DTC confirmation procedure again using a quick charger other than the one that is used for
the initial confirmation procedure. Refer to EVC-318, "DTC Description". H
Is DTC “P31CA” or “P31CB” detected again?
YES >> GO TO 3.
NO >> INSPECTION END (Quick charger malfunction) I

Perform self-diagnosis of PDM (Power Delivery Module). J
YES >> Perform diagnosis procedure of detected DTC. Refer to VC-31, "DTC Index".
NO >> GO TO 4. K
4.PRECONDITIONING
WARNING: L
M
>> GO TO 5.
5.CHECK QUICK CHARGE RELAY N
2. Check the continuity between Li-ion battery harness connector and quick charge port terminal (plug-in
side). O
JSCIA0700GB
EVC-319
: #11 terminal (plug-in side)

: #12 terminal (plug-in side)
+ −
Quick charge port
Li-ion battery Continuity
(plug-in side)
Connector Terminal Terminal
38 11
H17 Not existed
37 12
EVC-320
P31D3 M/C RELAY
P31D3 M/C RELAY
A

M/C RELAY When turn power switch ON (or READY), a voltage is input to A/C relay
P31D3
(Motor control relay) drive circuit of VCM even though VCM does not turn ON the M/C relay.
POSSIBLE CAUSE D
• M/C relay (stuck ON)
E
FAIL-SAFE
Not applicable
1.PRECONDITIONING
G
CAUTION:
vehicle handling. H
>> GO TO 2. I
With CONSULT J
4. Check DTC. K
Is DTC detected?
L
M
1.CHECK A/C RELAY DRIVE CIRCUIT VOLTAGE

2. Disconnect A/C relay.
3. Check the voltage between A/C relay harness connector terminals.
O
+
Voltage
A/C relay −
(Approx.)
Connector Terminal P
E52 1 Ground 0V
YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK M/C RELAY
EVC-321
P31D3 M/C RELAY
Check M/C relay. Refer to EVC-322, "Component Inspection (M/C Relay)".
YES >> GO TO 3.
NO >> Replace M/C relay.
3.CHECK A/C RELAY DRIVE CIRCUIT
Check harness for short to power, between M/C relay harness connector and A/C relay harness connector.
+
M/C relay − Voltage
Connector Terminal
E65 5 Ground 0V
YES >> GO TO 4.
4.CHECK M/C RELAY DRIVE CIRCUIT
2. Check harness for short to ground, between M/C relay harness connector and VCM harness connector.
+
M/C relay − Continuity
Connector Terminal
E65 1 Ground Not existed
5.CHECK A/C RELAY DRIVE CIRCUIT
2. Check harness for short to power, between A/C relay harness connector and VCM harness connector.
+
A/C relay − Voltage
Connector Terminal
E52 2 Ground 0V
Component Inspection (M/C Relay) INFOID:0000000010410337
1.CHECK M/C RELAY

2. Disconnect M/C relay.
EVC-322
P31D3 M/C RELAY
3. Check the continuity between M/C relay terminals under the fol-
lowing conditions. A
Termi- Continu-
Conditions
nals ity B
12 V direct current supply between terminals 1 and 2 Existed
3–5 Not ex-
No current supply
isted EVC
YES >> INSPECTION END PIIA2636J
NO >> Replace M/C relay. D
EVC-323
P31D4 PRE-CHARGE RELAY
DTC DETECTION LOGIC

After operating the power switch from OFF to READY, a break occurs in the
PRE CHARGE RELAY
P31D4 pre-charge relay drive circuit or resistance remains extremely high for 2.5
(Pre-charge relay)
seconds or more.
POSSIBLE CAUSE
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
3. Check DTC.
Is DTC detected?
1.CHECK PRE-CHARGE RELAY GROUND CIRCUIT

3. Check the continuity between Li-ion battery harness connector and ground.
Li-ion battery
Ground Continuity
Connector Terminal
Is inspection result normal?
YES >> GO TO 2.
2.CHECK PRE-CHARGE RELAY DRIVE CIRCUIT-1
Check the resistance between Li-ion battery connector terminals.
EVC-324
Li-ion battery A
+ − Resistance
Terminal
B
10 11 Less than 5 kΩ
YES >> GO TO 3. EVC
junction box. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Removal and Installation" (without battery cooler models) or EVB-515, "BATTERY JUNCTION D
E
3. CHECK PRE-CHARGE RELAY DRIVE CIRCUIT-2
2. Check continuity between VCM harness connector and Li-ion battery harness connector. F
+ −
VCM Li-ion battery Continuity G
E83 105 E128 11 Existed
H
YES >> INSPECTION END I
EVC-325
DTC DETECTION LOGIC

• The voltage of the traction motor inverter is 100 V or more immediately
PRE CHARGE RELAY before starting charging or immediately before READY.
P31D5
(Pre-charge relay) • The voltage of the traction motor inverter is 100 V or more when only the
system main relay 2 is ON.
POSSIBLE CAUSE
• Battery J/B
• VCM
• Battery heater
FAIL-SAFE
If DTC P31D5 is displayed with DTC P0AA2, P31D4, P31DB, or P31DD, first perform the trouble diagnosis for
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
With CONSULT
2. Turn power switch OFF and wait at least for 60 seconds.
Is DTC detected?
DANGER:
EVC-326
maintenance. A
WARNING:
ing inspection or maintenance of high voltage system harnesses and parts. B
• Never allow workers other than the responsible person to touch the vehicle containing high voltage EVC
• Refer to EVC-10, "High Voltage Precautions". D
CAUTION:
• Erase DTC after the work is completed. E

If DTC P31D5 is displayed with DTC P0AA2, P31D4, P31DB, or P31DD, first perform the trouble diagnosis for F
YES >> Perform diagnosis of applicable. Refer to EVC-98, "DTC Index". G
NO >> GO TO 2.
H
With CONSULT
Is DTC detected?
I
YES >> Perform detected DTC diagnosis procedure. Refer to TMS-34, "DTC Index".
NO >> GO TO 3.
3.CHECK SYSTEM MAIN RELAY DRIVE CIRCUIT J
3. Check the voltage between Li-ion battery harness connector and ground. K
+
Check item Li-ion battery − Voltage L
Connector Terminal
M
Pre-charge relay 11
YES >> GO TO 4.
NO >> Check harness for short to power.
4.PRECONDITIONING O
WARNING:
Follow the instructions below before starting the procedure. P
>> GO TO 5.
EVC-327
Electric compressor
+ − Resistance
Terminal
7 8 3 kΩ or more
YES >> GO TO 6.
6.CHECK PTC HEATER
Li-ion battery
Connector
Terminal
YES >> GO TO 7.
Li-ion battery
Connector
Terminal
PDM (Power Delivery
Module)
NO >> GO TO 8.
nals.
JSCIA0696ZZ

YES >> GO TO 9.
EVC-328
tion". A
B
lation".
EVC
Connector D
Terminal
3. Check the short circuit between high voltage harness connector (electric compressor side) and high volt- E
PDM (Power Delivery Module) F

G
YES >> GO TO 10. H
Check the short circuit between PDM (Power Delivery Module) terminals. I

J
+ − Resistance
Terminal
38 39 3 kΩ or more K
YES >> GO TO 13.
NO >> Replace PDM (Power Delivery Module). And then, GO TO 13. Refer to VC-108, "Removal and L
Installation".
11.CHECK BATTERY HEATER RELAY M
Installation".
3. Disconnect battery heater relay harness connector. N
Battery heater relay O

Continuity
Connector Terminal
10
LB18 Not existed P
11
YES >> GO TO 12.
EVC-329
Battery heater
Resistance
Connector Terminal
2
3
then, GO TO 13.
13.REPLACE BATTERY JUNCTION BOX
Replace battery junction box. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Removal and Installation" (without battery cooler models) or EVB-515, "BATTERY JUNCTION BOX AND BAT-
TERY HARNESS : Removal and Installation" (with battery cooler models) or EVB-814, "BATTERY JUNCTION
BOX AND BATTERY HARNESS : Removal and Installation" (with battery heater & cooler models).
>> INSPECTION END
EVC-330
P31D6 F/S RELAY
P31D6 F/S RELAY
A

F/S RELAY
P31D6 VCM detected the F/S relay stuck
(Fail-safe relay)
POSSIBLE CAUSE D
• IPDM E/R
• VCM E
FAIL-SAFE
Not applicable
F
1.PRECONDITIONING
G
CAUTION:
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the H
vehicle handling.
I
>> GO TO 2.
J
With CONSULT
2. Check DTC.
K
Is DTC detected?
L
M
1.CHECK F/S RELAY OUTPUT VOLTAGE-1
2. Check the voltage between IPDM E/R harness connector and ground. N
+
IPDM E/R − Voltage O
Connector Terminal
E15 55 Ground 0V
P
NO >> GO TO 2.
2.CHECK F/S RELAY DRIVE CIRCUIT VOLTAGE-1
Check the voltage between IPDM E/R harness connector and ground.
EVC-331
P31D6 F/S RELAY
+
Connector Terminal
12V battery volt-
E15 60 Ground
age
YES >> GO TO 5.
NO >> GO TO 3.
+
Connector Terminal
12V battery volt-
E15 60 Ground
age
NO >> GO TO 4.
4.CHECK F/S RELAY DRIVE CIRCUIT
2. Check harness for short to ground, between VCM harness connector and IPDM E/R harness connector.
+
IPDM E/R − Continuity
Connector Terminal
+
Connector Terminal
E15 55 Ground 0V
NO >> GO TO 6.
EVC-332
P31D6 F/S RELAY
+ A
Connector Terminal
B
E15 55 Ground 0V
YES >> Replace VCM. Refer to EVC-404, "Removal and Installation". EVC
NO >> Check harness for short to power, between VCM harness connector and IPDM E/R harness con-
nector.
D
EVC-333
P31D7 F/S RELAY
P31D7 F/S RELAY
DTC DETECTION LOGIC

F/S RELAY
P31D7 VCM detected the F/S relay open
(Fail-safe relay)
POSSIBLE CAUSE
• IPDM E/R
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
With CONSULT
2. Check DTC.
Is DTC detected?
1.CHECK FUSE
3. Check that fuse is not fusing.
YES >> GO TO 2.
2. Disconnect IPDM E/R harness connector (E9).
EVC-334
P31D7 F/S RELAY
+ A
Connector Terminal
B
12V battery volt-
E9 2 Ground
age
YES >> GO TO 3.
NO >> Check 12V battery power supply routing circuit.
3.CHECK F/S RELAY OUTPUT VOLTAGE D
1. Reconnect IPDM E/R harness connector (E15).
3. Check the voltage between IPDM E/R harness connector and ground. E
+
IPDM E/R − Voltage F
Connector Terminal
12V battery volt-
E15 55 Ground G
age
YES >> GO TO 9. H
NO >> GO TO 4.
Check the voltage between IPDM E/R harness connector and ground. I
+
Voltage J
IPDM E/R −
(Approx.)
Connector Terminal
E15 60 Ground 0V K
YES >> GO TO 7.
NO >> GO TO 5. L
5.CHECK F/S RELAY DRIVE CIRCUIT
1. Turn power switch OFF. M
2. Disconnect VCM harness connector and IPDM E/R harness connector.
3. Check continuity between VCM harness connector and IPDM E/R harness connector.
N
+ −
VCM IPDM E/R Continuity
Connector Terminal Connector Terminal O
P
YES >> GO TO 6.
EVC-335
P31D7 F/S RELAY
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
2. Disconnect IPDM E/R harness connector (E15).
3. Check the voltage between IPDM E/R connector and ground.
+
Terminal
60 Ground 12V battery voltage
YES >> GO TO 8.
8.CHECK F/S RELAY OUTPUT CIRCUIT
2. Check harness for short to ground, between IPDM E/R harness connector and VCM harness connector.
+
Connector Terminal
9.CHECK F/S RELAY OUTPUT CIRCUIT
2. Disconnect VCM harness connector and IPDM E/R harness connector.
3. Check continuity between VCM harness connector and IPDM E/R harness connector.
+ −
VCM IPDM E/R Continuity
EVC-336
P31DB SYSTEM MAIN RELAY +
A

HV BATT MAIN RELAY + System main relay 1 drive circuit remains short to ground for 2.5 seconds
P31DB
(High voltage battery main relay +) or more.
POSSIBLE CAUSE D
• VCM E
FAIL-SAFE
• READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
J
>> GO TO 2.
With CONSULT K
2. Check DTC.
Is DTC detected? L
1.CHECK SYSTEM MAIN RELAY 1 DRIVE CIRCUIT-1 N

3. Check continuity between Li-ion battery connector terminal and ground. O
+
P
Terminal
YES >> GO TO 2.
NO >> Check short circuit between Li-ion battery harness and ground.
EVC-337
2.CHECK SYSTEM MAIN RELAY 1 DRIVE CIRCUIT-2
2. Check harness for short to ground, between VCM harness connector and Li-ion battery harness connec-
tor.
+
Connector Terminal
EVC-338
P31DC SYSTEM MAIN RELAY -
A

HV BATT MAIN RELAY − System main relay 2 drive circuit remains short to ground for 2.5 seconds
P31DC
(High voltage battery main relay −) or more.
POSSIBLE CAUSE D
• VCM E
FAIL-SAFE
• READY OFF
1.PRECONDITIONING
CAUTION:
vehicle handling.
J
>> GO TO 2.
1. Set the vehicle to READY and wait at least 5 seconds. K
2. Check DTC.
Is DTC detected?
YES >> Proceed to EVC-339, "Diagnosis Procedure". L
M

N
3. Check continuity between Li-ion battery connector terminal and ground.
O
+
P
Terminal
YES >> GO TO 2.
EVC-339
tor.
+
Connector Terminal
EVC-340
P31DD PRE-CHARGE RELAY
A

PRE CHARGE RELAY Pre-charge relay drive circuit remains short to ground for 2.5 seconds or
P31DD
(Pre-charge relay) more.
POSSIBLE CAUSE D
• Harness or connectors (Pre-charge relay drive circuit is shorted.)
• Pre-charge relay
E
FAIL-SAFE
Not applicable
1.PRECONDITIONING
G
CAUTION:
vehicle handling. H
>> GO TO 2. I
1. Set the vehicle to READY and wait at least 5 seconds. J
2. Check DTC.
Is DTC detected?

3. Check continuity between Li-ion battery connector terminal and ground.
N
+
Terminal
O

Is the inspection result normal? P
YES >> GO TO 2.
tor.
EVC-341
+
Connector Terminal
EVC-342
P31DE SYSTEM MAIN RELAY
A

NOTE:
This DTC shows a forced system main relay disconnection by fail-safe.
EVC
HV BATT MAIN RELAY When the system main relay is shut off, VCM accumulates high voltage cur-
P31DE D
(High voltage battery main relay) rent value, and the accumulated value reaches the specified value.
POSSIBLE CAUSE
• Li-ion battery J/B E
• EV control system
FAIL-SAFE
F
TYPE 1
Traction motor output is limited.
TYPE 2 G
• READY OFF
H
DTC CONFIRMATION PROCEDURE I
1.PRECONDITIONING
CAUTION: J
vehicle handling. K
>> GO TO 2. L
With CONSULT M
2. Check DTC.
Is DTC detected?
N
O
1.PERFORM SELF-DIAGNOSIS OF VCM P

With CONSULT
Is DTC detected other than P31DE?
YES >> Perform diagnosis procedure of detected DTC. Refer to EVB-237, "BATTERY JUNCTION BOX
AND BATTERY HARNESS : Removal and Installation" (without battery cooler models) or EVB-
EVC-343
battery cooler models) or EVB-814, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Removal and Installation" (with battery heater & cooler models).
NO >> Replace Li-ion battery J/B. Refer to EVB-237, "BATTERY JUNCTION BOX AND BATTERY HAR-
NESS : Removal and Installation" (without battery cooler models) or EVB-515, "BATTERY JUNC-
TION BOX AND BATTERY HARNESS : Removal and Installation" (with battery cooler models) or
EVB-814, "BATTERY JUNCTION BOX AND BATTERY HARNESS : Removal and Installation"
(with battery heater & cooler models).
EVC-344
P31E0 HIGH VOLTAGE CIRCUIT INTERLOCK ERROR
A
The connection detecting circuit is used to detect the connection status of the PDM (Power Delivery Module) B
cover and the bus bar cover of PDM (Power Delivery Module).
The connection detecting circuit consists of two circuits (i.e. power supply circuit and signal input circuit).
When the PDM (Power Delivery Module) cover and the bus bar cover are installed normally, their protrusions
press the internal switch of PDM (Power Delivery Module). Accordingly, the connection detecting circuit is EVC
energized and a voltage signal is input.
D
DTC DETECTION LOGIC

E
VCM detects an excessively low voltage of the connection detecting circuit
HV SYSTEM INTERLOCK ERROR for 2.5 seconds during READY. F
P31E0
(High voltage system interlock error) VCM detects an excessively low voltage of the connection detecting circuit
for 0.5 seconds during power switch ON.
G
POSSIBLE CAUSE
• Harness or connectors (Connection detection circuit is open or shorted.)
H
FAIL-SAFE
TYPE 1
• Quick charge prohibited I
• READY OFF
• High-voltage power supply stop J
TYPE 2
Not applicable
K
1.PRECONDITIONING
• Turn power switch OFF and wait at least 90 seconds. L
CAUTION:
kind of vehicle handling is performed, then wait another 90 seconds or more from the time of the M
vehicle handling.
N
>> GO TO 2.
With CONSULT O
Is DTC detected? P
NO >> GO TO 3.
With CONSULT
1. Set the vehicle to READY at least 10 seconds.
EVC-345
Is DTC detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.OVERALL FUNCTION CHECK
With CONSULT
1. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “HV INTERLOCK (DC/DC)”.
2. Check that “On” is displayed.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
3.CHECK CONNECTION DETECTING CIRCUIT POWER SUPPLY
1. Disconnect PDM (Power Delivery Module) harness connector.
+
Connector Terminal
F18 12 Ground 3–7V
YES >> GO TO 5.
NO >> GO TO 4.
EVC-346
4.CHECK CONNECTION DETECTING CIRCUIT POWER SUPPLY CIRCUIT A
B
ground.
+
EVC
Connector Terminal
F18 12 Ground 0V D
NO >> Repair or replace error-detected parts. E
5.CHECK CONNECTION DETECTING CIRCUIT SIGNAL CIRCUIT

1. Turn power switch OFF. F
ground.
G
+
PDM (Power Delivery Module) − Voltage H
Connector Terminal
F18 15 Ground 0V
YES >> GO TO 6.
J
6.REPLACE VCM
2. Reconnect harness connector and parts disconnected. K
3. Perform DTC Confirmation Procedure. Refer to EVC-148, "DTC Description".
Is DTC P0A0B detected again?
YES >> Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation". L
EVC-347
VCM receives high voltage harness connector connection malfunction information via EV system CAN com-
munication sent from Li-ion battery controller. When Li-ion battery controller detects the connection malfunc-
tion of high voltage harness or detects the connection detecting system malfunction, Li-ion battery controller
sends a high voltage harness connector connection malfunction information to VCM.
DTC DETECTION LOGIC

HV SYSTEM INTERLOCK ERROR VCM receives the connection malfunction signal via EV system CAN com-
P31E1
(High voltage system interlock error) munication sent from Li-ion battery controller.
POSSIBLE CAUSE
• Harness and connector (Connection detecting circuit within Li-ion battery)
• Service plug
FAIL-SAFE
TYPE 1
• READY OFF
TYPE 2
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
2.PERFORM CONFIRMATION PROCEDURE-1
With CONSULT
Is DTC detected?
NO >> GO TO 3.
3.PERFORM CONFIRMATION PROCEDURE-2
With CONSULT
1. Set the vehicle to READY at least 10 seconds.
Is DTC detected?
EVC-348
DANGER: B
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are EVC
maintenance.
WARNING: D
CAUTION:
• Never bring the vehicle into the READY status with the service plug removed unless otherwise G
1. CHECK SELF-DIAGNOSTIC RESULT IN LBC H
Check self-diagnostic result in “HV BAT”.

Is any DTC detected? I
els).
J
NO >> GO TO 2.
2.PRECONDITIONING
WARNING: K
2. Check voltage in high voltage circuit. Refer to GI-31, "Check Voltage in High Voltage Circuit". L
>> GO TO 3.
3.CHECK SERVICE PLUG M
Check that the connection detection circuit within the service plug is not open. Refer to EVB-85, "Component
Inspection" (without battery cooler models) or EVB-359, "Component Inspection" (with battery cooler models)
or EVB-647, "Component Inspection" (with battery heater & cooler models). N
YES >> GO TO 4.
O
NO >> Replace service plug.
4.CHECK HIGH VOLTAGE HARNESS CONNECTOR INSTALLATION
Check high voltage harness connectors installation condition visually and tactually. P
CAUTION:
When reconnecting the high voltage harness connector, insert it slowly and directly.
YES >> GO TO 5.
5.CHECK HIGH VOLTAGE HARNESS CONNECTOR
EVC-349
1. Disconnect high voltage harness connector from Li-ion battery.
2. Check high voltage harness connector visually and tactually.
3. Check that the connection detection circuit (connector side) is not open.
YES >> Check a circuit within the Li-ion battery.
NO >> Replace error-detected parts.
EVC-350
P31E5 VCM POWER SUPPLY
A

VCM POWER SUPPLY The voltage of any one of two 12V battery power supplies becomes approx-
P31E5
(VCM power supply) imately 3 V or less when the power switch is ON.
POSSIBLE CAUSE D
Harness or connectors (Sensor power supply circuit is open or shorted.)
FAIL-SAFE E
Not applicable
1.PRECONDITIONING F

CAUTION:
G
vehicle handling.
>> GO TO 2.
I
With CONSULT
1. Turn power switch ON and wait at least 20 seconds. J
2. Check DTC.
Is DTC detected?
1.STOP LAMP FUNCTION CHECK

1. Depress the brake pedal. M
2. Check that the stop lamp lights up.
YES >> GO TO 6. N
NO >> GO TO 2.
2.CHECK FUSE O
2. Pull out #79 fuse and check that the fuse is not fusing.
YES >> GO TO 4.
NO >> GO TO 3.
2. Check harness for short to ground, between #37 fuse terminal and VCM harness connector.
EVC-351
+ − Continuity
#37 fuse terminal Ground Not existed
Check the voltage between #37 fuse terminal and ground.
+ − Voltage
#37 fuse terminal Ground 12V battery voltage
YES >> GO TO 5.
NO >> Perform trouble diagnosis for 12V battery power supply.
2. Check the continuity between #37 fuse terminal and VCM harness connector.
−
+ VCM Continuity
Connector Terminal
#37 fuse termi-
E81 1 Existed
nal
6.CHECK FUSE
2. Pull out #43 fuse and check that the fuse is not fusing.
YES >> GO TO 8.
NO >> GO TO 7.
3. Check harness for short to ground, between IPDM E/R harness connector and VCM harness connector.
+
Connector Terminal
EVC-352
+ A
Connector Terminal
B
YES >> GO TO 10. EVC
NO >> GO TO 9.
D
Check IPDM E/R power supply circuit. Refer to PCS-30, "Diagnosis Procedure".
YES >> Replace IPDM E/R. Refer to PCS-31, "Removal and Installation". E
1. Disconnect IPDM E/R harness connector. F
G
+ −
H
4. Also check harness for short to ground. I
YES >> GO TO 11.
NO >> Repair or replace error-detected parts. J
K
+
VCM − Continuity L
Connector Terminal
4
E81 M
8
Ground Existed
111
E83
112
N
EVC-353
P31E7 RESTART INHIBITION
P31E7 RESTART INHIBITION
DTC DETECTION LOGIC

RESTART INHIBITION
P31E7 VCM detects DTC “P0AA6”.
(Restart inhibition)
POSSIBLE CAUSE
VCM detects DTC “P0AA6”.
FAIL-SAFE
Doing READY again is prohibited.
1.INSPECTION START
NOTE:
This DTC is displayed when VCM detects DTC “P0AA6”. If this DTC displayed, perform trouble diagnosis for
DTC “P0AA6”.

Perform trouble diagnosis for DTC “P0AA6”. Refer to EVC-179, "DTC Description".
EVC-354
P31E8 WATER PUMP
P31E8 WATER PUMP
A

Electric water pump feedback duty keeps either of the following conditions
for 30 seconds.
WATER PUMP 1
P31E8 • Less than 3%
(Water pump 1) D
• 91% or more
• Between 13% and 17%
POSSIBLE CAUSE E
• Electric water pump
• VCM
F
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling. I
>> GO TO 2. J

With CONSULT K
3. Check DTC. L
Is DTC detected?
N
Is DTC detected other than P31E8? O
YES >> Perform diagnosis procedure of detected DTC. Refer to EVC-98, "DTC Index".
NO >> GO TO 2.
P
2.CHECK WATER PUMP FEEDBACK DUTY-1
With CONSULT
2. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “W/P 1 CRNT SPD DUTY”.
3. Check “W/P 1 CRNT SPD DUTY” value.
Is value more than 91%?
EVC-355
P31E8 WATER PUMP
YES >> GO TO 5.
NO >> GO TO 3.
With CONSULT
Check “W/P 1 CRNT SPD DUTY” value.
Is value less than 3%?
YES >> GO TO 5.
NO >> GO TO 4.
With CONSULT
1. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “W/P 1 CRNT SPD DUTY” and
“WATER PUMP 1 TRG DUTY”.
2. Check that “W/P 1 CRNT SPD DUTY” and “WATER PUMP 1 TRG DUTY” agree with the values listed
below.
W/P 1 CRNT SPD DUTY 17 – 82%

WATER PUMP 1 TRG DUTY 20 – 80%
Are the above values satisfied?
YES >> GO TO 5.
5.CHECK WATER PUMP SIGNAL CIRCUIT
2. Disconnect electric water pump harness connector and VCM harness connector.
3. Check the continuity between electric water pump harness connector and VCM harness connector.
Electric water pump VCM

Continuity
Connector Terminals Connector Terminals
3 E82 62
E67 Existed
4 E81 28
YES >> GO TO 6.
6.CHECK FUSE
YES >> GO TO 7.
7.CHECK WATER PUMP INPUT POWER VOLTAGE
2. Disconnect water pump harness connector.
4. Check the voltage between water pump harness connector and ground.
EVC-356
P31E8 WATER PUMP
+ A
Electric water pump − Voltage
Connector Terminal
B
12V battery volt-
E67 1 Ground
age
YES >> Replace electric water pump. Refer to HCO-24, "Removal and Installation".
NO >> GO TO 8.
8.CHECK WATER PUMP INPUT POWER CIRCUIT-1 D
3. Check the continuity between electric water pump harness connector and fuse terminal. E
+
Electric water pump − Continuity F
Connector Terminal
#81 fuse termi-
E67 1 Existed G
nal
YES >> GO TO 9.
9.CHECK WATER PUMP INPUT POWER CIRCUIT-2 I
1. Remove M/C relay.
2. Check the continuity between M/C relay harness connector and fuse terminal.
J
+
K
Connector Terminal
#81 fuse termi-
E65 5 Existed
nal L
YES >> Perform trouble diagnosis for M/C relay routing circuit. Refer to EVC-371, "Diagnosis Procedure". M
EVC-357
P31E9 WATER PUMP
P31E9 WATER PUMP
DTC DETECTION LOGIC

WATER PUMP 1 Electric water pump feedback duty keeps between 82% and 91% for 30
P31E9
(Water pump 1) seconds.
POSSIBLE CAUSE
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
3. Check DTC.
Is DTC detected?
1.CHECK DTC
Is DTC detected other than P31E9?
YES >> Perform diagnosis procedure of detected DTC. Refer to EVC-98, "DTC Index".
NO >> GO TO 2.
2.CHECK WATER PUMP FEEDBACK DUTY
With CONSULT
On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “W/P 1 CRNT SPD DUTY”.
Is value between 82% and 91%?
YES >> GO TO 3.
3.CHECK FUSE
EVC-358
P31E9 WATER PUMP
Is the inspection result normal? A
YES >> GO TO 4.
4.CHECK WATER PUMP INPUT POWER VOLTAGE B

2. Disconnect water pump harness connector.
EVC
4. Check the voltage between water pump harness connector and ground.
D
+
Electric water pump − Voltage
Connector Terminal E
12V battery volt-
E67 1 Ground
age
YES >> Replace electric water pump. Refer to HCO-24, "Removal and Installation".
NO >> GO TO 5.
5.CHECK WATER PUMP INPUT POWER CIRCUIT-1 G

3. Check the continuity between electric water pump harness connector and fuse terminal. H
+
I
Electric water pump − Continuity
Connector Terminal
E67 1
#81 fuse termi-
Existed
J
nal
YES >> GO TO 6.
6.CHECK WATER PUMP INPUT POWER CIRCUIT-2 L

2. Check the continuity between M/C relay harness connector and fuse terminal.
M
+
M/C relay − Continuity N
Connector Terminal
#81 fuse termi-
E65 5 Existed
nal O
P
YES >> Perform trouble diagnosis for M/C relay routing circuit. Refer to EVC-371, "Diagnosis Procedure".
EVC-359
P31EC WATER PUMP
P31EC WATER PUMP
DTC DETECTION LOGIC

NOTE:
This DTC may be detected where there is the mixing of air into coolant.

WATER PUMP 1 Electric water pump feedback duty keeps between 3% and 7% for 30 sec-
P31EC
(Water pump 1) onds.
POSSIBLE CAUSE
• VCM
FAIL-SAFE
Not applicable
1.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 2.
3. Check DTC.
Is DTC detected?
1.CHECK DTC
Is DTC detected other than P31EC?
YES >> Perform diagnosis procedure of detected DTC Refer to EVC-98, "DTC Index".
NO >> GO TO 2.
2.CHECK WATER PUMP FEEDBACK DUTY
On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “W/P 1 CRNT SPD DUTY”.
Is value between 3% and 7%?
YES >> GO TO 3.
NO >> GO TO 4.
3.CHECK COOLANT
EVC-360
P31EC WATER PUMP
2. Check that the coolant is free from air mixture.
YES >> GO TO 4.
NO >> Perform the air bleeding. Refer to HCO-11, "Draining".
4.PERFORM DTC CONFIRMATION PROCEDURE AGAIN B
With CONSULT
1. Turn power switch ON and erase DTC. EVC
Is DTC “P31EC” detected again?
EVC-361
P31EE REFRIGERANT PRESSURE SENSOR
DTC DETECTION LOGIC

• Signal voltage from refrigerant pressure sensor remains Approx. 0 V for
REFRIGERANT PRESSURE SENSOR 2.5 seconds or more
P31EE
(Refrigerant pressure sensor) • Signal voltage from refrigerant pressure sensor remains Approx. 4.7 V or
more for 2.5 seconds or more
POSSIBLE CAUSE
• Harness or connectors (Refrigerant pressure sensor circuit is open or shorted.)
• VCM
FAIL-SAFE
Not applicable
If DTC P31EE is displayed with DTC P31E5, first perform the trouble diagnosis for DTC P31E5.
NO >> GO TO 2.
2.PRECONDITIONING
CAUTION:
vehicle handling.
>> GO TO 3.
3.PERFORM CONFIRMATION PROCEDURE
With CONSULT
Is DTC detected?

If DTC P31EE is displayed with DTC P31E5, first perform the trouble diagnosis for DTC P31E5.
NO >> GO TO 2.
2.CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY-1
2. Disconnect refrigerant pressure sensor harness connector.
EVC-362
4. Check the voltage between refrigerant pressure sensor harness connector terminals. A
Refrigerant pressure sensor

Voltage B
+ −
Connector (Approx.)
Terminal
E96 3 1 5V
EVC
YES >> GO TO 7.
NO >> GO TO 3. D
3.CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY-2
Check the voltage between refrigerant pressure sensor harness connector and ground.
E
+
Voltage
Refrigerant pressure sensor −
(Approx.) F
Connector Terminal
E96 3 Ground 5V
YES >> GO TO 5.
NO >> GO TO 4.
H
4.CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT
2. Disconnect VCM harness connector. I
3. Check the continuity between refrigerant pressure sensor and VCM harness connector.
+ − J
Refrigerant pressure sensor VCM Continuity
E96 3 E82 33 Existed K
Is the inspection result normal? L
YES >> Check power supply circuit for sensor power supply. Refer to EVC-351, "Diagnosis Procedure".
5.CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT M
3. Check the continuity between refrigerant pressure sensor and VCM harness connector. N
+ −
Refrigerant pressure sensor VCM Continuity O
P
YES >> GO TO 6.
EVC-363
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
7.CHECK REFRIGERANT PRESSURE SENSOR SIGNAL CIRCUIT
3. Check the continuity between refrigerant pressure sensor harness connector and VCM harness connec-
tor.
+ −
Refrigerant pressure sensor VCM Continuity
4. Also check harness for short to power and short to ground.
YES >> Replace refrigerant pressure sensor. Refer to HA-111, "HIGH-PRESSURE PIPE (WITHOUT BAT-
TERY COOLER AND REAR COOLER) : Removal and Installation".
EVC-364
P31F2 AV INFORMATION MISMATCH
A

AV SET INFORMATION Setting of timer charge does not succeed for 5 seconds after VCM receives
P31F2
(AV set information) a timer charge set signal.
POSSIBLE CAUSE D
• AV control unit
• VCM
E
FAIL-SAFE
VCM inhibits the timer charge and the remote climate control.
1.PRECONDITIONING
G
CAUTION:
vehicle handling. H
>> GO TO 2. I
With CONSULT J
CAUTION:
vehicle handling.
3. Change the timer charge setting 1 on navigation display and wait at least 10 seconds. L
4. Check DTC.
Is DTC detected?
YES >> Proceed to EVC-366, "Diagnosis Procedure". M
NO >> GO TO 3.
N
With CONSULT
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some O
vehicle handling.
2. Turn power switch ON. P
3. Change the timer charge setting 2 on navigation display and wait at least 10 seconds.
4. Check DTC.
Is DTC detected?
NO >> GO TO 4.
EVC-365
With CONSULT
CAUTION:
vehicle handling.
3. Change the Climate Ctrl. Timer setting 1 on navigation display and wait at least 10 seconds.
4. Check DTC.
Is DTC detected?
NO >> GO TO 5.
CAUTION:
vehicle handling.
3. Change the Climate Ctrl. Timer setting 2 on navigation display and wait at least 10 seconds.
4. Check DTC.
Is DTC detected?
1.REPLACE AV CONTROL UNIT

1. Replace AV control unit. Refer to AV-187, "Removal and Installation".
2. Erase DTC.
EVC-366
COOLING FAN
COOLING FAN
A
Component Function Check INFOID:0000000010410376
1.CHECK COOLING FAN FUNCTION B
WITH CONSULT
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT. EVC
3. Check that cooling fan speed varies according to the percentage.
YES >> INSPECTION END D
E
1.CHECK COOLING FAN CONTROL MODULE POWER SUPPLY

2. Disconnect cooling fan control module harness connector.
4. Check the voltage between cooling fan control module harness connector and ground.
G
+
Cooling fan control module − Voltage H
Connector Terminal
12V battery volt-
E19 3 Ground
age I
YES >> GO TO 11.
NO >> GO TO 2. J
1. Turn power switch OFF. K
2. Remove cooling fan relay.
3. Check the voltage between cooling fan relay harness connector and ground.
L
+
Cooling fan relay − Voltage
12V battery volt-
E18 3 Ground
age
YES >> GO TO 3.
NO >> Check power supply circuit for 12V battery power supply.
3.CHECK COOLING FAN RELAY OUTPUT VOLTAGE-1 O

2. Check the voltage between cooling fan relay harness connector and ground.
P
+
Cooling fan relay − Voltage
Connector Terminal
12V battery volt-
E18 1 Ground
age
EVC-367
COOLING FAN
YES >> GO TO 8.
NO >> GO TO 4.
4.CHECK FUSE
YES >> GO TO 5.
5.CHECK COOLING FAN RELAY OUTPUT VOLTAGE-2
2. Check the voltage between fuse terminal and ground.
+ − Voltage
12V battery volt-
#83 fuse terminal Ground
age
YES >> GO TO 7.
NO >> GO TO 6.
6.CHECK M/C RELAY OUTPUT CIRCUIT
3. Check the continuity between M/C relay harness connector terminal and fuse harness connector.
+
Connector Terminal
#83 fuse termi-
E65 5 Existed
nal
YES >> Check M/C relay routing circuit. Refer to EVC-371, "Diagnosis Procedure".
7.CHECK COOLING FAN CONTROL MODULE POWER SUPPLY CIRCUIT
2. Check the continuity between cooling fan relay harness connector and fuse terminal.
+
Cooling fan relay − Continuity
Connector Terminal
#83 fuse termi-
E18 1 Existed
nal
8.CHECK COOLING FAN RELAY GROUND CIRCUIT
EVC-368
COOLING FAN
2. Check the continuity between cooling fan relay harness connector and ground.
A
+
Cooling fan relay − Continuity
B
Connector Terminal
YES >> GO TO 9.
9.CHECK COOLING FAN CONTROL MODULE POWER SUPPLY CIRCUIT D
1. Check the continuity between cooling fan relay harness connector and cooling fan control module harness
connector.
E
+ −
Cooling fan control module Cooling fan relay Continuity
F
E19 3 E18 5 Existed
2. Also check harness for short to ground. G
YES >> GO TO 10.
H
10.CHECK COOLING FAN RELAY
Check cooling fan relay. Refer to EVC-370, "Component Inspection (Cooling Fan Relay)". I
NO >> Replace cooling fan relay. J
11.CHECK COOLING FAN CONTROL MODULE GROUND CIRCUIT
K
2. Check the continuity between cooling fan control module harness connector and ground.
+
L
Cooling fan control module − Continuity
Connector Terminal
E19 1 Ground Existed M
YES >> GO TO 12.
NO >> Repair or replace error-detected parts. N
12.CHECK COOLING FAN MOTOR 1 AND 2

Check cooling fan motor. Refer to EVC-370, "Component Inspection (Cooling Fan Motor)". O
YES >> GO TO 13.
NO >> Replace malfunctioning cooling fan motor. Refer to HCO-21, "Exploded View". P
13.CHECK COOLING FAN CONTROL SIGNAL CIRCUIT
2. Check the continuity between cooling fan control module harness connector and VCM harness connector.
EVC-369
COOLING FAN
+ −
Cooling fan control module VCM Continuity
YES >> GO TO 14.
14.REPLACE COOLING FAN CONTROL MODULE
1. Replace cooling fan control module. Refer to HCO-21, "Exploded View".
2. Erase the DTC.
3. Perform component function check. Refer to EVC-367, "Component Function Check".
Component Inspection (Cooling Fan Motor) INFOID:0000000010410378
1.CHECK COOLING FAN MOTOR

2. Disconnect cooling fan control module harness connectors.
3. Supply cooling fan control module harness connector terminals with 12V battery voltage as per the follow-
ing, and check operation.
Cooling fan control module

Terminal Operation
Motor Connector
+ –
1 E301 4 5
Cooling fan operates.
2 E302 6 7
NO >> Replace malfunctioning cooling fan motor. Refer to HCO-21, "Exploded View".
Component Inspection (Cooling Fan Relay) INFOID:0000000010410379
1.CHECK COOLING FAN RELAY

2. Remove cooling fan relay.
3. Check the continuity between cooling fan relay terminals under
the following conditions.
Terminals Conditions Continuity

3 and 5
No current supply Not existed
NO >> Replace cooling fan relay.
MBIB0057E
EVC-370
M/C RELAY
M/C RELAY
A
1.CHECK BATTERY POWER SUPPLY-1 B

3. Check the voltage between M/C relay harness connector and ground. EVC
+
M/C relay − Voltage D
Connector Terminal
2 12V battery volt-
E65 Ground E
3 age

YES >> GO TO 5. F
NO >> GO TO 2.
2.CHECK FUSIBLE LINK
G
1. Remove #M fusible link.
2. Check that the fusible link is not fusing.
H
YES >> GO TO 3.
NO >> Replace the fusible link after repairing the applicable circuit.
3.CHECK BATTERY POWER SUPPLY-2 I
Check the voltage between fusible link harness connector and ground.
+ − Voltage J
12V battery volt-
#M fusible link terminal Ground
age
K
YES >> GO TO 4.
NO >> Check power supply circuit for battery power supply.
L
4.CHECK BATTERY POWER SUPPLY CIRCUIT
1. Check the continuity between M/C relay harness connector and fusible link harness connector.
M
−
+ M/C relay Continuity
N
Connector Terminal
#M fusible link 2
E65 Existed
terminal 3 O
YES >> Check intermittent incident. Refer to GI-47, "Intermittent Incident". P
5.CHECK M/C RELAY
YES >> GO TO 6.
EVC-371
M/C RELAY
6.CHECK M/C RELAY CONTROL SIGNAL CIRCUIT
3. Check the continuity between M/C relay harness connector and VCM harness connector.
+ −
M/C relay VCM Continuity
YES >> GO TO 7.
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
Component Inspection (M/C Relay) INFOID:0000000010410381
1.CHECK M/C RELAY

lowing conditions.

3 and 5
PIIA2636J
EVC-372
F/S CHG RELAY
F/S CHG RELAY
A
1.CHECK F/S CHG RELAY POWER SUPPLY-1 B

2. Remove F/S CHG relay.
4. Check the voltage between F/S CHG relay harness connector and ground.
+ D
F/S CHG relay − Voltage
Connector Terminal
E
12V battery volt-
E64 2 Ground
age
F
YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK F/S CHG RELAY POWER SUPPLY-2 G
+ H
Connector Terminal
I
12V battery volt-
E15 55 Ground
age
YES >> GO TO 3.
NO >> Check F/S relay routing circuit. Refer to EVC-334, "Diagnosis Procedure".
3.CHECK F/S CHG RELAY POWER SUPPLY CIRCUIT K
3. Check the continuity between F/S CHG relay harness connector and IPDM E/R harness connector. L
+ −
M
F/S CHG relay IPDM E/R Continuity
E64 2 E15 55 Existed N
YES >> Check intermittent incident. Refer to GI-47, "Intermittent Incident". O
P
Check the voltage between F/S CHG relay harness connector and ground.
EVC-373
F/S CHG RELAY
+
Connector Terminal
12V battery volt-
E64 3 Ground
age
YES >> GO TO 8.
NO >> GO TO 5.
5.CHECK FUSE
YES >> GO TO 6.
Check the voltage between #34 fuse harness connector and ground.
+ − Voltage
YES >> GO TO 7.
1. Check the continuity between F/S CHG relay harness connector and #33 fuse harness connector.
−
+ F/S CHG relay Continuity
Connector Terminal
#34 fuse termi-
E64 3 Existed
nal
8.CHECK F/S CHG RELAY
Check F/S CHG relay. Refer to EVC-375, "Component Inspection (F/S CHG Relay)".
YES >> GO TO 9.
NO >> Replace F/S CHG relay.
9.CHECK F/S CHG RELAY CONTROL SIGNAL CIRCUIT
3. Check the continuity between F/S CHG relay harness connector and VCM harness connector.
EVC-374
F/S CHG RELAY
+ − A
F/S CHG relay VCM Continuity
B
YES >> GO TO 10.
10.CHECK VCM GROUND CIRCUIT D

E
+
VCM − Continuity
4
E81
8
Ground Existed G
111
E83
112
I
Component Inspection (F/S CHG Relay) INFOID:0000000010410383
1.CHECK F/S CHG RELAY J

3. Check the continuity between F/S CHG relay terminals under
the following conditions. K

L
3 and 5
NO >> Replace F/S CHG relay.
PIIA2636J
N
EVC-375
REVERSE LAMP RELAY
REVERSE LAMP RELAY
1.CHECK REVERSE LAMP RELAY FUNCTION

2. Shift the selector lever in R position.
3. Check that the reverse lamp turns ON.
1.CHECK POWER ON POWER SUPPLY-1

1. Shift the selector lever in P position.
3. Remove reverse lamp relay.
5. Check the voltage between reverse lamp relay harness connector and ground.
+
Reverse lamp relay − Voltage
Connector Terminal
12V battery volt-
E27 1 Ground
age
YES >> GO TO 5.
NO >> GO TO 2.
+
Connector Terminal
12V battery volt-
E15 58 Ground
age
YES >> GO TO 4.
NO >> GO TO 3.
3.CHECK FUSE
YES >> Check power supply circuit for power ON power supply.
4.CHECK POWER ON POWER SUPPLY CIRCUIT
3. Check the continuity between reverse lamp relay harness connector and IPDM E/R harness connector.
EVC-376
REVERSE LAMP RELAY
+ − A
Reverse lamp relay IPDM E/R Continuity
B
YES >> Check intermittent incident. Refer to GI-47, "Intermittent Incident". EVC
D
Check the voltage between reverse lamp relay harness connector and ground.
+
E
Reverse lamp relay − Voltage
Connector Terminal
12V battery volt- F
E27 3 Ground
age
YES >> GO TO 7. G
NO >> GO TO 6.
6.CHECK POWER ON POWER SUPPLY CIRCUIT H
3. Check the continuity between reverse lamp relay harness connector and IPDM E/R harness connector.
I
+ −
Reverse lamp relay IPDM E/R Continuity J
K
L
7.CHECK REVERSE LAMP RELAY
Check reverse lamp relay. Refer to EVC-378, "Component Inspection (Reverse Lamp Relay)".
YES >> GO TO 8.
NO >> Replace reverse lamp relay.
8.CHECK REVERSE LAMP RELAY CONTROL SIGNAL CIRCUIT N

3. Check the continuity between reverse lamp relay harness connector and VCM harness connector. O
+ −
P
Reverse lamp relay VCM Continuity
YES >> GO TO 9.
EVC-377
REVERSE LAMP RELAY
+
VCM − Continuity
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
Component Inspection (Reverse Lamp Relay) INFOID:0000000010410389
1.CHECK REVERSE LAMP RELAY

2. Remove reverse lamp relay.
3. Check the continuity between reverse lamp relay terminals
under the following conditions.

3 and 5
NO >> Replace reverse lamp relay.
MBIB0057E
EVC-378
A/C RELAY
A/C RELAY
A
1.CHECK A/C RELAY POWER SUPPLY B

2. Remove A/C relay.
4. Check the voltage between A/C relay harness connector and ground.
+ D
Connector Terminal
E
12V battery volt-
E52 1 Ground
age
F
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK A/C RELAY POWER SUPPLY CIRCUIT G
3. Check the continuity between A/C relay harness connector and M/C relay harness connector. H
+ −
M/C relay A/C relay Continuity I
E65 5 E52 1 Existed
J
YES >> Perform trouble diagnosis for M/C relay related circuit. Refer to EVC-371, "Diagnosis Procedure".
NO >> Repair or replace error-detected parts. K
Check the voltage between A/C relay harness connector and ground.
L
+
M
Connector Terminal
3 12V battery volt-
E52 Ground
6 age N
YES >> GO TO 6.
NO >> GO TO 4. O
4.CHECK FUSE
1. Turn power switch OFF. P
YES >> GO TO 5.
EVC-379
A/C RELAY
Check the continuity between A/C relay harness connector and fuse terminal.
+
A/C relay − Continuity
Connector Terminal
3 #36 fuse termi-
E52 Existed
6 nal

YES >> Check 12V battery power supply circuit.
6.CHECK A/C RELAY
Check A/C relay. Refer to EVC-380, "Component Inspection (A/C Relay)".
YES >> GO TO 7.
NO >> Replace A/C relay.
7.CHECK A/C RELAY CONTROL SIGNAL CIRCUIT
2. Check the continuity between A/C relay harness connector and VCM harness connector.
+ −
A/C relay VCM Continuity
E52 2 E81 5 Existed
YES >> GO TO 8.
+
Connector Terminal
4
E81
8
Ground Existed
111
E83
112
Component Inspection (A/C Relay) INFOID:0000000010410391
1.CHECK A/C RELAY

2. Remove A/C relay.
EVC-380
A/C RELAY
3. Check the continuity between A/C relay terminals under the fol-
lowing conditions. A
Conditions Terminals Continuity

3–5 B
6–7
3–5
No current supply Not existed EVC
6–7
Is the inspection result normal? PBIB0077E

NO >> Replace A/C relay.
EVC-381
CHARGING STATUS INDICATOR
1.CHECK CHARGING STATUS INDICATOR FUNCTION

With CONSULT
2. Select “CHARGE STAT INDICATOR 1” of “ACTIVE TEST” mode in “EV/HEV” with CONSULT.
3. Activate the charging status indicator 1 and check that the indicator illuminates.
4. Check charging status indicator 2 and 3 in the same way.
1.CHECK CHARGING STATUS INDICATOR POWER SUPPLY

2. Disconnect charging status indicator harness connector.
3. Check the voltage between charging status indicator harness connector and ground.
+
Charging status indicator − Voltage
Connector Terminal
M101 4 Ground 12V battery voltage
YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK FUSE
Pull out #5 fuse and check that the fuse is not fusing.
YES >> GO TO 3.
NO >> Replace the fuse after repair the applicable circuit.
3.CHECK CHARGING STATUS INDICATOR POWER SUPPLY CIRCUIT
1. Check the continuity between charging status indicator and the fuse terminal.
+
Charging status indicator − Continuity
Connector Terminal
M101 4 #5 fuse terminal Existed
YES >> Check 12V battery power supply circuit.
4.CHECK CHARGING STATUS INDICATOR GROUND CIRCUIT
2. Check the continuity between charging status indicator harness connector and VCM harness connector.
EVC-382
+ − A
Items Charging status indicator VCM Continuity
B
Charging status indicator 1 1 86
Charging status indicator 2 M101 2 E83 85 Existed
Charging status indicator 3 3 92 EVC
3. Also check harness for short to ground and short to battery.
D
YES >> GO TO 5.
5.CHECK VCM GROUND CIRCUIT E
+ F
VCM − Continuity
Connector Terminal
G
4
E81
8
Ground Existed
111 H
E83
112
I
YES >> Replace charging status indicator. Refer to VC-133, "Removal and Installation".
EVC-383
IMMEDIATE CHARGING SWITCH
1.CHECK IMMEDIATE CHARGING SWITCH ILLUMINATION FUNCTION

2. Turn ON the headlamp.
3. Check that the immediate charging switch illumination lights up.
YES >> GO TO 6.
NO >> GO TO 2.
2.CHECK IMMEDIATE CHARGING SWITCH ILLUMINATION POWER SUPPLY
Check the voltage between immediate charging switch and ground.
+
Immediate charging switch − Voltage
Connector Terminal
YES >> GO TO 5.
NO >> GO TO 3.
3.CHECK FUSE
2. Turn OFF the headlamp.
YES >> GO TO 4.
4.CHECK IMMEDIATE CHARGING SWITCH ILLUMINATION POWER SUPPLY CIRCUIT
1. Disconnect immediate charging switch harness connector.
2. Check the continuity between immediate charging switch harness connector and fuse terminal.
+
Immediate charging switch − Continuity
Connector Terminal
#47 fuse termi-
M65 3 Existed
nal
YES >> Check power supply circuit.
5.CHECK IMMEDIATE CHARGING SWITCH GROUND CIRCUIT
4. Check the continuity between immediate charging switch harness connector and ground.
EVC-384
+ A
Connector Terminal
B
M65 4 Ground Existed
YES >> Replace immediate charging switch. Refer to VC-132, "Removal and Installation". EVC
6.CHECK IMMEDIATE CHARGING SWITCH POWER SUPPLY
D
4. Turn power switch ON. E
5. Check the voltage between immediate charging switch harness connector and ground.
+ F
Immediate charging switch − Voltage
Connector Terminal
G
12V battery volt-
M65 1 Ground
age
YES >> GO TO 8.
NO >> GO TO 7.
7.CHECK IMMEDIATE CHARGING SWITCH SIGNAL CIRCUIT I
3. Check the continuity between immediate charging switch harness connector and VCM harness connector. J
+ −
Immediate charging switch VCM Continuity K
L
YES >> GO TO 8. M
8.CHECK IMMEDIATE CHARGING SWITCH GROUND CIRCUIT
N
Check the continuity between immediate charging switch harness connector and ground.
+
O
Connector Terminal
M65 2 Ground Existed P
YES >> GO TO 9.
9.CHECK IMMEDIATE CHARGING SWITCH
Perform component inspection. Refer to EVC-386, "Component Inspection (Immediate Charging Switch)".
EVC-385
NO >> Replace immediate charging switch. Refer to VC-132, "Removal and Installation".
Component Inspection (Immediate Charging Switch) INFOID:0000000010410395
1.CHECK IMMEDIATE CHARGING SWITCH

3. Check the continuity between immediate charging switch terminals under the following conditions.
Immediate Released Not existed

1 and 2
charging switch Pressed Existed
NO >> Replace immediate charging switch. Refer to VC-132, "Removal and Installation".
EVC-386
ECO MODE SWITCH
ECO MODE SWITCH
A
1.CHECK ECO MODE SWITCH ILLUMINATION FUNCTION B

2. Turn ON the headlamp.
3. Check that the ECO mode switch illumination lights up. EVC
YES >> GO TO 6.
NO >> GO TO 2. D
2.CHECK ECO MODE SWITCH ILLUMINATION POWER SUPPLY
Check the voltage between ECO mode switch and ground. E
+
ECO mode switch − Voltage F
Connector Terminal
G
YES >> GO TO 5.
NO >> GO TO 3.
H
3.CHECK FUSE
2. Turn OFF the headlamp. I
YES >> GO TO 4.
4.CHECK ECO MODE SWITCH ILLUMINATION POWER SUPPLY CIRCUIT K
1. Disconnect ECO mode switch harness connector.
2. Check the continuity between ECO mode switch harness connector and fuse terminal.
L
+
ECO mode switch − Continuity
M
Connector Terminal
#47 fuse termi-
M55 3 Existed
nal
N
YES >> Check power supply circuit.
5.CHECK ECO MODE SWITCH GROUND CIRCUIT
2. Turn OFF the headlamp. P
4. Check the continuity between ECO mode switch harness connector and ground.
EVC-387
ECO MODE SWITCH
+
Connector Terminal
YES >> Replace ECO mode switch. Refer to EVC-406, "Removal and Installation".
6.CHECK ECO MODE SWITCH FUNCTION
With CONSULT
2. On the CONSULT screen, select “EV/HEV” >> “DATA MONITOR” >> “ECO MODE”.
3. Check each item indication under the following conditions.

Operate the ECO mode SW to put into
On
ECO mode.
ECO MODE
Operate the ECO mode SW again to
Off
cancel ECO mode.
NO >> GO TO 7.
7.CHECK ECO MODE SWITCH POWER SUPPLY
4. Check the voltage between ECO mode switch harness connector and ground.
+
ECO mode switch − Voltage
Connector Terminal
12V battery volt-
M55 1 Ground
age
YES >> GO TO 9.
NO >> GO TO 8.
8.CHECK ECO MODE SWITCH SIGNAL CIRCUIT
3. Check the continuity between ECO mode switch harness connector and VCM harness connector.
+ −
ECO mode switch VCM Continuity
YES >> GO TO 9.
EVC-388
ECO MODE SWITCH
9.CHECK ECO MODE SWITCH GROUND CIRCUIT A
Check the continuity between ECO mode switch harness connector and ground.
+ B
Connector Terminal
EVC
YES >> GO TO 10. D
10.CHECK ECO MODE SWITCH
Perform component inspection. Refer to EVC-389, "Component Inspection (ECO Mode Switch)". E
NO >> Replace ECO mode switch. Refer to EVC-406, "Removal and Installation". F
Component Inspection (ECO Mode Switch) INFOID:0000000011237787
G
1.CHECK ECO MODE SWITCH
2. Disconnect ECO mode switch harness connector. H
3. Check the continuity between ECO mode switch terminals under the following conditions.
Terminals Condition Continuity I

ECO mode Released Not existed
1 and 2
switch Pressed Existed
J
NO >> Replace ECO mode switch. Refer to EVC-406, "Removal and Installation".
K
EVC-389
EV CONTROL SYSTEM
SYMPTOM DIAGNOSIS
EV CONTROL SYSTEM
Symptom Index INFOID:0000000010410408
NOTE:
• Perform self-diagnoses with CONSULT before performing the symptom diagnosis.
• If any DTC is detected, perform the corresponding diagnosis.
Symptom Reference page

READY status cannot be achieved. EVC-391, "READY Status Cannot Be Achieved"
Unable to travel. EVC-392, "Unable to Travel"
Low electrical consumption EVC-393, "Low Electrical Consumption"
Power switch does not turn OFF. EVC-394, "Power Switch Does Not Turn OFF"
No regeneration EVC-395, "No Regeneration"
Decelerating force changes EVC-396, "Decelerating Force Changes"
Normal charge does not start. EVC-397, "Normal Charge Does Not Start"
Timer charge and remote charge does not start. EVC-398, "Timer Charge and Remote Charge Does Not Start"
Immediate charge does not start. EVC-399, "Immediate Charge Does Not Start"
Normal charge is not completed. EVC-399, "Normal Charge Is Not Completed"
Quick charge does not start. EVC-400, "Quick Charge Does Not Start"
Quick charge is not completed. EVC-400, "Quick Charge Is Not Completed"
Full charge cannot be achieved. EVC-401, "Full Charge Cannot Be Achieved"
Climate Ctrl. Timer does not start. EVC-401, "Climate Ctrl. Timer Does Not Start"
Remote climate control does not start. EVC-402, "Remote climate control Does Not Start"
EVC-390
EV CONTROL SYSTEM
READY Status Cannot Be Achieved INFOID:0000000010410409
Symptom Possible cause Action

EVC-213, "Component Inspection B
Abnormal stop lamp switch.
(Stop Lamp Switch)"
Abnormal stop lamp switch Check the signal line between stop
BCM does not output a signal line. lamp switch and BCM. EVC
READY signal. PCS-76,
Abnormal power switch
"Component Function Check"
Abnormal power switch sig- Check the signal line between BCM D
nal line. and VCM.
A READY signal is not input Abnormal READY signal Check the signal line between BCM
to VCM. line and VCM. E
READY status cannot be achieved.
Shift selector is shifted to

VCM recognizes that the se- Change the shift position to ″P″or
the driving range while the
lector lever is in a range oth- ″N″
READY lamp is blinking.
READY condition are not er than P and N. F
satisfied Shift system error. Perform self-diagnosis of VCM.
• Abnormal normal charge
connector connection de-
VCM recognizes that the G
tection circuit. Perform self-diagnosis of PDM
charge connector is con-
• Abnormal quick charge (Power Delivery Module).
nected.
connector connection de-
tection circuit. H
Fail-safe of VCM prohibits
EV control system error. Perform self-diagnosis of VCM.
READY.
VCM recognizes that Li-ion Li-ion battery remaining en- I

Charge Li-ion battery.
battery remaining energy is ergy is low.
low. Abnormal LBC. Perform self-diagnosis of LBC.
VCM recognizes that steer- Abnormal steering lock J
Check steering lock system.
ing lock is not released. mechanism.
• Abnormal combination Perform ACTIVE TEST of VCM to
The READY to drive indicator lamp does not turn ON de- meter. check the READY to drive indicator K
spite READY state. • Abnormal LED. lamp. Refer to EVC-69, "CONSULT
• Abnormal VCM. Function".
EVC-391
EV CONTROL SYSTEM
Unable to Travel INFOID:0000000010410410

VCM recognizes that the ac-
Abnormal accelerator pedal
celerator pedal is not de- EVC-215, "Diagnosis Procedure"
position sensor.
pressed.
• Abnormal stop lamp
VCM recognizes that brake switch.
EVC-205, "Diagnosis Procedure"
pedal is depressed. • Abnormal stop lamp
switch signal line.
An output limit request sig-
TCS/VDC/ABS system er- Perform self-diagnosis of ABS actu-
nal of TCS/VDC/ABS is re-
ror. ator and electric unit (control unit).
Unable to travel.
Drive force is not generated. ceiced.

Traction motor inverter re-
Traction motor system error.
quests the output limit. Check the “POWER LIMIT CAUSE”
LBC requests the output in DATA MONITOR item of VCM.
LBC system error.
limit.
Fail-safe of VCM prohibits
EV control system error. Perform self-diagnosis of VCM.
READY.
Motor output is not con-
Abnormal reduction gear. Check reduction gear.
veyed to drive wheels.
Brake applied. Brake dragging. Check for brake dragging.
Braking force is generated. A brake signal is input to Check the signal line between stop
Abnormal stop lamp switch
ABS actuator and electric lamp switch and ABS actuator and
signal line.
unit (control unit). electric unit (control unit).
EVC-392
EV CONTROL SYSTEM
Low Electrical Consumption INFOID:0000000010410411

Low tire pressure. Adjust tire pressure. B
Running resistance of tires
is high. Tire size is not of standard
Install standard-size tires.
Traction motor requires a size.
large amount of power. Parking brake is applied. Brake dragging. Check reduction dragging. EVC
Sliding resistance of reduc-
Abnormal reduction gear. Check reduction gear.
tion gear is high.
The set temperature is low. Adjust the set temperature. D
Electric compressor re-
quires a large amount of Perform self-diagnosis of A/C auto
power. Abnormal A/C auto amp.
Air conditioner requires a amp.
large amount of power. E
The set temperature is high. Adjust the set temperature.
PTC heater requires a large
amount of power. Perform self-diagnosis of A/C auto
Abnormal A/C auto amp.
amp.
F
High-capacity auxiliaries is
Auxiliaries requires a large amount of power. Check vehicle condition.
connected.
Incorrect service plug con- Check installation condition of the
Low efficient Li-ion battery. G
nection. service plug.
Perform inspection according to the
Low electrical consumption
diagnosis procedure of DTC P33E6

of EV battery control system. Refer H
to EVB-170, "Diagnosis Procedure"
Low Li-ion battery cell ca- (without battery cooler models) or
Lower energy storage, com- Battery charge level at full pacity. EVB-444, "Diagnosis Procedure"
(with battery cooler models) or I
pared to meter indication. charge is low.
EVB-732, "Diagnosis Procedure"
(with battery heater & cooler mod-
els).
J
Li-ion battery charged with Charge Li-ion battery with its room-
its temperature low. temperature condition.
Perform EV battery control system K
diagnosis by symptom. Refer to
(without battery cooler models) or
Abnormal Li-ion battery. EVB-487, "Diagnosis Procedure" L
(with battery cooler models) or
els). M
Available driving range becomes shorter. Perform inspection according to the
diagnosis procedure of DTC P33E6
of EV battery control system. Refer N
to EVB-170, "Diagnosis Procedure"
Low Li-ion battery cell ca- (without battery cooler models) or
pacity. EVB-444, "Diagnosis Procedure"
(with battery cooler models) or O
els).
P
EVC-393
EV CONTROL SYSTEM
Power Switch Does Not Turn OFF INFOID:0000000010410412

Short circuit between the
Check the power ON power supply
power ON power supply cir-
Power switch does not turn OFF.
circuit.
cuit of VCM and power.
Power is continuously sup- Perform self-diagnosis of IPDM E/
VCM recognizes that the Abnormal IPDM E/R.
plied to the power ON power R.
power switch is not OFF.
supply terminal of VCM.
Abnormal BCM. Perform self-diagnosis of BCM.
PCS-76,
Abnormal power switch.
"Component Function Check"
• Abnormal immediate
charging switch signal cir-
Immediate charging switch signal is continuously received. cuit. EVC-384, "Diagnosis Procedure"
charging switch.
EVC-394
EV CONTROL SYSTEM
No Regeneration INFOID:0000000010410413

Fail-safe of traction motor B
TMS-31, "Fail-safe"
inverter.
Drive motor inverter limits
output. The temperature of traction Check the “POWER LIMIT CAUSE”
motor or traction motor in- in the DATA MONITOR item of EVC
verter is high. VCM.
EVB-50, "Fail-safe" (without battery
cooler models) or EVB-324, "Fail-
Fail-safe of LBC. safe" (with battery cooler models)
D
or EVB-612, "Fail-safe" (with bat-
tery heater & cooler models)
Damaged bus bar (connect- E
ing part of Li-ion battery Check bus bar.
The amount of regeneration module).
LBC limits output.
is limited.
Degradation in Li-ion bat- F
tery temperature sensor Check the “POWER LIMIT CAUSE”
characteristics. in the DATA MONITOR item of
The temperature of Li-ion VCM.
battery is too high/low.
G
No regeneration
Li-ion battery is fully

Normal operation.
charged.
H
ABS actuator and electric
unit (control unit) limits out- ABS operates. Normal operation.
put.
Hydraulic brake actuation Fail-safe of hydraulic brake BR-44, "Fail-Safe" (LHD) or BR- I
module limits output. actuation module. 524, "Fail-Safe" (RHD)
ABS actuator and electric
unit (control unit) limits out- VDC operates. Normal operation. J
put.
The regeneration prohibit Vehicle speed is 14 km/h (9

— Normal operation.
conditions are satisfied. MPH) or less. K
Accelerator pedal is de-
pressed.
— Under full braking. Normal operation. L
• ECO mode or B mode are
Driving mode is changed. canceled. Normal operation.
• Range changes to N.
M
The amount of target regen-
Brake applied during sharp
eration changes. — Normal operation.
turn.
Slip detected during ECO N
mode.
EVC-395
EV CONTROL SYSTEM
Decelerating Force Changes INFOID:0000000010410414

Fail-safe of traction motor
TMS-31, "Fail-safe"
inverter.
Traction motor inverter lim-
its output. The temperature of traction
Check the “POWER LIMIT CAUSE”
motor or traction motor in-
in the DATA MONITOR of VCM.
verter is high.
EVB-50, "Fail-safe" (without battery
cooler models) or EVB-324, "Fail-
Fail-safe of LBC. safe" (with battery cooler models)
or EVB-612, "Fail-safe" (with bat-
Deceleration G changes.
The amount of regeneration tery heater & cooler models)

is limited.
Damaged bus bar (connect-
ing part of Li-ion battery Check bus bar.
LBC limits output. module).
Degradation in Li-ion bat-
tery temperature Check the “POWER LIMIT CAUSE”
The temperature of Li-ion in the DATA MONITOR of VCM.
battery is too high/low.
Normal operation.
charged.
Range changes from D to
Selector lever range posi-
ECO (or B) or from ECO (or Normal operation.
The amount of target regen- tion is changed.
B) to D.
eration changes.
Accelerator pedal is de-
pressed.
EVC-396
EV CONTROL SYSTEM
Normal Charge Does Not Start INFOID:0000000010410415

VCM recognizes that the se- The shift position is in a Change the shift position to ″P″ B
lector lever is in a range oth- range other than ″P″ range. range.
er than P range.
Shift system error. Perform self-diagnosis of VCM.
EVC
— Power switch is not OFF. Normal operation.
Check to see if charge stop condi-
VCM receives a charge stop tions are satisfied. Refer to EVC-
— request signal from PDM 42, "LI-ION BATTERY CHARGE
D
(Power Delivery Module). CONTROL : Normal Charge Con-
trol".
Abnormal connection detec- E
VCM recognizes that quick tion circuit of quick charge Check quick charge port.
charge connector and nor- port.
mal charge connector are
Normal charge does not start.
connected simultaneously. Abnormal PDM (Power De- Perform self-diagnosis of PDM F

livery Module). (Power Delivery Module).
VCM prohibits charging. Fail-safe of VCM. EVC-93, "Fail-Safe"
Normal charge start condi-
tions are not satisfied. Abnormal connection detec- G
VCM recognizes that nor- tion circuit of normal charge Check normal charge port.
mal charge connector is not port.
connected. Abnormal PDM (Power De- Perform self-diagnosis of PDM H
AC power, no input.
Check outlet.
(Disconnect from outlet)
I
AC power, no input.
VCM recognizes that a Check AC power.
(Blackout)
PWM signal is not received
from EVSE. EVSE does not transmit a
J
PWM signal. Perform self-diagnosis of PDM
Abnormal PDM (Power De- (Power Delivery Module).
livery Module).
K
• Cancel timer charge setting.
— Timer charge is set. • Turn ON the immediate charging
switch.
L
Judged as fully-charged. — Normal operation.
charged.
EVC-397
EV CONTROL SYSTEM

• Plug EVSE alone into an outlet
(AC source) and check that the
“Fault” lamp on EVSE does not
blink.
EVSE detects electric leak- If the lamp blinks, replace EVSE.
age • Check that no electric leakage
exists between EVSE control box
and PDM (Power Delivery Mod-
Normal charge does not start.
ule) or in the PDM (Power Deliv-

ery Module) itself.
Plug EVSE alone into an outlet (AC
source) and check that the “Fault”
EVSE does not activate. EVSE has a malfunction lamp of EVSE does not turn ON.
If the lamp turns ON, replace
EVSE.
source) and check that the
EVSE not energized “Ready” lamp of EVSE turns ON.
If the lamp does not turn ON, re-
place EVSE.
EVSE communication line source) and check that the “Fault”
has a malfunction lamp on EVSE does not blink.
If the lamp blinks, replace EVSE.
Timer Charge and Remote Charge Does Not Start INFOID:0000000010410416

Timer charge or remote charge does not start.
The timer charge start con-

— Timer charge is not set. Set timer charge.
ditions are not satisfied.
Remote charge request is
not sent to the Information The request is sent from an Send a remote charge request in a
Center (Nissan CARWINGS out of service area. service area.
Data Center).
The remote charge start

conditions are not satisfied. Remote charge request is
not sent from the Informa- The vehicle is located an out Send a remote charge request in a
tion Center (Nissan CAR- of service area. service area.
WINGS Data Center).
EVC-398
EV CONTROL SYSTEM
Immediate Charge Does Not Start INFOID:0000000010410417

Turn ON the immediate charging B
— Timer charge is set.
switch.
Immediate charge does not start.
Power switch is ON. Turn power switch OFF.

A lapse of more than 15 EVC
minutes to connect the Connect charge connector within
Immediate charge start con- charge connector after op- 15 minutes after operating the im-
dition are not satisfied. The operation of immediate erating the immediate mediate charging switch.
charging switch does not charging switch.
D
start immediate charge.
charging switch.
• Abnormal immediate EVC-384, "Diagnosis Procedure" E
charging switch signal cir-
cuit.
F
Normal Charge Is Not Completed INFOID:0000000010410418
Symptom Possible cause Action G

Normal charge is not completed.
Normal charge is not completed despite full charge. Abnormal LBC. Perform self-diagnosis of LBC.
Timer charge end time is not I

Timer charge is not completed. Set timer charge end time.
set.
EVC-399
EV CONTROL SYSTEM
Quick Charge Does Not Start INFOID:0000000010410419
VCM recognizes that the se- The shift position is in a Change the shift position to ″P″
lector lever is in a range oth- range other than ″P″ range. range.
er than P range. Shift system error. Perform self-diagnosis of VCM.
— Power switch is not OFF. Normal operation.
VCM receives a charge stop
Check that charging condition is
— request signal from PDM
normal.
Quick charge does not start.
VCM recognizes that the Abnormal connection detec-

Quick charge start condi- quick charge connector and tion circuit of normal charge Check normal charge port.
tions are not satisfied. the normal charge connec- port.
tor are simultaneously con- Abnormal PDM (Power De- Perform self-diagnosis of PDM
nected. livery Module). (Power Delivery Module).
VCM prohibits charging. Fail-safe of VCM. EVC-93, "Fail-Safe"
Abnormal connection detec-
VCM recognizes that the tion circuit of quick charge Check quick charge port.
quick charge connector is port.
not connected. Abnormal PDM (Power De- Perform self-diagnosis of PDM
• Check PDM (Power Delivery
Insulation resistance degra-
Quick charger detects insu- Module).
Quick charger does not per- dation between PDM (Pow-
lation resistance degrada- • Check high voltage harness.
mit quick charge. er Delivery Module) and
tion in high voltage circuit. • Check quick charge port.
quick charger.
• Check quick charger.
Quick Charge Is Not Completed INFOID:0000000010410420

Quick charge is not completed.
Charging is not completed despite full charge. Abnormal LBC. Perform self-diagnosis of LBC.
Quick charger communica- Perform self-diagnosis of PDM

VCM does not receive a quick charge stop request signal.
tion error. (Power Delivery Module).
EVC-400
EV CONTROL SYSTEM
Full Charge Cannot Be Achieved INFOID:0000000010410421

The setting of the timer B
charge charging rate is Set charging rate to 100%
80%.
— —
Implementation of quick EVC
charge under a low Li-ion Perform quick charge again.
battery level.
A/C power consumption is
large.
D
Power consumption is large Refer to EVC-393, "Low Electrical
Full charge cannot be achieved.
during charge. Power consumption of auxil- Consumption".

Charge power is low or iaries is large.
charging stops. E
Perform inspection according to the
Charge Insulation Resis-
diagnosis procedure of DTC
Charge power is limited. tance Loss Protection Con-
P3141. Refer to EVC-263, "DTC
trol is active.
Description". F
Normal operation.
NOTE:
Charge level depends on Li-ion bat-
Indication decreases after Temperature change in Li- tery temperature. For meter indica-
G
Target charge level differs the completion of charge. ion battery. tion method, refer to MWI-23, "LI-
from the meter indication. ION BATTERY AVAILABLE
CHARGE GAUGE : System De- H
scription".
Meter indication does not MWI-91, "On Board Diagnosis
LED malfunction
reach maximum. Function"
I
Chargeable electricity is lim- LBC limits chargeable elec- Check “POWER LIMIT CAUSE” of
Charge level is low.
ited. tricity. DATA MONITOR item in VCM.
Climate Ctrl. Timer Does Not Start INFOID:0000000010410422

J
Symptom Possible cause Action K

Climate Ctrl. Timer is not
Set Climate Ctrl. Timer.
set.
Climate Ctrl. Timer does not start.
Normal operation. L
NOTE:
Climate Ctrl. Timer start conditions are not satisfied. Remote climate control is If Climate Ctrl. Timer and remote
set. climate control are requested simul-
taneously, remote climate control is M
prioritized.
EVSE is not connected. Connect EVSE.
A/C auto amp. does not rec- Perform self-diagnosis of A/C auto N
Abnormal A/C auto amp.
ognize Climate Ctrl. Timer. amp.
A/C system does not start.
Abnormal A/C system pow- HAC-177, "A/C AUTO AMP. : Diag-
—
er supply. nosis Procedure" O
EVC-401
EV CONTROL SYSTEM
Remote climate control Does Not Start INFOID:0000000010410423

Remote climate control does not start.
• Connect EVSE.
— Li-ion battery level is low.* • Charge Li-ion battery.
Remote climate control re-
Remote climate control start
A remote climate control request is sent in an out of
conditions are not satisfied. Send remote climate control re-
quest signal cannot be re- service area.
quest again in a service area.
ceived. The vehicle is located in out
of service area.
A/C auto amp. does not rec-
Perform self-diagnosis of A/C auto
ognize remote climate con- Abnormal A/C auto amp.
amp.
A/C system does not start. trol.
Abnormal A/C system pow- HAC-177, "A/C AUTO AMP. : Diag-
—
er. nosis Procedure"
*: Only during no AC power input.
EVC-402
NORMAL OPERATING CONDITION
A
CHARGE INSULATION RESISTANCE LOSS PROTECTION CONTROL B

When the insulation resistance of the high voltage circuit decreases while charging due to a temporary cause,
VCM limits the charging energy and waits until the insulation resistance state recovers. VCM restarts charging
after the recovery of the insulation resistance status. If the situation is not improved after several repetitions of EVC
this control, VCM stops charging and detects DTC P3141.
NOTE:
If the insulation resistance status does not recover despite the limitation of charging energy under protection
control, DTC P0AA6 is detected. D
CHARGING CONNECTOR-CONNECTING PROTECTION CONTROL

When VCM detects a vehicle speed immediately after the charging connector is connected, the hydraulic
E
brake actuation system is activated.
NOTE:
This control cannot stop the vehicle completely.
F
EVC-403
VCM
VCM
JSCIA1302GB
VCM VCM bracket

Vehicle front
REMOVAL (LHD MODELS)

CAUTION:
Before replacing VCM, perform “SAVE DATA FOR CPU REPLACE” in “WORK SUPPORT” of CONSULT
to save the current VCM data in CONSULT. Refer to EVC-120, "Work Procedure".
CAUTION:
vehicle handling.
2. Disconnect the 12V battery negative terminal. Refer to EVC-9, "Precautions for Removing Battery Termi-
nal".
3. Remove the dash side finisher LH. Refer to INT-27, "Exploded View" (except full trim models), INT-79,
"Exploded View" (full trim models).
4. Remove the instrument lower panel assembly. Refer to IP-13, "Exploded View".
NOTE:
Close peripheral holes with waste to prevent screws from dropping.
EVC-404
VCM
5. Remove fuse box bracket mounting screw .
A
EVC
JSCIA1319ZZ
D
6. Insert flat-blade screwdriver (A) into the position as shown in the
figure and disengage the pawl located on top of fuse box .
E
G
JSCIA1320ZZ
7. Disconnect connector and remove harness clip to secure work space.

H
9. Remove VCM mounting nuts.
10. Remove VCM. I
11. Remove VCM bracket mounting nuts.
12. Remove VCM bracket.
J
REMOVAL (RHD MODELS)
CAUTION:
Before replacing VCM, perform “SAVE DATA FOR CPU REPLACE” in “WORK SUPPORT” of CONSULT
to save the current VCM data in CONSULT. Refer to EVC-120, "Work Procedure". K
CAUTION:
During this period, never perform vehicle handling such as opening and closing of doors. If some L
vehicle handling.
2. Disconnect the 12V battery negative terminal. Refer to EVC-9, "Precautions for Removing Battery Termi- M
nal".
3. Remove the dash side finisher LH. Refer to INT-27, "Exploded View" (except full trim models), INT-79,
"Exploded View" (full trim models). N
4. Remove the instrument lower cover. Refer to IP-13, "Exploded View".
NOTE:
Close peripheral holes with waste to prevent screws from dropping.
O
6. Remove VCM mounting nuts.
7. Remove VCM. P
8. Remove VCM bracket mounting nuts.
9. Remove VCM bracket.
INSTALLATION
CAUTION:
Must be perform additional service when replacing VCM. Refer to EVC-120, "Work Procedure".
EVC-405
ECO MODE SWITCH
ECO MODE SWITCH
REMOVAL
1. Remove the cluster lid C lower. Refer to IP-13, "Exploded View".
2. Remove the eco mode switch from switch panel as follows.
a. Disengage the pawls while pressing the behind of switch ( ).
using a suitable tool (B).
JSCIA1321ZZ
INSTALLATION
CAUTION:
Must be perform additional service when replacing VCM. Refer to EVC-120, "Work Procedure".
EVC-406
M/C RELAY
M/C RELAY
A
1.CHECK BATTERY POWER SUPPLY-1 B

3. Check the voltage between M/C relay harness connector and ground. EVC
LHD models
+
D
Connector Terminal
2 12V battery volt- E
E65 Ground
3 age
RHD models
F
+
Connector Terminal G
2 12V battery volt-
E65 Ground
3 age
H
YES >> GO TO 5.
NO >> GO TO 2.
I
2.CHECK FUSIBLE LINK
1. Remove #G fusible link.
2. Check that the fusible link is not fusing. J
YES >> GO TO 3.
NO >> Replace the fusible link after repairing the applicable circuit. K
3.CHECK BATTERY POWER SUPPLY-2
Check the voltage between fusible link harness connector and ground. L
+ − Voltage
#G fusible link terminal Ground

12V battery volt- M
age
YES >> GO TO 4. N
O
1. Check the continuity between M/C relay harness connector and fusible link harness connector.
LHD models
− P
Connector Terminal
#G fusible link 2
E65 Existed
terminal 3
EVC-407
M/C RELAY
RHD models
−
Connector Terminal
#G fusible link 2
E65 Existed
terminal 3
5.CHECK M/C RELAY
YES >> GO TO 6.
6.CHECK M/C RELAY CONTROL SIGNAL CIRCUIT
3. Check the continuity between M/C relay harness connector and VCM harness connector.
LHD models
+ −
RHD models
+ −
YES >> GO TO 7.
LHD models
+
VCM − Continuity
Connector Terminal
58
E110
65
Ground Existed
118
E111
126
E V C -4 0 8
M/C RELAY
RHD models
+ A
VCM − Continuity
Connector Terminal
B
58
E116
65
Ground Existed
118 EVC
E117
126
D
Component Inspection (M/C Relay) INFOID:0000000010410381 E
1.CHECK M/C RELAY

lowing conditions. G

12 V direct current supply between terminals 1 and 2 Existed H
3 and 5
I
PIIA2636J
EVC-409
SECTION
EV BATTERY SYSTEM
EVB B
EVB
E
CONTENTS
WITHOUT BATTERY COOLER SYSTEM ............................................................ 35 F
PRECAUTION .............................................. 12 LI-ION BATTERY CONTROL SYSTEM ....................35

LI-ION BATTERY CONTROL SYSTEM : System
G
PRECAUTIONS ..................................................12 Description ...............................................................35
Precaution for Technicians Using Medical Electric.... 12 Circuit Diagram ........................................................38
Precaution for Supplemental Restraint System Fail-safe ...................................................................40
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- H
SIONER" ................................................................. 12 WARNING/INDICATOR/CHIME LIST ........................40
Precaution for Procedure without Cowl Top Cover.... 13 WARNING/INDICATOR/CHIME LIST : Warning
Precautions for Removing Battery Terminal ........... 13 lamps/Indicator lamps ..............................................40
I
CAUTIONS AS TO HIGH VOLTAGE .................15 HANDLING PRECAUTION ............................... 42
How to Disconnect High Voltage ............................. 15 EV Battery System ..................................................42
High Voltage Precautions ........................................ 17 J
DIAGNOSIS SYSTEM (LBC) ............................ 43
Check Voltage in High Voltage Circuit .................... 19
CONSULT Function .................................................43
Insulated Protective Wear and Insulating Tools ...... 23 ECU DIAGNOSIS INFORMATION .............. 45 K
Cautions for Scrapping Vehicles ............................. 23
Handling of a Vehicle with a Dead Battery .............. 23 EV BATTERY SYSTEM .................................... 45
Reference Value ......................................................45 L
PREPARATION ........................................... 24 Fail-safe ...................................................................50
DTC Index ...............................................................55
PREPARATION ..................................................24
Special Service Tools .............................................. 24 WIRING DIAGRAM ...................................... 61 M
Commercial Service Tools ...................................... 25
Sealant or/and Lubricant ......................................... 28 VCM ................................................................... 61
Wiring Diagram ........................................................61 N
SYSTEM DESCRIPTION ............................. 29
BASIC INSPECTION ................................... 73
COMPONENT PARTS .......................................29
Component Parts Location ...................................... 29 DIAGNOSIS AND REPAIR WORK FLOW ....... 73 O
Li-ion Battery ........................................................... 30 Work Flow ................................................................73
Li-ion Battery Controller .......................................... 31 Diagnostic Work Sheet ............................................74
Module .................................................................... 31 P
Battery Temperature Sensor ................................... 32 SAVE BATTERY INFORMATION DATA .......... 76
Battery Junction Box ............................................... 33 Description ...............................................................76
Battery Current Sensor ........................................... 33 Work Procedure .......................................................76
Service Plug ............................................................ 33
WRITE BATTERY INFORMATION DATA ........ 77
Description ...............................................................77
Work Procedure .......................................................77
EVB-1
CLEAR BATTERY GRADUAL CAPACITY P3062 BYPASS SWITCH .................................. 97
LOSS DATA ....................................................... 78 DTC Description ...................................................... 97
Description .............................................................. 78 Diagnosis Procedure ............................................... 97
Work Procedure ...................................................... 78
P3064 CELL CONT ASIC .................................. 98
CLEAR BATT CHARGE/DISCHARGE IN- DTC Description ...................................................... 98
FORMATION DATA ........................................... 79 Diagnosis Procedure ............................................... 98
Description .............................................................. 79
Work Procedure ...................................................... 79
P308B-P3096 CELL CONTROLLER ASIC
OPEN ................................................................. 99
ADDITIONAL SERVICE WHEN REPLACING DTC Description ...................................................... 99
LI-ION BATTERY CONTROLLER ..................... 80 Diagnosis Procedure ............................................. 100
Description .............................................................. 80
Work Procedure ...................................................... 80
P3097-P30A2 CELL CONTROLLER ASIC
OPEN ................................................................ 102
ADDITIONAL SERVICE WHEN REPLACING DTC Description .................................................... 102
MODULE ............................................................ 81 Diagnosis Procedure ............................................. 103
Description .............................................................. 81
Work Procedure ...................................................... 81
P30E0 DLC DIAGNOSIS VCM ......................... 106
DTC Description .................................................... 106
MODULE CHARGE BALANCE ......................... 82 Diagnosis Procedure ............................................. 106
Description .............................................................. 82
Work Procedure ...................................................... 82
P30E2 DLC DIAGNOSIS HVAC ....................... 107
DTC Description .................................................... 107
DTC/CIRCUIT DIAGNOSIS ......................... 84 Diagnosis Procedure ............................................. 107
P0A0D HV SYSTEM INTERLOCK ERROR ...... 84 P30E3 DLC DIAGNOSIS MC ........................... 108
DTC Description ..................................................... 84 DTC Description .................................................... 108
Diagnosis Procedure .............................................. 84 Diagnosis Procedure ............................................. 108
Component Inspection ............................................ 85
P30E4 DLC DIAGNOSIS PDM(POWER DE-
P0A1F BATTERY ENERGY CONTROL MOD- LIVERY MODULE) ........................................... 109
ULE .................................................................... 86 DTC Description .................................................... 109
DTC Description ..................................................... 86 Diagnosis Procedure ............................................. 109
P318D COMMUNICATION ERROR ................. 110
P3030 CELL CONTROLLER LIN ...................... 87 DTC Description .................................................... 110
P318E COMMUNICATION ERROR ................. 111
P3031-P303C CELL CONTROLLER ASIC ....... 88 DTC Description .................................................... 111
P3191 COMMUNICATION ERROR ................. 112
P303D-P3048 CELL CONTROLLER ASIC ....... 90 DTC Description .................................................... 112
P3049-P3054 CELL CONTROLLER ASIC DTC Description .................................................... 113
VOLTAGE .......................................................... 92 Diagnosis Procedure ............................................. 113
DTC Description ..................................................... 92 P3198 COMMUNICATION ERROR ................. 114
DTC Description .................................................... 114
P3055-P3060 CELL CONTROLLER ASIC Diagnosis Procedure ............................................. 114
VOLTAGE .......................................................... 94 P3199 COMMUNICATION ERROR ................. 115
P3061 CELL BATTERY VOLTAGE .................. 96 P319C COMMUNICATION ERROR ................. 116
EVB-2
P31A4 CAN ERROR VCM ............................... 117 DTC Description .................................................... 161
DTC Description .................................................... 117 Diagnosis Procedure ............................................. 161 A
Diagnosis Procedure ............................................. 117 Component Inspection ........................................... 162
P31A7 CAN ERROR INV/MC ........................... 118 P33DF BAT VOLTAGE ISOLATION SEN ...... 164
DTC Description .................................................... 164 B
DTC Description .................................................... 118
P3302-P330D CELL OVER VOLTAGE ........... 119 P33E0 BAT VOLTAGE ISOLATION SEN ...... 165 EVB
Component Inspection .......................................... 121 D
P33E1 BAT VOLTAGE ISOLATION SEN ...... 166
P330E-P3319 CELL OVER VOLTAGE ............ 123 DTC Description .................................................... 166
Diagnosis Procedure ............................................. 124 E
Component Inspection .......................................... 125 P33E2 BATT PACK OVER TEMP .................. 167
DTC Description .................................................... 167
P331A-P3325 CELL OVER VOLTAGE ........... 127 Diagnosis Procedure ............................................. 167
F
DTC Description .................................................... 127
Diagnosis Procedure ............................................. 128 P33E4, P33E5 TEMPERATURE SENSOR ..... 168
Component Inspection .......................................... 130 DTC Description .................................................... 168
Diagnosis Procedure ............................................. 168 G
P3326-P3331 CELL OVER VOLTAGE ............ 132 Component Inspection ........................................... 169
DTC Description .................................................... 132
Diagnosis Procedure ............................................. 133 P33E6 CELL CONTROLLER .......................... 170
DTC Description .................................................... 170 H
Component Inspection .......................................... 136
P3375-P3380 CELL OVER DISCHARGE ........ 137
DTC Description .................................................... 137 P33ED BATTERY PARALLEL DIAGNOSIS .. 175 I
Diagnosis Procedure ............................................. 138 DTC Description .................................................... 175
Component Inspection .......................................... 139 Diagnosis Procedure ............................................. 176
U1000 CAN COMM CIRCUIT ......................... 177 J

P3381-P338C CELL OVER DISCHARGE ....... 141
Component Inspection .......................................... 143 K
HIGH VOLTAGE CIRCUIT .............................. 178
P338D-P3398 CELL OVER DISCHARGE ....... 145 Diagnosis Procedure ............................................. 178
DTC Description .................................................... 145 LI-ION BATTERY INSULATION RESIS- L
TANCE LOSS CHECK .................................... 180
P3399-P33A4 CELL OVER DISCHARGE ....... 150 M
POWER SUPPLY AND GROUND CIRCUIT .. 204
DTC Description .................................................... 150
Component Inspection .......................................... 154 SYMPTOM DIAGNOSIS ............................ 207 N
P33D4 BATT GRADUAL CAPA LOSS DIAG.. 155 EV BATTERY SYSTEM .................................. 207
DTC Description .................................................... 155 Symptom Index ...................................................... 207
REDUCTION IN THE DRIVING RANGE ......... 208
P33D5 CURRENT SENSOR ............................ 156 Description ............................................................. 208
DTC Description .................................................... 156 Diagnosis Procedure ............................................. 208 P
NORMAL OPERATING CONDITION ............. 209
P33D6 CURRENT SENSOR ............................ 159 Description ............................................................. 209
DTC Description .................................................... 159
Diagnosis Procedure ............................................. 159 PERIODIC MAINTENANCE ...................... 210
P33D7, P33D9, P33DB, P33DD TEMPERA- EV BATTERY USAGE REPORT .................... 210
TURE SENSOR ................................................ 161 Inspection .............................................................. 210
EVB-3
REMOVAL AND INSTALLATION .............. 211 Precaution for Supplemental Restraint System
LI-ION BATTERY UNDERCOVER .................. 211 SIONER" ............................................................... 280
Exploded View .......................................................211 Precaution for Procedure without Cowl Top Cover. 281
Removal and Installation .......................................211 Precautions for Removing Battery Terminal ......... 281
UNIT REMOVAL AND INSTALLATION .... 213 CAUTIONS AS TO HIGH VOLTAGE ............... 283
How to Disconnect High Voltage .......................... 283
LI-ION BATTERY ............................................. 213 High Voltage Precautions ..................................... 285
Exploded View .......................................................213 Check Voltage in High Voltage Circuit .................. 287
Removal and Installation .......................................213 High Voltage Warning Label ................................. 290
Inspection ..............................................................219 Insulated Protective Wear and Insulating Tools .... 291
Cautions for Scrapping Vehicles ........................... 291
UNIT DISASSEMBLY AND ASSEMBLY .. 221 Handling of a Vehicle with a Dead Battery ............ 291
LI-ION BATTERY ............................................. 221
PREPARATION ......................................... 292
BATTERY PACK UPPER CASE .............................221
BATTERY PACK UPPER CASE : Exploded View..221
PREPARATION ................................................ 292
Special Service Tools ........................................... 292
BATTERY PACK UPPER CASE : Removal and
Commercial Service Tools .................................... 293
Installation .............................................................222
Sealant or/and Lubricant ....................................... 296
LI-ION BATTERY CONTROLLER ...........................231
LI-ION BATTERY CONTROLLER : Exploded SYSTEM DESCRIPTION .......................... 297
View .......................................................................232
COMPONENT PARTS ...................................... 297
LI-ION BATTERY CONTROLLER : Removal and
Component Parts Location ................................... 297
Installation .............................................................232
Li-ion Battery ......................................................... 299
BATTERY JUNCTION BOX AND BATTERY HAR- Li-ion Battery Controller ........................................ 299
NESS ........................................................................234 Module .................................................................. 300
BATTERY JUNCTION BOX AND BATTERY Li-ion Battery Coolong Unit ................................... 301
HARNESS : Exploded View ..................................234 Battery Temperature Sensor ................................. 302
BATTERY JUNCTION BOX AND BATTERY Battery Junction Box ............................................. 303
HARNESS : Removal and Installation ...................237 Battery Current Sensor ......................................... 303
Service Plug .......................................................... 303
FRONT MODULE STACK .......................................242 High Voltage Warning Label ................................. 303
FRONT MODULE STACK : Exploded View ..........242
FRONT MODULE STACK : Removal and Installa- SYSTEM ........................................................... 305
tion .........................................................................246
LI-ION BATTERY CONTROL SYSTEM .................. 305
FRONT MODULE STACK : Disassembly and As-
sembly ...................................................................251
Description ............................................................ 305
REAR MODULE STACK ..........................................259
LI-ION BATTERY COOLER CONTROL SYSTEM . 308
REAR MODULE STACK : Exploded View .............259
LI-ION BATTERY COOLER CONTROL SYSTEM
REAR MODULE STACK : Removal and Installa-
: System Description ............................................. 308
tion .........................................................................263
Circuit Diagram ..................................................... 310
REAR MODULE STACK : Disassembly and As-
Fail-safe ................................................................ 313
sembly ...................................................................267
Inspection ..............................................................275 WARNING/INDICATOR/CHIME LIST ..................... 313
WARNING/INDICATOR/CHIME LIST : Warning
SERVICE DATA AND SPECIFICATIONS lamps/Indicator lamps ........................................... 313
(SDS) .......................................................... 279
HANDLING PRECAUTION .............................. 315
SERVICE DATA AND SPECIFICATIONS EV Battery System ................................................ 315
(SDS) ................................................................ 279
Li-ion Battery .........................................................279 DIAGNOSIS SYSTEM (LBC) ........................... 316
WITH BATTERY COOLER CONSULT Function .............................................. 316
PRECAUTION ............................................ 280 ECU DIAGNOSIS INFORMATION ............ 319
PRECAUTIONS ............................................... 280 EV BATTERY SYSTEM .................................... 319

Precaution for Technicians Using Medical Electric..280 Reference Value ................................................... 319
EVB-4
Fail-safe ................................................................ 324 P3031-P303C CELL CONTROLLER ASIC .... 362
DTC Index ............................................................. 329 DTC Description .................................................... 362 A
WIRING DIAGRAM .................................... 335
P303D-P3048 CELL CONTROLLER ASIC .... 364
VCM .................................................................. 335 B
DTC Description .................................................... 364
Wiring Diagram ..................................................... 335 Diagnosis Procedure ............................................. 365
BASIC INSPECTION ................................. 347 P3049-P3054 CELL CONTROLLER ASIC EVB
VOLTAGE ....................................................... 366
DIAGNOSIS AND REPAIR WORK FLOW ...... 347
DTC Description .................................................... 366
Work Flow ............................................................. 347
Diagnosis Procedure ............................................. 367 D
Diagnostic Work Sheet .......................................... 348
P3055-P3060 CELL CONTROLLER ASIC
SAVE BATTERY INFORMATION DATA ......... 350
Description ............................................................ 350
VOLTAGE ....................................................... 368
DTC Description .................................................... 368 E
Work Procedure .................................................... 350
WRITE BATTERY INFORMATION DATA ....... 351
Description ............................................................ 351
P3061 CELL BATTERY VOLTAGE ................ 370 F
DTC Description .................................................... 370
Work Procedure .................................................... 351
CLEAR BATTERY GRADUAL CAPACITY
P3062 BYPASS SWITCH ............................... 371 G
LOSS DATA ..................................................... 352
DTC Description .................................................... 371
Description ............................................................ 352
Work Procedure .................................................... 352
H
P3064 CELL CONT ASIC ............................... 372
CLEAR BATT CHARGE/DISCHARGE IN-
DTC Description .................................................... 372
FORMATION DATA ......................................... 353 Diagnosis Procedure ............................................. 372
Description ............................................................ 353 I
Work Procedure .................................................... 353 P308B-P3096 CELL CONTROLLER ASIC
OPEN ............................................................... 373
ADDITIONAL SERVICE WHEN REPLACING
DTC Description .................................................... 373 J
LI-ION BATTERY CONTROLLER ................... 354 Diagnosis Procedure ............................................. 374
Description ............................................................ 354
Work Procedure .................................................... 354 P3097-P30A2 CELL CONTROLLER ASIC
OPEN ............................................................... 376 K
DTC Description .................................................... 376
MODULE .......................................................... 355 Diagnosis Procedure ............................................. 377
Description ............................................................ 355
L
Work Procedure .................................................... 355 P30E0 DLC DIAGNOSIS VCM ....................... 380
DTC Description .................................................... 380
MODULE CHARGE BALANCE ....................... 356 Diagnosis Procedure ............................................. 380
Description ............................................................ 356 M
Work Procedure .................................................... 356 P30E2 DLC DIAGNOSIS HVAC ..................... 381
DTC Description .................................................... 381
DTC/CIRCUIT DIAGNOSIS ....................... 358 Diagnosis Procedure ............................................. 381 N
P0A0D HV SYSTEM INTERLOCK ERROR ..... 358 P30E3 DLC DIAGNOSIS MC .......................... 382
Diagnosis Procedure ............................................. 358 Diagnosis Procedure ............................................. 382 O
P30E4 DLC DIAGNOSIS PDM(POWER DE-
P0A1F BATTERY ENERGY CONTROL MOD- LIVERY MODULE) .......................................... 383
ULE ................................................................... 360 P
DTC Description .................................................... 383
P318D COMMUNICATION ERROR ............... 384
P3030 CELL CONTROLLER LIN .................... 361 DTC Description .................................................... 384
P318E COMMUNICATION ERROR ................ 385
EVB-5
DTC Description ....................................................385 DTC Description .................................................... 419
Diagnosis Procedure .............................................385 Diagnosis Procedure ............................................. 420
DTC Description ....................................................386 P3399-P33A4 CELL OVER DISCHARGE ....... 424
P3196 COMMUNICATION ERROR ................. 387 Component Inspection .......................................... 428
DTC Description ....................................................387
Diagnosis Procedure .............................................387 P33D4 BATT GRADUAL CAPA LOSS DIAG .. 429
DTC Description .................................................... 429
P3198 COMMUNICATION ERROR ................. 388 Diagnosis Procedure ............................................. 429
DTC Description ....................................................388
Diagnosis Procedure .............................................388 P33D5 CURRENT SENSOR ............................ 430
DTC Description .................................................... 430
P3199 COMMUNICATION ERROR ................. 389 Diagnosis Procedure ............................................. 430
DTC Description ....................................................389
Diagnosis Procedure .............................................389 P33D6 CURRENT SENSOR ............................ 433
DTC Description .................................................... 433
P319C COMMUNICATION ERROR ................ 390 Diagnosis Procedure ............................................. 433
DTC Description ....................................................390
Diagnosis Procedure .............................................390 P33D7, P33D9, P33DB, P33DD TEMPERA-
TURE SENSOR ................................................ 435
P31A4 CAN ERROR VCM ............................... 391 DTC Description .................................................... 435
Diagnosis Procedure .............................................391 Component Inspection .......................................... 436
P31A7 CAN ERROR INV/MC .......................... 392 P33DF BAT VOLTAGE ISOLATION SEN ....... 438
P3302-P330D CELL OVER VOLTAGE ........... 393 P33E0 BAT VOLTAGE ISOLATION SEN ........ 439
Component Inspection ...........................................395
P33E1 BAT VOLTAGE ISOLATION SEN ........ 440
P330E-P3319 CELL OVER VOLTAGE ........... 397 DTC Description .................................................... 440
Component Inspection ...........................................399 P33E2 BATT PACK OVER TEMP ................... 441
DTC Description .................................................... 441
P331A-P3325 CELL OVER VOLTAGE ........... 401 Diagnosis Procedure ............................................. 441
DTC Description ....................................................401
Diagnosis Procedure .............................................402 P33E4, P33E5 TEMPERATURE SENSOR ...... 442
Component Inspection ...........................................404 DTC Description .................................................... 442
P3326-P3331 CELL OVER VOLTAGE ........... 406 Component Inspection .......................................... 443
DTC Description ....................................................406
Diagnosis Procedure .............................................407 P33E6 CELL CONTROLLER ........................... 444
Component Inspection ...........................................410 DTC Description .................................................... 444
P3375-P3380 CELL OVER DISCHARGE ....... 411
DTC Description ....................................................411 P33ED BATTERY PARALLEL DIAGNOSIS .. 449
Component Inspection ...........................................413 Diagnosis Procedure ............................................. 450
P3381-P338C CELL OVER DISCHARGE ....... 415 P33F2 EVAPORATOR TEMP SENSOR .......... 451
Component Inspection ...........................................417 Component Inspection .......................................... 452
P338D-P3398 CELL OVER DISCHARGE ....... 419 P33F5 BATTERY FAN ..................................... 453
EVB-6
DTC Description .................................................... 453 BATTERY JUNCTION BOX AND BATTERY HAR-
Diagnosis Procedure ............................................. 453 NESS ........................................................................ 513 A
BATTERY JUNCTION BOX AND BATTERY
U1000 CAN COMM CIRCUIT ........................... 456 HARNESS : Exploded View .................................. 513
DTC Description .................................................... 456 BATTERY JUNCTION BOX AND BATTERY
Diagnosis Procedure ............................................. 456 B
HARNESS : Removal and Installation ................... 515
HIGH VOLTAGE CIRCUIT ............................... 457 LI-ION BATTERY COOLING UNIT .......................... 521
Diagnosis Procedure ............................................. 457 LI-ION BATTERY COOLING UNIT : Exploded EVB
view ....................................................................... 522
LI-ION BATTERY INSULATION RESIS- LI-ION BATTERY COOLING UNIT : Removal and
TANCE LOSS CHECK ..................................... 459 Installation ............................................................. 522
Component Inspection .......................................... 459 D
FRONT MODULE STACK ....................................... 526
POWER SUPPLY AND GROUND CIRCUIT .... 483 FRONT MODULE STACK : Exploded View .......... 526
Diagnosis Procedure ............................................. 483 FRONT MODULE STACK : Removal and Installa- E
tion ......................................................................... 530
SYMPTOM DIAGNOSIS ............................ 486 FRONT MODULE STACK : Disassembly and As-
EV BATTERY SYSTEM ................................... 486 sembly ................................................................... 535 F
Symptom Index ..................................................... 486 REAR MODULE STACK ......................................... 543
REDUCTION IN THE DRIVING RANGE .......... 487 REAR MODULE STACK : Exploded View ............ 543
REAR MODULE STACK : Removal and Installa- G
Description ............................................................ 487
Diagnosis Procedure ............................................. 487 tion ......................................................................... 547
REAR MODULE STACK : Disassembly and As-
NORMAL OPERATING CONDITION ............... 488 sembly ................................................................... 551 H
Description ............................................................ 488 Inspection .............................................................. 559
PERIODIC MAINTENANCE ....................... 489 SERVICE DATA AND SPECIFICATIONS

(SDS) .......................................................... 563 I
EV BATTERY USAGE REPORT ..................... 489
Inspection .............................................................. 489 SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... 563 J
REMOVAL AND INSTALLATION ............. 490 Li-ion Battery ......................................................... 563
LI-ION BATTERY UNDERCOVER ................... 490 WITH BATTERY HEATER & COOLER
Exploded View ...................................................... 490 K
PRECAUTION ............................................ 564
PRECAUTIONS ............................................... 564
UNIT REMOVAL AND INSTALLATION .... 492 Precaution for Technicians Using Medical Electric.. 564 L
LI-ION BATTERY ............................................. 492 Precaution for Supplemental Restraint System
Exploded View ...................................................... 492 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Removal and Installation ....................................... 492 SIONER" ............................................................... 564 M
Inspection .............................................................. 498 Precaution for Procedure without Cowl Top Cover.. 565
Precautions for Removing Battery Terminal .......... 565
UNIT DISASSEMBLY AND ASSEMBLY . 500 N
CAUTIONS AS TO HIGH VOLTAGE .............. 567
LI-ION BATTERY ............................................. 500 How to Disconnect High Voltage ........................... 567
High Voltage Precautions ...................................... 569
BATTERY PACK UPPER CASE ............................. 500 Check Voltage in High Voltage Circuit ................... 571 O
BATTERY PACK UPPER CASE : Exploded View.. 500 High Voltage Warning Label .................................. 574
BATTERY PACK UPPER CASE : Removal and Insulated Protective Wear and Insulating Tools .... 575
Installation ............................................................. 501 Cautions for Scrapping Vehicles ........................... 575 P
Handling of a Vehicle with a Dead Battery ............ 575
LI-ION BATTERY CONTROLLER ........................... 510
LI-ION BATTERY CONTROLLER : Exploded PREPARATION ......................................... 576
View ...................................................................... 511
LI-ION BATTERY CONTROLLER : Removal and PREPARATION ............................................... 576
Installation ............................................................. 511 Special Service Tools ............................................ 576
Commercial Service Tools ..................................... 577
Sealant or/and Lubricant ....................................... 580
EVB-7
SYSTEM DESCRIPTION ........................... 581 WRITE BATTERY INFORMATION DATA ....... 639
Description ............................................................ 639
COMPONENT PARTS ..................................... 581 Work Procedure .................................................... 639
Component Parts Location ....................................581
Li-ion Battery .........................................................584 CLEAR BATTERY GRADUAL CAPACITY
Li-ion Battery Controller .........................................584 LOSS DATA ..................................................... 640
Module ...................................................................585 Description ............................................................ 640
Heater Relay Unit ..................................................586 Work Procedure .................................................... 640
Li-ion Battery Heater & Cooling Unit ......................586
Battery Temperature Sensor .................................588 CLEAR BATT CHARGE/DISCHARGE IN-
Battery Junction Box ..............................................588 FORMATION DATA ......................................... 641
Battery Current Sensor ..........................................588 Description ............................................................ 641
Service Plug ..........................................................589 Work Procedure .................................................... 641
High Voltage Warning Label ..................................589
SYSTEM ........................................................... 591 LI-ION BATTERY CONTROLLER ................... 642
Description ............................................................ 642
LI-ION BATTERY CONTROL SYSTEM ..................591 Work Procedure .................................................... 642
Description .............................................................591 ADDITIONAL SERVICE WHEN REPLACING
MODULE ........................................................... 643
LI-ION BATTERY HEATER CONTROL SYSTEM ..594
Description ............................................................ 643
LI-ION BATTERY HEATER CONTROL SYSTEM
Work Procedure .................................................... 643
: System Description ..............................................594
MODULE CHARGE BALANCE ....................... 644
LI-ION BATTERY COOLER CONTROL SYSTEM .. 596
Description ............................................................ 644
Work Procedure .................................................... 644
: System Description ..............................................596
Circuit Diagram ......................................................598 DTC/CIRCUIT DIAGNOSIS ....................... 646
Fail-safe .................................................................601
P0A0D HV SYSTEM INTERLOCK ERROR ..... 646
WARNING/INDICATOR/CHIME LIST ......................602 DTC Description .................................................... 646
WARNING/INDICATOR/CHIME LIST : Warning Diagnosis Procedure ............................................. 646
lamps/Indicator lamps ............................................602 Component Inspection .......................................... 647
HANDLING PRECAUTION .............................. 603 P0A1F BATTERY ENERGY CONTROL MOD-
EV Battery System ................................................603
ULE ................................................................... 648
DIAGNOSIS SYSTEM (LBC) ........................... 604 DTC Description .................................................... 648
CONSULT Function ...............................................604 Diagnosis Procedure ............................................. 648
ECU DIAGNOSIS INFORMATION ............. 607 P3030 CELL CONTROLLER LIN ..................... 649
DTC Description .................................................... 649
EV BATTERY SYSTEM ................................... 607 Diagnosis Procedure ............................................. 649
Reference Value ....................................................607
Fail-safe .................................................................612 P3031-P303C CELL CONTROLLER ASIC ...... 650
DTC Index .............................................................617 DTC Description .................................................... 650
WIRING DIAGRAM .................................... 623
P303D-P3048 CELL CONTROLLER ASIC ...... 652
VCM ................................................................. 623 DTC Description .................................................... 652
Wiring Diagram ......................................................623 Diagnosis Procedure ............................................. 653
BASIC INSPECTION .................................. 635 P3049-P3054 CELL CONTROLLER ASIC

VOLTAGE ......................................................... 654
DIAGNOSIS AND REPAIR WORK FLOW ...... 635 DTC Description .................................................... 654
Work Flow ..............................................................635 Diagnosis Procedure ............................................. 655
Diagnostic Work Sheet ..........................................636
P3055-P3060 CELL CONTROLLER ASIC
SAVE BATTERY INFORMATION DATA ........ 638 VOLTAGE ......................................................... 656
Work Procedure .....................................................638 Diagnosis Procedure ............................................. 657
EVB-8
P3061 CELL BATTERY VOLTAGE ................. 658 P319C COMMUNICATION ERROR ............... 678
DTC Description .................................................... 658 DTC Description .................................................... 678 A
P3062 BYPASS SWITCH ................................. 659 P31A4 CAN ERROR VCM .............................. 679
B
P3064 CELL CONT ASIC ................................ 660 P31A7 CAN ERROR INV/MC ......................... 680 EVB
P308B-P3096 CELL CONTROLLER ASIC P3302-P330D CELL OVER VOLTAGE .......... 681 D
OPEN ................................................................ 661 DTC Description .................................................... 681
Diagnosis Procedure ............................................. 662 Component Inspection ........................................... 683 E
P3097-P30A2 CELL CONTROLLER ASIC P330E-P3319 CELL OVER VOLTAGE .......... 685
OPEN ................................................................ 664 DTC Description .................................................... 685
F
P30E0 DLC DIAGNOSIS VCM ......................... 668 P331A-P3325 CELL OVER VOLTAGE .......... 689 G
Component Inspection ........................................... 692 H
P30E2 DLC DIAGNOSIS HVAC ...................... 669
DTC Description .................................................... 669 P3326-P3331 CELL OVER VOLTAGE ........... 694
Diagnosis Procedure ............................................. 695 I
P30E3 DLC DIAGNOSIS MC ........................... 670 Component Inspection ........................................... 698
DTC Description .................................................... 670
Diagnosis Procedure ............................................. 670 P3375-P3380 CELL OVER DISCHARGE ....... 699
J
DTC Description .................................................... 699
P30E4 DLC DIAGNOSIS PDM(POWER DE- Diagnosis Procedure ............................................. 700
LIVERY MODULE) ........................................... 671 Component Inspection ........................................... 701
DTC Description .................................................... 671 K
Diagnosis Procedure ............................................. 671 P3381-P338C CELL OVER DISCHARGE ...... 703
DTC Description .................................................... 703
P318D COMMUNICATION ERROR ................. 672 Diagnosis Procedure ............................................. 704 L
DTC Description .................................................... 672 Component Inspection ........................................... 705
P338D-P3398 CELL OVER DISCHARGE ...... 707
P318E COMMUNICATION ERROR ................. 673 DTC Description .................................................... 707 M
N
P3191 COMMUNICATION ERROR ................. 674 P3399-P33A4 CELL OVER DISCHARGE ...... 712
Component Inspection ........................................... 716 O
DTC Description .................................................... 675 P33D4 BATT GRADUAL CAPA LOSS DIAG . 717
Diagnosis Procedure ............................................. 675 DTC Description .................................................... 717 P
DTC Description .................................................... 676 P33D5 CURRENT SENSOR ........................... 718
DTC Description .................................................... 677 P33D6 CURRENT SENSOR ........................... 721
EVB-9
Diagnosis Procedure .............................................721 LI-ION BATTERY INSULATION RESIS-
TANCE LOSS CHECK ..................................... 752
P33D7, P33D9, P33DB, P33DD TEMPERA- Component Inspection .......................................... 752
TURE SENSOR ............................................... 723
DTC Description ....................................................723 LI-ION BATTERY HEATER SYSTEM INSU-
Diagnosis Procedure .............................................723 LATION RESISTANCE CHECK ....................... 776
Component Inspection ...........................................724 Diagnosis Procedure ............................................. 776
P33DF BAT VOLTAGE ISOLATION SEN ...... 726 POWER SUPPLY AND GROUND CIRCUIT .... 778
SYMPTOM DIAGNOSIS ........................... 781
P33E0 BAT VOLTAGE ISOLATION SEN ....... 727
DTC Description ....................................................727 EV BATTERY SYSTEM .................................... 781
Diagnosis Procedure .............................................727 Symptom Index ..................................................... 781
P33E1 BAT VOLTAGE ISOLATION SEN ....... 728 REDUCTION IN THE DRIVING RANGE .......... 782
DTC Description ....................................................728 Description ............................................................ 782
P33E2 BATT PACK OVER TEMP ................... 729 BATTERY TEMPERATURE WARNING
DTC Description ....................................................729 LAMP ON .......................................................... 783
Diagnosis Procedure .............................................729 Description ............................................................ 783
P33E4, P33E5 TEMPERATURE SENSOR ..... 730
DTC Description ....................................................730 NORMAL OPERATING CONDITION ............... 784
Diagnosis Procedure .............................................730 Description ............................................................ 784
Component Inspection ...........................................731
PERIODIC MAINTENANCE ...................... 785
P33E6 CELL CONTROLLER .......................... 732
DTC Description ....................................................732 EV BATTERY USAGE REPORT ...................... 785
Diagnosis Procedure .............................................732 Inspection .............................................................. 785
P33EA BATTERY HEATER RELAY ............... 737 REMOVAL AND INSTALLATION ............. 786
DTC Description ....................................................737
Diagnosis Procedure .............................................737 LI-ION BATTERY UNDERCOVER ................... 786
Component Inspection ...........................................739 Exploded View ...................................................... 786
P33ED BATTERY PARALLEL DIAGNOSIS ... 740
DTC Description ....................................................740 UNIT REMOVAL AND INSTALLATION ... 788
LI-ION BATTERY ............................................. 788
P33EE BATTERY HEATER CONTROL SYS- Exploded View ...................................................... 788
TEM .................................................................. 742 Removal and Installation ....................................... 788
DTC Description ....................................................742 Inspection .............................................................. 794
UNIT DISASSEMBLY AND ASSEMBLY .. 796
P33F2 EVAPORATOR TEMP SENSOR ......... 744
DTC Description ....................................................744
LI-ION BATTERY ............................................. 796
Diagnosis Procedure .............................................744 BATTERY PACK UPPER CASE ............................ 796
Component Inspection ...........................................745 BATTERY PACK UPPER CASE : Exploded View. 796
BATTERY PACK UPPER CASE : Removal and
P33F5 BATTERY FAN .................................... 746
Installation ............................................................. 797
DTC Description ....................................................746
Diagnosis Procedure .............................................746 LI-ION BATTERY CONTROLLER .......................... 806
LI-ION BATTERY CONTROLLER : Exploded
U1000 CAN COMM CIRCUIT .......................... 749 View ...................................................................... 807
DTC Description ....................................................749 LI-ION BATTERY CONTROLLER : Removal and
Installation ............................................................. 807
HIGH VOLTAGE CIRCUIT .............................. 750 LI-ION BATTERY HEATER RELAY UNIT .............. 809
EVB-10
LI-ION BATTERY HEATER RELAY UNIT : Ex- FRONT MODULE STACK : Removal and Installa-
ploded view ........................................................... 810 tion ......................................................................... 828 A
LI-ION BATTERY HEATER RELAY UNIT : Re- FRONT MODULE STACK : Disassembly and As-
moval and Installation ........................................... 810 sembly ................................................................... 833
BATTERY JUNCTION BOX AND BATTERY HAR- REAR MODULE STACK ......................................... 841 B
NESS ....................................................................... 812 REAR MODULE STACK : Exploded View ............ 841
BATTERY JUNCTION BOX AND BATTERY REAR MODULE STACK : Removal and Installa-
HARNESS : Exploded View .................................. 812 tion ......................................................................... 845 EVB
BATTERY JUNCTION BOX AND BATTERY REAR MODULE STACK : Disassembly and As-
HARNESS : Removal and Installation .................. 814 sembly ................................................................... 849
Inspection .............................................................. 857 D
LI-ION BATTERY HEATER & COOLING UNIT ...... 819
LI-ION BATTERY HEATER & COOLING UNIT : SERVICE DATA AND SPECIFICATIONS
Exploded view ....................................................... 820 (SDS) .......................................................... 861
LI-ION BATTERY HEATER & COOLING UNIT : E
Removal and Installation ....................................... 820 SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... 861
FRONT MODULE STACK ....................................... 824
Li-ion Battery ......................................................... 861 F
FRONT MODULE STACK : Exploded View .......... 824
EVB-11
PRECAUTIONS
< PRECAUTION > [WITHOUT BATTERY COOLER]
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
WARNING:
EVB-12
PRECAUTIONS
B
connectors.
WARNING: EVB
D
injury.
windshield.
G
PIIB3706J
I
J
NOTE:
SEF289H
WORK PROCEDURE
NOTE:
tion. O
NOTE: P
detected.
CAUTION:
EVB-13
PRECAUTIONS
NOTE:
the power switch.
NOTE:
NOTE:
EVB-14
A

1. Turn power switch OFF. EVB
CAUTION:
from damage. E
JMJIB0266ZZ
H
I
: Pawl
K
JMJIB0267ZZ

: Metal clip
M
JMJIB0268ZZ
O
EVB-15
:Vehicle front
JSCIA1194ZZ
ALAIA0088ZZ
DANGER:
WARNING:
battery side.
DANGER:

JSCIA1303ZZ
EVB-16
A
EVB
ALAIA0089ZZ
DANGER: D
E
WARNING: F
H
DANGER:
maintenance. J
WARNING:
K
CAUTION: M
blow gun.
NOTE:
EVB-17
WARNING:
EVB-18
workers. A
EVB
JSAIA1600GB P
DANGER:
EVB-19
maintenance.
WARNING:
CAUTION:
INSPECTION
WARNING:
Installation".
DANGER:

tective gear.

JSCIA1328ZZ

DANGER:

tective gear.
JSCIA1361ZZ
EVB-20
• Because there is the danger of electric shock, immediately insulate disconnected high volt- A
EVB
JSCIA1329ZZ
E
DANGER: F
G
JSCIA1195ZZ
K
CAUTION:
EVB-21
JSAIA3647ZZ

PTC elements heater
Electric compressor
Li-ion battery
COOLER
Service plug
COOLER
COOLER
CAUTION:
EVB-22
A
B
DAILY INSPECTION
• Insulated gloves EVB
JPCIA0061ZZ H


INSULATING TOOLS
L
CAUTION:
N
CAUTION: O
P
EVB-23
PREPARATION
< PREPARATION > [WITHOUT BATTERY COOLER]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000011103403
Tool name
Tool number Description
(SPX-North America No.)
Palette
NI-4037 When removing/installing Li-ion battery.
(—)
JPCIA0239ZZ
Air leak checker

When checking air leaks after disassembling/assem-
KV99111400
bling Li-ion battery.
(—)
JSCIA0257ZZ
Module terminal cover

Protect module terminals (For LEAF)
KV99111500
24 pieces/set
(—)
JPCIA0069ZZ
Module voltage adjustment

Kit for EV Module charge balancer
NOTE:
—
This kit includes the module charge balancer and the
(J-50346-A)
module charge balancer module box.
JPCIA0070ZZ
Safety lock out plug

NI-4031 When installing cover after removing service plug.
(—)
JPCIA0156ZZ
EVB-24
PREPARATION

B
nents
Insulated gloves • Use protective gloves made of insulating EVB
material.
JMCIA0149ZZ D
• Removing and installing high voltage com-

E
ponents
tight] F
JPCIA0066ZZ
Removing and installing high voltage compo- G

nents
Insulated safety shoes • Use protective shoes made of insulating
material. H
JPCIA0011ZZ
I

ponents J
to electric line
K
JPCIA0167ZZ
L
ponents
Safety glasses
• To protect face from the spatter on the work
to electric line M
JPCIA0012ZZ

Insulated helmet O
nents
JPCIA0013ZZ P
EVB-25
PREPARATION

Insulated rubber sheet
nents
JPCIA0019ZZ

Insulated cover sheet
nents
JPCIA0018ZZ
Battery lift table Removing and installing Li-ion battery
JPCIA0024ZZ
Stacker Removing and installing Li-ion battery
JPCIA0015ZZ
VAT Measuring voltage and insulation
JSCIA0083ZZ

JPCIA0014ZZ
Insulated hand tools Disassembling and assembling Li-ion battery
JPCIA0067ZZ
EVB-26
PREPARATION
A
B
Insulated torque wrench Disassembling and assembling Li-ion battery
EVB
JPCIA0068ZZ
• Removing and installing battery module

stack
D
• Installing battery pack upper case
NOTE:
Carabineer [small]
• D: 8.0 mm (0.31 in)
• L: 74.0 mm (2.91 in) E
• S: 10.0 mm (0.39 in)
JPCIA0016ZZ
• W: 22.5 mm (0.89 in)
F
Removing and installing battery module stack
NOTE:
• D: 14.0 mm (0.55 in)
Carabineer [large] G
• L: 204.0 mm (8.03 in)
• S: 47.0 mm (1.85 in)
• W: 105.0 mm (4.13 in)
JPCIA0017ZZ
H
Removing and installing battery module stack I

Belt slinger NOTE:
Length: 2.0 m (6.562 ft)
J
JPCIA0021ZZ
Mobile floor crane Removing and installing battery module stack

L
JPCIA0020ZZ
Removing and installing battery rear module N

Lashing belt
stack
JPCIA0022ZZ
O
P
Removing battery pack upper case
Windshield cutter [Gasket cutter]
(Cut the adhesive)
JSCIA0640ZZ
EVB-27
PREPARATION
Installing battery pack upper case

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

Scraper
(Smooth the adhesive)
JSCIA0643ZZ
Tube presser [Gasket material appli- Installing battery pack upper case
cator] (Apply the adhesive)
JSCIA0639ZZ
Assembling battery module stack

NOTE:
Metal bar
• D: φ 7 mm (0.28 in)
• L: 1 m (3.28 ft)
JSCIA0735ZZ
Tool name
Description
Tool number
Adhesive
KE561-32090
Dam rubber
KE390-00590
Primer (Adhesive primer)
KE560-15090
Primer sufacer (anti-corrosion praimer)
—
EVB-28
COMPONENT PARTS
< SYSTEM DESCRIPTION > [WITHOUT BATTERY COOLER]
COMPONENT PARTS
B
EVB
JSCIA1082ZZ
EVB-29
COMPONENT PARTS
Front of battery pack Back of battery pack

: Vehicle front
No. Component Function

Li-ion battery EVB-30, "Li-ion Battery"
Service plug EVB-33, "Service Plug"
Battery temperature sensor 1 (center of rear module) EVB-32, "Battery Temperature Sensor"
Front module stack RH EVB-31, "Module"
Battery junction box EVB-33, "Battery Junction Box"
Front module stack LH EVB-31, "Module"
Battery temperature sensor 3 (left side of rear module) EVB-32, "Battery Temperature Sensor"
Li-ion battery controller EVB-31, "Li-ion Battery Controller"
Rear module stack EVB-31, "Module"
Battery temperature sensor 2 (center of LH front module) EVB-32, "Battery Temperature Sensor"
Battery temperature sensor 4 (rear side of LH front module) EVB-32, "Battery Temperature Sensor"
Battery current sensor EVB-33, "Battery Current Sensor"
Li-ion Battery INFOID:0000000011103409
• 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.
JSCIA1085ZZ
• Four cells are integrated into a single module. The Li-ion battery consists of 48 modules placed in series.
JSCIA1086ZZ
EVB-30
COMPONENT PARTS
Li-ion Battery Controller INFOID:0000000011103410
A
• Li-ion battery controller (LBC) is included in the battery pack and
installed on the left surface of the rear module stack.
• The LBC is the core of battery control. Li-ion battery controller B
detects the voltage and current of the assembled battery, the tem-
perature 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 EVB
to VCM (Vehicle control module). VCM controls the vehicle,
according to the battery state.
D
JSCIA1128ZZ
Main Role of Li-ion Battery Controller E

1. Li-ion battery state check
• State of charge
• Possible output value F
• Possible input value
• Temperature
2. Optimization of Li-ion battery voltage G
3. Prevention of overvoltage and overcurrent
4. Prevention of overheat
5. Detection of decrease in insulation resistance of high-voltage circuit H
6. Detection of a fit of high voltage harness connector and service plug
Module INFOID:0000000011103411
I
• Four laminated cells are integrated into one module.
• The Li-ion battery is equipped with 48 modules.
• There are two kinds of modules, according to the location of posi- J
tive and negative terminals.
Positive terminal : Red K

Negative terminal : Black
JSCIA0703ZZ
MODULE INTERNAL CIRCUIT M

A module consists of two parallel-connected cells placed in series.
The Li-ion battery has 48 modules placed in series in total. Ninety-six
parallel-connected cell pairs are connected in series. N
NOTE:
Cell voltage displayed on the data monitor of CONSULT means the
potential difference between the upstream and the downstream of
the parallel circuit. O
P
JPCIA0197GB
MODULE LAYOUT
EVB-31
COMPONENT PARTS
JSCIA1087GB
NOTE:
The highest potential is module (MD) 1 and the lowest is module (MD) 48.
CELL
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 battery
life.
• Light and thin structure increases flexibility in layout.
Battery Temperature Sensor INFOID:0000000011103414
• Four battery temperature sensors mounted in the battery pack measure the temperature.
JSCIA1091ZZ
• The installation position of the sensors are;

- Front module stack RH: Two for front and rear
- Rear module stack: Two for center and left side
EVB-32
COMPONENT PARTS
• The sensor uses a thermistor with a resistance value that varies
according to changes in temperature. The electrical resistance of A
the thermistor decreases as the temperature increases.
EVB
JPCIA0295GB
D
Battery Junction Box INFOID:0000000011103415
• The battery junction box is installed to the front side in the battery
pack. E
• The battery junction box includes:
- System main relay to provide/interrupt DC current sent from Li-ion
battery. F
- 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 G
system main relay provides DC current to the Li-ion battery during
motor regeneration or charge.
JSCIA0506ZZ
• When an error occurs in the system, the system main relay is H
turned OFF and the Li-ion battery is interrupted for ensuring safety, based on a command from VCM (Vehi-
cle control module).
I
Battery Current Sensor INFOID:0000000011103416
• The battery current sensor is installed to bus bar between battery

junction box and front module stack LH. J
• This sensor measures charge/discharge current sent to Li-ion bat-
tery and transmits a current signal to Li-ion battery controller
(LBC). K
• Li-ion Battery controller (LBC) measures remaining battery level
according to charge/discharge current and sends the data to VCM.
L
JSCIA1092ZZ
M
Service Plug INFOID:0000000011103417
• The service plug is included in the Li-ion battery to securely dis-

N
connect the high voltage during high voltage part inspection and
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- O
vice plug cover is removed.
• Always use insulating protective equipment when removing and
installing service plug. P
JSCIA0706ZZ
High voltage warning label is affixed to each of the following component parts.
EVB-33
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 Li-ion battery.
JSCIA1093ZZ
: Vehicle front
Li-ion Battery Controller

The label is affixed to the main body of controller.
JSCIA0111ZZ
Service Plug
The label is affixed to the inspection hole cover .
JSCIA1095ZZ
EVB-34
SYSTEM
SYSTEM
A
LI-ION BATTERY CONTROL SYSTEM
LI-ION BATTERY CONTROL SYSTEM : System Description INFOID:0000000011103419
B
SYSTEM DIAGRAM
EVB
JSCIA0814GB K
INPUT/OUTPUT SIGNAL ITEM
Input Signal Item L
Transmit unit Signal name

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

N
EVB-35
SYSTEM
Received unit Signal name

High voltage discharge permit signal
Li-ion battery main relay cut request signal
Li-ion battery connector interlock signal
Li-ion battery voltage signal
Li-ion battery current signal
Li-ion battery chargeable power signal
Li-ion battery dischargeable power signal
Li-ion battery charge completion signal
Li-ion battery available charge signal
VCM EV system CAN
Li-ion battery capacity signal
Li-ion battery gradual capacity loss signal
Insulation resistance signal
Diagnostic trouble code signal
System main relay ON permit signal
Li-ion battery cell control signal
Power limit cause (LBC) signal
Remaining time to charge completion signal
Charge type signal
DESCRIPTION
The Li-ion battery controller (LBC) monitors the status of the inside of the Li-ion battery at all times and sends
information, such as the charging status of Li-ion battery and possible power, to VCM (vehicle control module)
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.
• 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.
• 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.
• 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
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
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.
Control item Control Operating condition

Gradual control of charging energy as the cell voltage ap-
Charging energy control
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.
EVB-36
SYSTEM
Control item Control Operating condition
A
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 B
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. EVB
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. D
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 E
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. F
JPCIA0094GB
INSULATION RESISTANCE LOSS DETECTION FUNCTION K

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. L
VCM judges abnormal insulation resistance in each high voltage part, based on the received insulation resis-
tance value.
M
JSCIA0815GB
EVB-37
SYSTEM
Circuit Diagram INFOID:0000000011103422
JSCIA1291GB
EVB-38
SYSTEM
EVB
N
JSCIA1292GB
Harness Layout
O
EVB-39
SYSTEM
JSCIA1293GB
: Vehicle front
Fail-safe INFOID:0000000011199168
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
• 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
Regarding the arrangement. Refer to MWI-9, "METER SYSTEM : Design".
EVB-40
SYSTEM
Item Design Reference A
Battery temperature warning For function, refer to MWI-28, "WARNING LAMPS/INDICATOR LAMPS : Battery
lamp Temperature Warning Lamp".
B
EVB
EVB-41
HANDLING PRECAUTION
HANDLING PRECAUTION
EV Battery System INFOID:0000000011103427
• 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
1. Apply insulating tape to the service plug and high voltage harness connector, and protect the terminals so
that nothing contacts them.
2. Store in a well-ventilated location that is not exposed to direct sunlight.
(Storing outdoors or unprotected is prohibited.)
3. Never set directly on the floor.
4. Lay an anti-static rubber sheet underneath the battery.
5. Never invert the battery.
6. Never stack batteries.
7. Cover with an anti-static cover sheet.
8. Put a caution display stating "CAUTION! HIGH VOLTAGE" on the insulated cover sheet.
9. Put identification display showing the name of person in charge on the insulated cover sheet.
10. Never allow water to contact the battery.
11. Prevent other objects from falling onto the battery.
EVB-42
DIAGNOSIS SYSTEM (LBC)
A
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
This mode enables a technician to adjust some devices faster and more accurately by following the
Work Support
indications on the CONSULT.
E
CAN Diagnosis Displays the CAN diagnosis results.
CAN Diagnosis Support Monitor Displays the CAN communication status.
*: The following diagnosis information is cleared when the VCM memory is erased. F
ECU IDENTIFICATION G
Part number of LBC can be checked.
SELF-DIAGNOSTIC RESULTS H
Regarding items of DTC, refer to EVB-55, "DTC Index".
How to Erase DTC I
1. Select “HV BAT” with CONSULT.
2. Select “Self-diagnostic results”.
3. Touch “ERASE”. (DTC in LBC will be erased.) J
K
BATT ELECTRIC CURRENT A Displays the Li-ion battery current value L
12V BATTERY VOLTAGE mV Displays 12V battery power supply voltage
Displays the maximum to minimum difference of voltage magnitude of the on-board
IR SEN SHORT PULSE mV M
isolation resistance monitoring system
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug
CLOSE
N
CELL VOLTAGE 01 - 96 mV Displays each cell voltage
TOTAL BATTERY VOLTAGE V Displays the total voltage of the Li-ion battery
BATTERY TEMPERATURE 1 °C Displays the temperature calculated with a signal voltage from battery temperature 1 O
BATTERY TEMPERATURE 2 °C Displays the temperature calculated with a signal voltage from battery temperature 2
P
DATA MONITOR
NOTE:
EVB-43
×:Applicable
Monitored item Unit ALL MAIN MAIN MAIN MAIN Remark

SIG- SIGN SIGN SIGN SIGN
NALS AL1 AL2 AL3 AL4
BATT ELECTRIC CUR-
A × × Displays the Li-ion battery current value
RENT
12V BATTERY VOLT-
mV × × Displays 12V battery power supply voltage
AGE
Displays the maximum to minimum difference of volt-
IR SEN SHORT PULSE mV × × age magnitude of the on-board isolation resistance
monitoring system
SERVICE PLUG IN- OPEN /
× × Displays the OPEN/CLOSE state of the service plug
TERLOCK CLOSE
CELL VOLTAGE 01 - 96 mV × × Displays each cell voltage
TOTAL BATTERY
V × × Displays the total voltage of the Li-ion battery
VOLTAGE
MAXIMUM CELL VOLT-
mV × × Displays the maximum cell voltage value
AGE
MINIMUM CELL VOLT-
mV × × Displays the minimum cell voltage value
AGE
BATTERY TEMPERA- Displays the temperature calculated with a signal volt-
°C × ×
TURE 1 age from battery temperature 1
°C × ×
°C × ×
°C × ×
EVAPORATOR TEM- Displays the temperature calculated with a signal volt-
°C × ×
PERATURE age from evaporator temperature
FAN DUTY % × Displays drive duty ratio of blower motor
FAN SPEED rpm × Displays revolutions of blower motor
Displays a 100ms average value of battery fan rotation
FAN FREQUENCY — ×
signal frequency.
PTC HEATER RELAY
On / Off × Displays the ON/OFF status of heater relay
STAT SIG
PTC HEAT RELAY
On / Off × Displays the ON/OFF request status of heater relay
CONT SIG
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 INFORMATION When Li-ion battery and LBC are
The CONSULT stored data can be written in LBC.
DATA replaced.
CLEAR BATTERY GRADUAL CA- Erases Li-ion battery capacity related information stored in
When all modules are replaced.
PACITY LOSS DATA LBC
CLEAR BATT CHARGE/DIS- Erases Li-ion battery charge/discharge related information
CHARGE INFORMATION DATA stored in LBC
This inspection identifies a cell of which cell voltage is on the
CELL VOLTAGE LOSS INSPEC- When checking voltage of all
decrease. If identified, this type of cell may be judged as an
TION cells.
abnormal cell, unless it is replaced.
EVB-44
EV BATTERY SYSTEM
< ECU DIAGNOSIS INFORMATION > [WITHOUT BATTERY COOLER]

EV BATTERY SYSTEM
B
VALUE ON THE DIAGNOSIS TOOL

NOTE: EVB
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
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
EVB-45
EV BATTERY SYSTEM
EVB-46
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
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
EVB-47
EV BATTERY SYSTEM
EVB-48
EV BATTERY SYSTEM
A
D
H
K
TOTAL BATTERY VOLTAGE READY Approx. 240 - 420 V
M
MAXIMUM CELL VOLTAGE READY
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-
cle)
EVB-49
EV BATTERY SYSTEM
20°C - 30°C (68°F - 86°F)
READY (Stop the vehi- [Equivalent to air temperature
cle) around front RH module stack (rear
side)]
20°C - 30°C (68°F - 86°F)
EVAPORATOR TEMPERA- READY (Stop the vehi-
Ambient temperature: 25°C (77°F) [Equivalent to air temperature
TURE cle)
around evaporator]
Li-ion battery cooler or heater is oper-
100%
ating
FAN DUTY READY Blower motor is running to dry inside
40%
the Li-ion battery.
Other than those above 0%
600 - 8,000 rpm
ating
FAN SPEED READY
Revolutions of blower motor < 600
Other than those above
rpm
10 Hz ≤ Frequency of blower motor
FAN FREQUENCY READY ating
Other than those above Frequency of blower motor < 10 Hz
PTC HEATER RELAY STAT Li-ion battery heater is operating On

READY
SIG Other than those above Off
PTC HEAT RELAY CONT Li-ion battery heater is operating On

READY
FAIL-SAFE PATTERN
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 ×
EVB-50
EV BATTERY SYSTEM
Pattern
DTC CONSULT screen items A
A B C D
P303A CELL CONT ASIC10 ×
P303B CELL CONT ASIC11 × B
P303C CELL CONT ASIC12 ×
P303D CELL CONT ASIC13 ×
P303E CELL CONT ASIC14 × EVB
P303F CELL CONT ASIC15 ×
D
P3043 CELL CONT ASIC19 × E
F
P3048 CELL CONT ASIC24 × G
P3049 CELL CONT ASIC1 VOLT ×
P304A CELL CONT ASIC2 VOLT ×
H
P304B CELL CONT ASIC3 VOLT ×
P304C CELL CONT ASIC4 VOLT ×
P304D CELL CONT ASIC5 VOLT × I
P304E CELL CONT ASIC6 VOLT ×
P304F CELL CONT ASIC7 VOLT ×
J

K
P3055 CELL CONT ASIC13 VOLT × L
M
P305A CELL CONT ASIC18 VOLT × N
O
P305D CELL CONT ASIC21 VOLT ×
P305F CELL CONT ASIC23 VOLT × P
P3061 CELL BATTERY VOLT ×
P3062 BYPASS SW ×
P3064 CELL CONT ASIC ×
P308B CELL CONT ASIC1 OPEN ×
EVB-51
EV BATTERY SYSTEM
Pattern
A B C D
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 ×
P309A CELL CONT ASIC16 OPEN ×
P30A0 CELL CONT ASIC22 OPEN ×
P30E0 DLC DIAGNOSIS VCM ×
P30E2 DLC DIAGNOSIS HVAC No fail-safe
P30E3 DLC DIAGNOSIS MC No fail-safe
P30E4 DLC DIAGNOSIS PD MODULE No fail-safe
P318D COMMUNICATION ERROR ×
P318E COMMUNICATION ERROR ×
P3191 COMMUNICATION ERROR No fail-safe
P3199 COMMUNICATION ERROR ×
P319C COMMUNICATION ERROR No fail-safe
P31A4 CAN ERROR VCM ×
P31A7 CAN ERROR INV/MC No fail-safe
P3302 CELL OVER VOLTAGE MODULE1 ×
EVB-52
EV BATTERY SYSTEM
Pattern
A B C D
P330A CELL OVER VOLTAGE MODULE9 × B
P330B CELL OVER VOLTAGE MODULE10 ×
P330C CELL OVER VOLTAGE MODULE11 ×
P330D CELL OVER VOLTAGE MODULE12 × EVB
P330E CELL OVER VOLTAGE MODULE13 ×
P330F CELL OVER VOLTAGE MODULE14 ×
D
P3312 CELL OVER VOLTAGE MODULE17 × E
F
P3317 CELL OVER VOLTAGE MODULE22 × G
H
P331A CELL OVER VOLTAGE MODULE25 ×
P331C CELL OVER VOLTAGE MODULE27 × I
P331D CELL OVER VOLTAGE MODULE28 ×
J

K
P3324 CELL OVER VOLTAGE MODULE35 × L
M
P3329 CELL OVER VOLTAGE MODULE40 × N
O
P332E CELL OVER VOLTAGE MODULE45 × P
P3375 CELL OVER DISCHARGE MODULE1 ×
EVB-53
EV BATTERY SYSTEM
Pattern
A B C D
P337A CELL OVER DISCHARGE MODULE6 ×
P337B CELL OVER DISCHARGE MODULE7 ×
P337C CELL OVER DISCHARGE MODULE8 ×
P337D CELL OVER DISCHARGE MODULE9 ×
P337E CELL OVER DISCHARGE MODULE10 ×
P337F CELL OVER DISCHARGE MODULE11 ×
P33A0 CELL OVER DISCHARGE MODULE44 ×
EVB-54
EV BATTERY SYSTEM
Pattern
A B C D
P33A3 CELL OVER DISCHARGE MODULE47 × B
P33D4 BATT GRADUAL CAPA LOSS DIAG ×
P33D5 CURRENT SENSOR × EVB
P33D6 CURRENT SENSOR ×
P33D7 TEMPERATURE SENSOR No fail-safe
D
P33DB TEMPERATURE SENSOR No fail-safe
P33DD TEMPERATURE SENSOR No fail-safe E
P33DF BATT VOLTAGE ISOLATION SEN ×
P33E0 BATT VOLTAGE ISOLATION SEN ×
F
P33E2 BATT PACK OVER TEMP ×
P33E4 TEMPERATURE SENSOR No fail-safe G
P33E5 TEMPERATURE SENSOR No fail-safe
P33E6 CELL VOLTAGE DEVIATION DIAG ×
H
P33ED BATTERY PARALLEL DIAGNOSIS ×
U1000 CAN COMM CIRCUIT × ×
I
×: Applicable —: Not applicable

J
EV system
DTC CONSULT screen items warning Trip Reference
lamp
P0A0D HV SYSTEM INTERLOCK ERROR × 1 EVB-84 K
P0A1F BATTERY ENERGY CONTROL MODULE × 1 EVB-86
P3030 CELL CONT LIN × 1 EVB-87
L
P3031 CELL CONT ASIC1 × 1 EVB-88
P3033 CELL CONT ASIC3 × 1 EVB-88 M
N
P3038 CELL CONT ASIC8 × 1 EVB-88 O
P303A CELL CONT ASIC10 × 1 EVB-88
P303B CELL CONT ASIC11 × 1 EVB-88 P
P303C CELL CONT ASIC12 × 1 EVB-88
P303D CELL CONT ASIC13 × 1 EVB-90
P303E CELL CONT ASIC14 × 1 EVB-90
P303F CELL CONT ASIC15 × 1 EVB-90
EVB-55
EV BATTERY SYSTEM
EV system
lamp
P3049 CELL CONT ASIC1 VOLT × 1 EVB-92
P304A CELL CONT ASIC2 VOLT × 1 EVB-92
P304B CELL CONT ASIC3 VOLT × 1 EVB-92
P304C CELL CONT ASIC4 VOLT × 1 EVB-92
P304D CELL CONT ASIC5 VOLT × 1 EVB-92
P304E CELL CONT ASIC6 VOLT × 1 EVB-92
P304F CELL CONT ASIC7 VOLT × 1 EVB-92
P3061 CELL BATTERY VOLT × 1 EVB-96
P3062 BYPASS SW × 1 EVB-97
P3064 CELL CONT ASIC × 1 EVB-98
P308B CELL CONT ASIC1 OPEN × 1 EVB-99
P308C CELL CONT ASIC2 OPEN × 1 EVB-99
P308D CELL CONT ASIC3 OPEN × 1 EVB-99
P308E CELL CONT ASIC4 OPEN × 1 EVB-99
P308F CELL CONT ASIC5 OPEN × 1 EVB-99
P3090 CELL CONT ASIC6 OPEN × 1 EVB-99
EVB-56
EV BATTERY SYSTEM
EV system
DTC CONSULT screen items warning Trip Reference A
lamp
P3094 CELL CONT ASIC10 OPEN × 1 EVB-99 B
EVB
P3099 CELL CONT ASIC15 OPEN × 1 EVB-102 D
P309A CELL CONT ASIC16 OPEN × 1 EVB-102
E
P309E CELL CONT ASIC20 OPEN × 1 EVB-102 F
P30A0 CELL CONT ASIC22 OPEN × 1 EVB-102
G

P30E0 DLC DIAGNOSIS VCM × 1 EVB-106 H
P30E2 DLC DIAGNOSIS HVAC — 1 EVB-107
P30E3 DLC DIAGNOSIS MC — 1 EVB-108
P30E4 DLC DIAGNOSIS PD MODULE — 1 EVB-109 I
P318D COMMUNICATION ERROR × 1 EVB-110
P318E COMMUNICATION ERROR × 1 EVB-111
J
P3191 COMMUNICATION ERROR — 1 EVB-112
P3198 COMMUNICATION ERROR — 1 EVB-114 K
P3199 COMMUNICATION ERROR × 1 EVB-115
P319C COMMUNICATION ERROR — 1 EVB-116
L
P31A4 CAN ERROR VCM × 1 EVB-117
P31A7 CAN ERROR INV/MC — 1 EVB-118
P3302 CELL OVER VOLTAGE MODULE1 × 1 EVB-119 M
P3303 CELL OVER VOLTAGE MODULE2 × 1 EVB-119
N
P3307 CELL OVER VOLTAGE MODULE6 × 1 EVB-119 O
P330A CELL OVER VOLTAGE MODULE9 × 1 EVB-119 P
P330B CELL OVER VOLTAGE MODULE10 × 1 EVB-119
P330C CELL OVER VOLTAGE MODULE11 × 1 EVB-119
P330D CELL OVER VOLTAGE MODULE12 × 1 EVB-119
P330E CELL OVER VOLTAGE MODULE13 × 1 EVB-123
P330F CELL OVER VOLTAGE MODULE14 × 1 EVB-123
EVB-57
EV BATTERY SYSTEM
EV system
lamp
P331A CELL OVER VOLTAGE MODULE25 × 1 EVB-127
P3375 CELL OVER DISCHARGE MODULE1 × 1 EVB-137
P337A CELL OVER DISCHARGE MODULE6 × 1 EVB-137
P337B CELL OVER DISCHARGE MODULE7 × 1 EVB-137
P337C CELL OVER DISCHARGE MODULE8 × 1 EVB-137
P337D CELL OVER DISCHARGE MODULE9 × 1 EVB-137
EVB-58
EV BATTERY SYSTEM
EV system
lamp
P337E CELL OVER DISCHARGE MODULE10 × 1 EVB-137
P337F CELL OVER DISCHARGE MODULE11 × 1 EVB-137 B
EVB
P3384 CELL OVER DISCHARGE MODULE16 × 1 EVB-141 D
E
P3389 CELL OVER DISCHARGE MODULE21 × 1 EVB-141 F
G

P338E CELL OVER DISCHARGE MODULE26 × 1 EVB-145 H
P338F CELL OVER DISCHARGE MODULE27 × 1 EVB-145
P3391 CELL OVER DISCHARGE MODULE29 × 1 EVB-145 I
J
P3396 CELL OVER DISCHARGE MODULE34 × 1 EVB-145 K
L
P339B CELL OVER DISCHARGE MODULE39 × 1 EVB-150 M
N
P33A0 CELL OVER DISCHARGE MODULE44 × 1 EVB-150 O
P33A1 CELL OVER DISCHARGE MODULE45 × 1 EVB-150
P33A3 CELL OVER DISCHARGE MODULE47 × 1 EVB-150 P
P33D4 BATT GRADUAL CAPA LOSS DIAG × 1 EVB-155
P33D5 CURRENT SENSOR × 1 EVB-156
P33D7 TEMPERATURE SENSOR — 1 EVB-161
EVB-59
EV BATTERY SYSTEM
EV system
lamp
P33DB TEMPERATURE SENSOR — 1 EVB-161
P33DD TEMPERATURE SENSOR — 1 EVB-161
P33DF BATT VOLTAGE ISOLATION SEN × 1 EVB-164
P33E0 BATT VOLTAGE ISOLATION SEN × 1 EVB-165
P33E2 BATT PACK OVER TEMP × 1 EVB-167
P33E4 CELL VOLTAGE DEVIATION DIAG — 1 EVB-168
P33E6 CELL VOLTAGE DEVIATION DIAG × 2 EVB-170
P33ED BATTERY PARALLEL DIAGNOSIS × 1 EVB-175
U1000 CAN COMM CIRCUIT × 1 EVB-177
EVB-60
VCM
< WIRING DIAGRAM > [WITHOUT BATTERY COOLER]
WIRING DIAGRAM A
VCM
B
EVB
JRCWC0704GB
EVB-61
VCM
JRCWC0705GB
EVB-62
VCM
EVB
JRCWC0706GB
EVB-63
VCM
JRCWC0707GB
EVB-64
VCM
EVB
JRCWC0708GB
EVB-65
VCM
JRCWC0709GB
EVB-66
VCM
EVB
JRCWC0710GB
EVB-67
VCM
JRCWC0711GB
EVB-68
VCM
EVB
JRCWC0712GB
EVB-69
VCM
JRCWC0713GB
EVB-70
VCM
EVB
JRCWC0714GB
EVB-71
VCM
JRCWC0715GB
EVB-72
< BASIC INSPECTION > [WITHOUT BATTERY COOLER]
BASIC INSPECTION A
B
DETAILED FLOW
1.GET INFORMATION FOR SYMPTOM EVB
the incident/malfunction occurred) using the “Question sheet”. (Refer to EVB-74, "Diagnostic Work Sheet".)
D
>> GO TO 2.
2.CHECK DTC E
1. Check DTC.
2. Perform the following procedure if DTC is displayed.
- Record DTC and freeze frame data. (Print them out with CONSULT.) F
- 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-390, "Symptom Index".)
3. Check related service bulletins for information. G
Symptom is described, DTC is detected>>GO TO 3.
H
3.CONFIRM THE SYMPTOM I
and EVB-50, "Fail-safe".
J
K
>> GO TO 5.
Try to confirm the symptom described by the customer. L
Diagnosis Work Sheet is useful to verify the incident. M
>> GO TO 6. N
again. O
NOTE:
• Perform Component Function Check if DTC CONFIRMATION PROCEDURE is not included on Service P
Manual. This simplified check procedure is an effective alternative though DTC cannot be detected during
this check.
MATION PROCEDURE.
Is DTC detected?
YES >> GO TO 7.
EVB-73

Detect malfunctioning system according to EVC-390, "Symptom Index" based on the confirmed symptom in
YES >> GO TO 7.
NO >> Monitor input data from related sensors using CONSULT.
YES >> GO TO 8.
ment.
>> GO TO 9.
9.FINAL CHECK
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
Incident Date VIN
Customer name
MR/MS
EVB-74
Question Sheet
A
lamp is on
B
Detailed symptom EVB
Onomatopoeia
D

Charging condition Full Medium Low E
Weather
Not affected
conditions
Weather Fine Clouding Raining Snowing Other ( ) F
Temp. [Approx. °C
( °F)]
Humidity High Middle Low Humidity (Approx. %) G
road
Flat road While turning (Right / Left) Bump H
Other
Shift position Not affected
I
P position R position N position D position ECO mode
Power switch ON → OFF Power switch OFF → ON READY (stop the vehicle) J
While cruis- While decel- Just before Just after stop-
While recharging Other K
Vehicle speed [ km/h ( MPH)] Accelerator pedal ( / 8)
L
Disappears while driving Disappears when stopped
Does not disappear M
Other
Other N
EVB-75
SAVE BATTERY INFORMATION DATA
This function enables the saving of data stored in Li-ion battery controller (LBC) into CONSULT.
This work is necessary when performing the following work.
• When LBC is replaced.
1.PERFORM SAVE BATTERY INFORMATION DATA

With CONSULT
1. Power switch ON.
2. Select “WORK SUPPORT” mode of “HV BAT”.
3. Select “SAVE BATTERY INFORMATION DATA”.
4. Touch “START”.
5. Save the LBC internal information.
>> WORK END
EVB-76
WRITE BATTERY INFORMATION DATA
A
This function enables the writing of Li-ion battery (LBC) data saved in CONSULT into a new LBC. B
EVB
1.PERFORM WRITE BATTERY INFORMATION DATA D

With CONSULT
1. Power switch ON.
E
3. Select “WRITE BATTERY INFORMATION DATA”.
5. Write LBC data saved in CONSULT into a new LBC.
F
>> WORK END
EVB-77
CLEAR BATTERY GRADUAL CAPACITY LOSS DATA
This function enables the erasing of the data stored in Li-ion battery controller (LBC).
This work is necessary to be performed after the following work.
• When all modules (48) are replaced.
NOTE:
When all modules are replaced with LBC, this work is not necessary.
1.PERFORM CLEAR BATTERY INFORMATION

With CONSULT
1. Power switch ON.
3. Select “CLEAR BATTERY GRADUAL CAPACITY LOSS DATA”.
5. Clear the LBC internal information.
>> WORK END
EVB-78
CLEAR BATT CHARGE/DISCHARGE INFORMATION DATA
A
This function enables the erasing of the data stored in Li-ion battery controller (LBC). B
NOTE: EVB
D
With CONSULT
E
1. Power switch ON.
3. Select “CLEAR BATTERY CHARGE/DISCHARGE INFORMATION DATA”.
4. Touch “START”. F
>> WORK END G
EVB-79
ADDITIONAL SERVICE WHEN REPLACING LI-ION BATTERY CONTROLLER
ADDITIONAL SERVICE WHEN REPLACING LI-ION BATTERY CONTROL-
LER
When only Li-ion Battery Controller (LBC) is replaced, it is necessary to save the battery information stored in
LBC to the new LBC.
1.SAVE THE LI-ION BATTERY CONTROLLER (LBC) INTERNAL INFORMATION

With CONSULT
1. Select “SAVE BATTERY INFORMATION DATA” in “WORK SUPPOTRT” mode.
>> GO TO 2.
Replace Li-ion battery controller (LBC). Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
>> 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
EVB-80
ADDITIONAL SERVICE WHEN REPLACING MODULE
A
• When all modules (48 modules) of Li-ion battery are replaced, battery information stored in Li-ion battery B
controller must be cleared after replacement.
• When both Li-ion battery controller and all modules (48 modules) are replaced, it is not necessary to clear
battery information stored in Li-ion battery controller.
EVB
1.REMOVAL OF MODULE D
Remove module. Refer to EVB-246, "FRONT MODULE STACK : Removal and Installation" (FRONT MOD-
ULE STACK) or EVB-263, "REAR MODULE STACK : Removal and Installation" (REAR MODULE STACK).
E
>> GO TO 2.
2.ADJUSTMENT OF MODULE VOLTAGE
F
Adjust the voltage of module requiring replacement. Refer to EVB-82, "Work Procedure".
>> GO TO 3. G
3.INSTALLATION OF MODULE
Install new module. Refer to EVB-246, "FRONT MODULE STACK : Removal and Installation" (FRONT MOD-
ULE STACK) or EVB-263, "REAR MODULE STACK : Removal and Installation" (REAR MODULE STACK). H
When one module is replaced>>WORK END

When all modules are replaced>>GO TO 4. I
4.CLEAR LBC INTERNAL INFORMATION

With CONSULT J
3. Touch “START”. K
4. Touch “END” when completed.
5. Select “CLEAR BATT CHARGE/DISCHARGE INFORMATION DATA”.
7. Touch “END” when completed. L
>> WORK END

M
EVB-81
MODULE CHARGE BALANCE
If a malfunction (e.g. abnormal voltage) occurs in a Li-ion battery cell, the module which includes the malfunc-
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.
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)].
1.CHECK ADJUSTMENT VOLTAGE VALUE
With CONSULT
1. Power switch ON.
2. Select “DATA MONITOR”of “HV BAT”.
3. Check “MAXIMUM CELL VOLTAGE”.
4. Double the “MAXIMUM CELL VOLTAGE” and use that value as the module adjustment value.
Adjustment voltage value : MAXIMUM CELL VOLTAGE× 2

Example: 3.925 V (MAXIMUM CELL VOLTAGE) × 2 = 7.850 V (Adjustment voltage value)
>> GO TO 2.
2.CHECK MODULE VOLTAGE
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual.
1. Set the new module to the module charge balancer.
2. Measure module voltage and compare it with “adjustment voltage value” confirmed in Step1.
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
CAUTION:
Discharge the module to 5.0 V using module charge balancer.
Discharge voltage : 5.0 V
>> GO TO 4.
4.ADJUST VOLTAGE WITH A MODULE CHARGE BALANCER
CAUTION:
1. Enter “adjustment voltage value” into module charge balancer.

2. Start the voltage adjustment.
>> 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.
EVB-82
Standard : Adjustment voltage value ± 10 mV A
>> GO TO 6.
B
6.CHECK CELL VOLTAGE
With CONSULT
1. After adjusting the voltage, install the module to the vehicle. EVB
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. D
Standard : MAXIMUM CELL VOLTAGE ± 33 mV

E
>> WORK END

F
EVB-83
P0A0D HV SYSTEM INTERLOCK ERROR
< DTC/CIRCUIT DIAGNOSIS > [WITHOUT BATTERY COOLER]
DTC DETECTION LOGIC
Trouble diagnosis name

DTC DTC detecting condition
HV SYSTEM INTERLOCK ERROR Self diagnosis program of Li-ion battery controller detects a malfunction in the
P0A0D
(High voltage system interlock error) CPU.
POSSIBLE CAUSES
FAIL-SAFE
EV system warning lamp illuminate
With CONSULT
2. Select “Self Diagnostic Result” of “HV BAT”.
3. Check DTC.
Is P0A0D detected?
YES >> Refer to EVB-84, "Diagnosis Procedure".
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Disconnect the high voltage. Refer to EVB-15, "How to Disconnect High Voltage".
Installation".
EVB-84
>> GO TO 2. A
2.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-1
1. Disconnect Li-ion battery controller (LBC) harness connector. B
2. Disconnect interlock detecting switch (high voltage harness connector) harness connector.
3. Check the continuity between Li-ion battery controller harness connector and ground.
EVB
LBC
— Continuity
Connector Terminal
LB10 8 Ground Not existed D
YES >> GO TO 3.
NO >> Replace Li-ion battery vehicle communication harness. E
1. Disconnect interlock detecting switch (service plug) harness connector. F
LBC G
— Continuity
Connector Terminal
LB10 6 Ground Not existed
H
YES >> GO TO 4.
NO >> Replace Li-ion battery vehicle communication harness.
I
4.CHECK INTERLOCK DETECTIONG SWITCH (SERVICE PLUG)
Refer to EVB-85, "Component Inspection".
YES >> Replace Li-ion battery controller. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
NO >> Replace service plug. K
1.CHECK INTERLOCK DETECTIONG SWITCH (SERVICE PLUG) L
Check the continuity between terminals in the figure.

M
Value: Approx. 0 Ω
YES >> INSPECTION END N
JPCIA0347ZZ
EVB-85
P0A1F BATTERY ENERGY CONTROL MODULE
DTC DETECTION LOGIC

BATTERY ENERGY CONTROL MOD-
Self diagnosis program of Li-ion battery controller detects a malfunction in the
P0A1F ULE
CPU.
(Battery energy control module)
POSSIBLE CAUSES
FAIL-SAFE
• No driving
• Charge stop
• EV system warning lamp illuminate
• Driving output power limit
With CONSULT
3. Check DTC.
Is P0A1F detected?
NO-1 >> To check malfunction symptom before repair: Refer toGI-47, "Intermittent Incident".
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-232, "LI-ION BATTERY CONTROL-
LER : Removal and Installation".
EVB-86
P3030 CELL CONTROLLER LIN
A

(Trouble diagnosis content) EVB
CELL CONT LIN
A malfunction occurs with the communication function in Li-ion battery control-
P3030 (Cell controller local interconnect net-
ler.
work)
D
POSSIBLE CAUSES
• Module E
FAIL-SAFE
• Driving output power limit F
• Charge stop

With CONSULT H
3. Check DTC. I
Is P3030 detected?
NO-1 >> To check malfunction symptom before repair: Refer toGI-47, "Intermittent Incident". J
K
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. L
2. Check to see if “P3375 - P33A4” is detected simultaneously with “P3030”.
Is P3030 detected?
YES >> • When “P3375” - “P3380” are detected simultaneously, perform the diagnosis procedure of M
“P3375” - “P3380”. Refer to EVB-138, "Diagnosis Procedure".
• When “P3381” - “P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381” - “P338C”. Refer to EVB-142, "Diagnosis Procedure". N
• When “P338D” - “P3398” are detected simultaneously, perform the diagnosis procedure of
“P338D” - “P3398”. Refer to EVB-146, "Diagnosis Procedure".
• When “P3399” - “P33A4” are detected simultaneously, perform the diagnosis procedure of
O
“P3399” - “P33A4”. Refer to EVB-151, "Diagnosis Procedure".
NO >> Replace Li-ion battery controller. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal
and Installation".
P
EVB-87
P3031-P303C CELL CONTROLLER ASIC
DTC DETECTION LOGIC

CELL CONT ASIC1
P3031 (Cell controller application specific inte-
grated circuit1)
CELL CONT ASIC2
grated circuit2)
CELL CONT ASIC3
grated circuit3)
CELL CONT ASIC4
grated circuit4)
CELL CONT ASIC5
grated circuit5)
CELL CONT ASIC6
grated circuit6) A malfunction occurs with the communication function in Li-ion battery con-
CELL CONT ASIC7 troller.
grated circuit7)
CELL CONT ASIC8
grated circuit8)
CELL CONT ASIC9
grated circuit9)
CELL CONT ASIC10
P303A (Cell controller application specific inte-
grated circuit10)
CELL CONT ASIC11
P303B (Cell controller application specific inte-
grated circuit11)
CELL CONT ASIC12
P303C (Cell controller application specific inte-
grated circuit12)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
With CONSULT
EVB-88
3. Check DTC.
Is any DTC detected? A
NO-2 >> Confirmation after repair: INSPECTION END B
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER EVB
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. D
2. Check to see if “P3030” is detected simultaneously with “P3031 -P303C”.
Is P3030 detected?
YES >> Perform diagnosis on the detected P3030. Refer to EVB-87, "Diagnosis Procedure". E
and Installation".
EVB-89
P303D-P3048 CELL CONTROLLER ASIC
DTC DETECTION LOGIC

CELL CONT ASIC13
P303D (Cell controller application specific inte-
grated circuit13)
CELL CONT ASIC14
P303E (Cell controller application specific inte-
grated circuit14)
CELL CONT ASIC15
P303F (Cell controller application specific inte-
grated circuit15)
CELL CONT ASIC16
grated circuit16)
CELL CONT ASIC17
grated circuit17)
CELL CONT ASIC18
grated circuit19)
CELL CONT ASIC20
grated circuit20)
CELL CONT ASIC21
grated circuit21)
CELL CONT ASIC22
grated circuit22)
CELL CONT ASIC23
grated circuit23)
CELL CONT ASIC24
grated circuit24)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
With CONSULT
EVB-90
3. Check DTC.
With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P303D” -“P3048”.
Is P3030 detected?
and Installation".
EVB-91
P3049-P3054 CELL CONTROLLER ASIC VOLTAGE
DTC DETECTION LOGIC

CELL CONT ASIC1 VOLT
P3049 (Cell controller application specific integrated
circuit1 voltage)
P304A (Cell controller application specific integrated
circuit2 voltage)
P304B (Cell controller application specific integrated
circuit3 voltage)
P304C (Cell controller application specific integrated
circuit4 voltage)
P304D (Cell controller application specific integrated
circuit5 voltage)
P304E (Cell controller application specific integrated
circuit6 voltage)
The A/D converter in Li-ion battery controller is malfunctioning.
P304F (Cell controller application specific integrated
circuit7 voltage)
circuit8 voltage)
circuit9 voltage)
circuit10 voltage)
circuit11 voltage)
circuit12 voltage)
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge stop
With CONSULT
EVB-92
2. Select “Self Diagnostic Result” of “HV BAT”. A
3. Check DTC.
YES >> Refer to EVB-93, "Diagnosis Procedure". B
EVB

D
With CONSULT
2. Check DTC.
E
YES-1 >> “P3302” - “P3331” are detected simultaneously.
• When “P3302” - “P330D” are detected simultaneously, perform the diagnosis procedure of
“P3302” - “P330D”. Refer to EVB-120, "Diagnosis Procedure". F
• When “P330E” - “P3319” are detected simultaneously, perform the diagnosis procedure of
“P330E” - “P3319”. Refer to EVB-124, "Diagnosis Procedure".
• When “P331A” - “P3325” are detected simultaneously, perform the diagnosis procedure of G
“P331A” - “P3325”. Refer to EVB-128, "Diagnosis Procedure".
• When “P3326” - “P3331” are detected simultaneously, perform the diagnosis procedure of
YES-2 >> “P3375” - “P33A4” are detected simultaneously. H
• When “P3381” - “P338C” are detected simultaneously, perform the diagnosis procedure of I
“P3381” - “P338C”. Refer to EVB-142, "Diagnosis Procedure".
J
NO >> When only “P3049” - “P3054” are detected, replace Li-ion battery controller. Refer to EVB-232,
"LI-ION BATTERY CONTROLLER : Removal and Installation". K
EVB-93
DTC DETECTION LOGIC

circuit13 voltage)
circuit14 voltage)
circuit15 voltage)
circuit16 voltage)
circuit17 voltage)
circuit18 voltage)
circuit19 voltage)
circuit20 voltage)
circuit21 voltage)
circuit22 voltage)
circuit23 voltage)
circuit24 voltage)
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge stop
With CONSULT
EVB-94
3. Check DTC.
EVB

D
With CONSULT
2. Check DTC.
E
J
EVB-95
P3061 CELL BATTERY VOLTAGE
DTC DETECTION LOGIC

CELL BATTERY VOLT An open circuit diagnosis detection circuit in Li-ion battery controller is malfunc-
P3061
(Cell battery voltage) tioning.
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P3061 detected?
EVB-96
P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
A

BYPASS SW
P3062 A malfunction of the bypass switch in Li-ion battery controller is detected.
(Bypass switch)
POSSIBLE CAUSES D
• Module
• Harness or connector E
FAIL-SAFE
F
DTC DETECTION LOGIC
G
With CONSULT
3. Check DTC. H
Is P3062 detected?
NO-1 >> To check malfunction symptom before repair: Refer toGI-47, "Intermittent Incident". I
J
With CONSULT K
2. Check to see if “P3375”-“P33A4” is detected simultaneously with “P3062”.
Is P3375-P33A4 detected? L
YES >> • When “P3375” - “P3380” are detected simultaneously, perform the diagnosis procedure of
M
• When “P3399” - “P33A4” are detected simultaneously, perform the diagnosis procedure of N
and Installation". O
EVB-97
P3064 CELL CONT ASIC
DTC DETECTION LOGIC

CELL CONTROLLER ASIC
P3064 (Cell controller application specific in-
ler.
tegrated circuit)
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P3064 detected?
EVB-98
P308B-P3096 CELL CONTROLLER ASIC OPEN
A

CELL CONT ASIC1 OPEN
circuit1 open)
D
circuit2 open)
E
circuit3 open)
CELL CONT ASIC4 OPEN F
circuit4 open)
CELL CONT ASIC5 OPEN G
circuit5 open)
CELL CONT ASIC6 OPEN H
circuit6 open) Self diagnosis program of Li-ion battery controller detects an open cir-
CELL CONT ASIC7 OPEN cuit in the cell voltage detection line.
P3091 (Cell controller application specific integrated I
circuit7 open)
P3092 (Cell controller application specific integrated J
circuit8 open)
P3093 (Cell controller application specific integrated K
circuit9 open)
circuit10 open) L
circuit11 open) M
circuit12 open) N
POSSIBLE CAUSES
• Harness or connector O
FAIL-SAFE
P
• Charge stop
DTC DETECTION LOGIC
With CONSULT
EVB-99
>> GO TO 3.
3.CHECK CONNECTION STATUS A

2. Check connection status of Li-ion battery controller harness connector and module harness connector.
B
YES >> GO TO 4.
NO >> Recover the connection status.
EVB
4.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER
1. Disconnect module harness connector and Li-ion battery controller harness connector.
2. Refer to below table and continuity between module and Li-ion battery controller, according to detected D
DTC.
Module Module Li-ion battery controller E

DTC Continuity
No. Connector Terminal Connector Terminal
1 25 50
P308B LB8 LB12 Existed F
2 10 51
3 26 52
P308C LB8 LB12 Existed
4 11 53 G
5 27 54
P308D LB8 LB12 Existed
6 12 55
H
7 28 56
P308E LB8 LB12 Existed
8 13 57
9 29 58 I
P308F LB8 LB12 Existed
10 14 59
11 30 60
P3090 LB8 LB12 Existed J
12 15 61
13 33 62
P3091 LB7 LB12 Existed
14 49 63
K
15 34 77
16 50 78
17 35 80 L
18 51 81
19 36 82
P3094 LB7 LB13 Existed M
20 52 83
21 37 84
22 53 85 N
23 38 86
24 54 87
O
and Installation".
NO >> Repair harness or connector. P
EVB-101
P3097-P30A2 CELL CONTROLLER ASIC OPEN
DTC DETECTION LOGIC

circuit13 open)
circuit14 open)
circuit15 open)
circuit16 open)
circuit17 open)
circuit19 open)
circuit20 open)
circuit21 open)
P30A0 (Cell controller application specific integrated
circuit22 open)
circuit23 open)
circuit24 open)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
DTC DETECTION LOGIC
With CONSULT
EVB-102
3. Check DTC. A
Is P3097-P30A2 detected?
NO-1 >> To check malfunction symptom before repair: Refer toGI-47, "Intermittent Incident". B
EVB
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of D
maintenance.
E
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in F
before beginning work on the high voltage system. G
• Refer to EVB-17, "High Voltage Precautions". H
CAUTION:
instructed in the Service Manual. A malfunction may occur if this is not observed. I
With CONSULT J
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? K
YES-1 >> “P3049”-“P3060” are detected simultaneously.
• When “P3049”-“P3054” are detected simultaneously, perform the diagnosis procedure of
“P3049”-“P3054”. Refer to EVB-93, "Diagnosis Procedure" L
“P3055”-“P3060”. Refer to EVB-95, "Diagnosis Procedure"
YES-2 >> “P3375”-“P33A4” are detected simultaneously. M
“P3375”-“P3380”. Refer to EVB-138, "Diagnosis Procedure".
• When “P3381”-“P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381”-“P338C”. Refer to EVB-142, "Diagnosis Procedure". N
• When “P338D”-“P3398” are detected simultaneously, perform the diagnosis procedure of
“P338D”-“P3398”. Refer to EVB-146, "Diagnosis Procedure".
• When “P3399”-“P33A4” are detected simultaneously, perform the diagnosis procedure of O
“P3399”-“P33A4”. Refer to EVB-151, "Diagnosis Procedure"
NO >> GO TO 2.
2.PRECONDITIONING P
WARNING:
Installation".
EVB-103
>> GO TO 3.
3.CHECK CONNECTION STATUS
YES >> GO TO 4.
4.CHECK HARNESS BETWEEN MODULE OR BUS BAR AND LI-ION BATTERY CONTROLLER
1. Disconnect module harness connector (Front module stack) or bus bar (Rear module stack) and Li-ion
battery controller harness connector.
2. Refer to below table and continuity between module and Li-ion battery controller (Front module stack) or
voltage detection terminal of bus bar and Li-ion battery controller (Rear module stack), according to
detected DTC.
JSCIA1223ZZ
Module Module Li-ion battery controller

DTC Continuity
25 40 110
26 56 111
EVB-104

DTC Continuity A
27 112
P3098 LB14 Existed
28 113 B
29 114
P3099 LB14 Existed
30 115
31 116 EVB
P309A LB14 Existed
32 117
33 118
P309B LB14 Existed D
34 119
35 120
P309C LB14 Existed
36 Voltage detection terminal of bus 121 E
37 bar 122
P309D LB14 Existed
38 123
F
39 124
P309E LB14 Existed
40 125
41 127 G
P309F LB14 Existed
42 128
43 137
P30A0 LB15 Existed H
44 138
45 140
P30A1 LB15 Existed
46 141 I
47 16 142
P30A2 LB8 LB15 Existed
48 32 143
J
and Installation".
NO >> Repair harness or connector. K
EVB-105
P30E0 DLC DIAGNOSIS VCM
DTC DETECTION LOGIC

DLC DIAGNOSIS VCM
When no CAN communication signal is received from VCM continuously for 2
P30E0 (Data length code diagnosis vehicle
seconds or more.
control module)
POSSIBLE CAUSES
• CAN communication line
• VCM
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P30E0 detected?
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?
NO >> GO TO 2.
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P30E0”.
Is U1000 detected?
and Installation".
EVB-106
P30E2 DLC DIAGNOSIS HVAC
A

DLC DIAGNOSIS HVAC When no CAN communication signal is received from A/C auto amp. (With au-
P30E2 (Data length code diagnosis heating tomatic air conditioning) or heater auto amp. (With automatic heater) continu-
ventilation, and conditioning) ously for 2 seconds or more.
D
POSSIBLE CAUSES
• Li-ion battery controller E
• A/C auto amp. (With automatic air conditioning)
• Heater auto amp. (With automatic heater)
FAIL-SAFE F
None
G
With CONSULT
1. Power switch ON and wait for 10 seconds or more. H
3. Check DTC.
Is P30E2 detected? I
NO-2 >> Confirmation after repair: INSPECTION END J
1.PERFORM THE SELF-DIAGNOSIS K
With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P30E2” is detected. L
Is P30E2 detected?
YES >> Replace A/C auto amp. or heater auto amp. Refer to HAC-202, "Removal and Installation" (A/C
auto amp.) or HAC-329, "Removal and Installation" (Heater auto amp.). M
NO >> GO TO 2.
2.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER N
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P30E2”. O
Is U1000 detected?
and Installation". P
EVB-107
P30E3 DLC DIAGNOSIS MC
DTC DETECTION LOGIC

DLC DIAGNOSIS MC
When no CAN communication signal is received from traction motor inverter
P30E3 (Data length code diagnosis motor
continuously for 2 seconds or more.
controller)
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P30E3 detected?

With CONSULT
Is P30E3 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-108
P30E4 DLC DIAGNOSIS PDM(POWER DELIVERY MODULE)
A

DLC DIAGNOSIS PD MODULE
When no CAN communication signal is received from PDM (Power Delivery
P30E4 (Data length code power delivery
Module) continuously for 2 seconds or more.
module)
D
POSSIBLE CAUSES
FAIL-SAFE
None F
1.PERFORM DTC CONFIRMATION PROCEDURE G
With CONSULT
2. Select “Self Diagnostic Result” of “HV BAT”. H
3. Check DTC.
Is P30E4 detected?
YES >> Refer to EVB-109, "Diagnosis Procedure". I
J

K
With CONSULT
L
Is P30E4 detected?
NO >> GO TO 2.
M
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. N
Is U1000 detected?
YES >> Replace Li-ion battery controller. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal O
and Installation".
P
EVB-109
P318D COMMUNICATION ERROR
DTC DETECTION LOGIC

COMMUNICATION ERROR
P318D When no CAN communication signal is received continuously.
(Communication error)
POSSIBLE CAUSES
• VCM
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P318D detected?
EVB-110
P318E COMMUNICATION ERROR
A

NOTE:
When the 12V 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

D
COMMUNICATION ERROR
P318E When no CAN communication signal is received from VCM continuously.
POSSIBLE CAUSES E
• VCM
F
FAIL-SAFE
With CONSULT H
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 12V battery negative termi-
I
nal. Refer to EVB-13, "Precautions for Removing Battery Terminal".
6. Select “Self Diagnostic Result” of “HV BAT”. J
7. Check DTC.
Is P318E detected?
YES >> Refer to EVB-111, "Diagnosis Procedure". K
L

M
With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P318E” is detected.
N
Is P318E detected?
NO >> GO TO 2.
O
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. P
2. Check to see if “U1000” is detected simultaneously with “P318E”.
Is U1000 detected?
and Installation".
EVB-111
P3191 COMMUNICATION ERROR
DTC DETECTION LOGIC

NOTE:
When the 12V 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.

COMMUNICATION ERROR When no CAN communication signal is received from traction motor inverter
P3191
(Communication error) continuously.
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
7. Check DTC.
Is P3191 detected?

With CONSULT
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-106, "Removal and Installation"
NO >> GO TO 2.
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P3191”.
Is U1000 detected?
and Installation".
EVB-112
A

NOTE:

D
COMMUNICATION ERROR When no CAN communication signal is received from on-board charger continu-
P3196
(Communication error) ously.
POSSIBLE CAUSES E
F
FAIL-SAFE
None
With CONSULT H
I
7. Check DTC.
Is P3196 detected?
L

M
With CONSULT
N
Is P3196 detected?
YES >> Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation"
NO >> GO TO 2.
O
With CONSULT
Is U1000 detected?
and Installation".
EVB-113
DTC DETECTION LOGIC

When no CAN communication signal is received from A/C auto amp. (With au-
COMMUNICATION ERROR
P3198 tomatic air conditioning) or heater auto amp. (With automatic heater) continu-
ously for 2 seconds or more.
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P3198 detected?

With CONSULT
Is P3198 detected?
auto amp.) or HAC-329, "Removal and Installation" (Heater auto amp.).
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-114
A

COMMUNICATION ERROR
P3199 When a CRC error from VCM is detected.
POSSIBLE CAUSES D
• VCM
E
FAIL-SAFE
With CONSULT G
3. Check DTC.
H
Is P3199 detected?
NO-2 >> Confirmation after repair: INSPECTION END I
J
When this DTC is detected, replace VCM. Refer to EVC-404, "Removal and Installation".
EVB-115
P319C COMMUNICATION ERROR
DTC DETECTION LOGIC

COMMUNICATION ERROR
P319C When a CRC error from traction motor inverter is detected.
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P319C detected?
When this DTC is detected, replace traction motor inverter. Refer to TMS-106, "Removal and Installation".
EVB-116
P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
A

CAN ERROR VCM If the CAN data from VCM has not change from the value which was previously
P31A4
(CAN error vehicle control module) received.
POSSIBLE CAUSES D
VCM
FAIL-SAFE E
1.PERFORM DTC CONFIRMATION PROCEDURE F
With CONSULT
1. Power switch ON and wait for 10 seconds or more. G
3. Check DTC.
Is P31A4 detected?
H
I
J
EVB-117
P31A7 CAN ERROR INV/MC
DTC DETECTION LOGIC

CAN ERROR INV/MC If the CAN data from traction motor inverter has not change from the value
P31A7
(CAN error inverter/motor controller) which was previously received.
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P31A7 detected?
EVB-118
P3302-P330D CELL OVER VOLTAGE
A

CELL OVER VOLTAGE MODULE1
P3302
(Cell over voltage module1)
CELL OVER VOLTAGE MODULE2 D
P3303
P3304
E
P3305
CELL OVER VOLTAGE MODULE5 F
P3306
P3307
(Cell over voltage module6) When cell voltage exceeds the allowable working voltage
G
CELL OVER VOLTAGE MODULE7 range.
P3308
P3309 H
P330A
I
P330B
P330C
J
P330D
K
POSSIBLE CAUSES
• Overcharge caused by traction motor inverter/VCM malfunction
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
1.PERFORM DTC CONFIRMATION PROCEDURE O
With CONSULT
3. Check DTC.
EVB-119
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
1. Perform “All DTC Reading” 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.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
2. Refer to below table and check the continuity between corresponding module and Li-ion battery controller.

DTC Continuity
1 33
P3302 1 LB8 25 LB12 50 Existed
17 34
17 34
2 35
2 35
18 36
EVB-120

DTC Continuity A
18 36
P3305 4 LB8 11 LB12 53 Existed B
3 37
3 37
P3306 5 LB8 27 LB12 54 Existed EVB
19 38
19 38
D
4 39
4 39 E
20 40
F
20 40
5 42 G
5 42
P330A 9 LB8 29 LB12 58 Existed
H
21 43
21 43
P330B 10 LB8 14 LB12 59 Existed I
6 44
6 44
P330C 11 LB8 30 LB12 60 Existed
J
22 45
22 45
K
P330D 12 LB8 15 LB12 61 Existed
7 46
YES >> GO TO 4.
M
Check voltage of corresponding module. Refer to EVB-121, "Component Inspection".
and Installation".
NO >> Replace corresponding module. Refer to EVB-251, "FRONT MODULE STACK : Disassembly and O
Assembly".
P
EVB-121
Check voltage of module.
JSCIA0338ZZ
: Positive terminal (Red)

: Negative terminal (Black)
Terminals
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
NO >> Replace module. Refer to EVB-251, "FRONT MODULE STACK : Disassembly and Assembly".
EVB-122
P330E-P3319 CELL OVER VOLTAGE
A

P330E
P330F
P3310
E
P3311
P3312
P3313
G
P3314
P3315 H
P3316
I
P3317
P3318
J
P3319
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-123
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
1. Perform “All DTC Reading”.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
LB8 7 46
P330E 13 33 LB12 62 Existed
LB7
57 47
57 47
P330F 14 LB7 49 LB12 63 Existed
42 48
42 LB12 48
P3310 15 LB7 34 77 Existed
LB13
58 65
EVB-124

DTC Continuity A
58 65
P3311 16 LB7 50 LB13 78 Existed B
43 66
43 66
59 69
59 69
D
P3313 18 LB7 51 LB13 81 Existed
44 70
44 70 E
P3314 19 LB7 36 LB13 82 Existed
60 71
F
60 71
P3315 20 LB7 52 LB13 83 Existed
45 72 G
45 72
P3316 21 LB7 37 LB13 84 Existed
H
61 73
61 73
P3317 22 LB7 53 LB13 85 Existed I
46 74
46 74
P3318 23 LB7 38 LB13 86 Existed
J
62 75
62 75
K
P3319 24 LB7 54 LB13 87 Existed
47 76
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-125
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-126
P331A-P3325 CELL OVER VOLTAGE
A

P331A
P331B
P331C
E
P331D
P331E
P331F
G
P3320
P3321 H
P3322
I
P3323
P3324
J
P3325
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-127
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT
2. Identify the malfunctioning module based on detected DTC.
EVB-128
4. Refer to below table and check the continuity between corresponding module and Li-ion battery controller
(Front module stack) or corresponding bus bar and Li-ion battery controller (Rear module stack). A
EVB
JSCIA1228GB

DTC Continuity
No. Connector Terminal Connector Terminal K
55 89
48 90 L
48 90
P331B 26 LB7 56 LB14 111 Existed
M
64 91
EVB-129

DTC Continuity
LB7 64 91
P331C 27 LB14 112 Existed
92
92
P331D 28 LB14 113 Existed
93
93
P331E 29 LB14 114 Existed
94
94
P331F 30 LB14 115 Existed
95
95
P3320 31 LB14 116 Existed
96
Bus bar 96
97
97
99
99
100
100
101
101
102
YES >> GO TO 4.
and Installation".
NO >> Replace corresponding module. Refer to EVB-251, "FRONT MODULE STACK : Disassembly and
Assembly" (FRONT MODULE STACK) or EVB-267, "REAR MODULE STACK : Disassembly and
Assembly" (REAR MODULE STACK).
EVB-130
A
EVB
G
JSCIA0338ZZ
H
I
Terminals
Voltage
(+) (-)
(Approx.) J
Module
NO >> Replace module. Refer to EVB-251, "FRONT MODULE STACK : Disassembly and Assembly"
(FRONT MODULE STACK) or EVB-267, "REAR MODULE STACK : Disassembly and Assembly" L
(REAR MODULE STACK).
EVB-131
P3326-P3331 CELL OVER VOLTAGE
DTC DETECTION LOGIC

P3326
P3327
P3328
P3329
P332A
P332B
P332C
P332D
P332E
P332F
P3330
P3331
POSSIBLE CAUSES
• Module
• Bus bar
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
EVB-132
A
DANGER:
maintenance.
EVB
WARNING:
before beginning work on the high voltage system. E
• Refer to EVB-17, "High Voltage Precautions". F
CAUTION:
1. CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
H
I
NO >> GO TO 2.
2.PRECONDITIONING J
WARNING:
1. Remove Li-ion battery. Refer to EVB-213, "Removal and Installation". K
Installation".
L
>> GO TO 3.
M
With CONSULT
3. Disconnect module harness connector (Front module stack) or bus bar (Rear module stack) and Li-ion N
EVB-133
(Front module stack) or corresponding bus bar and Li-ion battery controller (Rear module stack).
JSCIA1228GB
EVB-134
Module Module Li-ion battery controller A

DTC Continuity
102
B
103
103 EVB
104
D
104
105 E
105
106
F
106
P332A 41 LB14 127 Existed
G
107
Bus bar 107
P332B 42 LB14 128 Existed H
108
LB14 108
I
P332C 43 137 Existed
LB15
130
130 J
131
K
131
132 L
132
M
133
133
P3330 47 16 LB15 142 Existed N
LB8
8 134
8 134
P3331 48 LB8 32 LB15 143 Existed O
24 135
YES >> GO TO 4.
EVB-135
and Installation".

JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
(FRONT MODULE STACK) or EVB-267, "REAR MODULE STACK : Disassembly and Assembly"
EVB-136
P3375-P3380 CELL OVER DISCHARGE
A

CELL OVER DISCHARGE MODULE1
P3375
(Cell over discharge module1)
CELL OVER DISCHARGE MODULE2 D
P3376
P3377
E
P3378
CELL OVER DISCHARGE MODULE5 F
P3379
P337A
(Cell over discharge module6) When cell voltage lowers below the allowable working
G
CELL OVER DISCHARGE MODULE7 voltage range.
P337B
P337C H
P337D
I
P337E
P337F
J
P3380
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
• EV system warning lamp illuminate N

With CONSULT
3. Check DTC.
EVB-137
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
1 33
17 34
17 34
2 35
2 35
18 36
EVB-138

DTC Continuity A
18 36
3 37
3 37
19 38
19 38
D
4 39
4 39 E
20 40
F
20 40
5 42 G
5 42
H
21 43
21 43
P337E 10 LB8 14 LB12 59 Existed I
6 44
6 44
J
22 45
22 45
K
P3380 12 LB8 15 LB12 61 Existed
7 46
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-139
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-140
P3381-P338C CELL OVER DISCHARGE
A

P3381
P3382
P3383
E
P3384
P3385
P3386
(Cell over discharge module18) When cell voltage lowers below the allowable working voltage
G
CELL OVER DISCHARGE MODULE19 range.
P3387
P3388 H
P3389
I
P338A
P338B
J
P338C
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-141
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
LB8 7 46
P3381 13 33 LB12 62 Existed
LB7
57 47
57 47
P3382 14 LB7 49 LB12 63 Existed
42 48
42 LB12 48
P3383 15 LB7 34 77 Existed
LB13
58 65
EVB-142

DTC Continuity A
58 65
P3384 16 LB7 50 LB13 78 Existed B
43 66
43 66
59 69
59 69
D
P3386 18 LB7 51 LB13 81 Existed
44 70
44 70 E
P3387 19 LB7 36 LB13 82 Existed
60 71
F
60 71
P3388 20 LB7 52 LB13 83 Existed
45 72 G
45 72
P3389 21 LB7 37 LB13 84 Existed
H
61 73
61 73
P338A 22 LB7 53 LB13 85 Existed I
46 74
46 74
J
62 75
62 75
K
47 76
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-143
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-144
P338D-P3398 CELL OVER DISCHARGE
A

P338D
P338E
P338F
E
P3390
P3391
P3392
G
P3393
P3394 H
P3395
I
P3396
P3397
J
P3398
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-145
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT
EVB-146
EVB
JSCIA1228GB

DTC Continuity
55 89
48 90 L
48 90
P338E 26 LB7 56 LB14 111 Existed
M
64 91
EVB-147

DTC Continuity
LB7 64 91
92
92
93
93
94
94
95
95
96
Bus bar 96
97
97
99
99
100
100
101
101
102
YES >> GO TO 4.
and Installation".
EVB-148
A
EVB
G
JSCIA0338ZZ
H
I
Terminals
Voltage
(+) (-)
(Approx.) J
Module
EVB-149
P3399-P33A4 CELL OVER DISCHARGE
DTC DETECTION LOGIC

P3399
P339A
P339B
P339C
P339D
P339E
P339F
P33A0
P33A1
P33A2
P33A3
P33A4
POSSIBLE CAUSES
• Module
• Bus bar
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
EVB-150
A
DANGER:
maintenance.
EVB
WARNING:
CAUTION:
With CONSULT
H
I
NO >> GO TO 2.
2.PRECONDITIONING J
WARNING:
Installation".
L
>> GO TO 3.
M
With CONSULT
EVB-151
JSCIA1228GB
EVB-152

DTC Continuity
102
B
103
103 EVB
104
D
104
P339B 39 LB14 124 Existed
105 E
105
106
F
106
G
107
Bus bar 107
P339E 42 LB14 128 Existed H
108
LB14 108
I
P339F 43 137 Existed
LB15
130
130 J
P33A0 44 LB15 138 Existed
131
K
131
132 L
132
M
133
133
P33A3 47 16 LB15 142 Existed N
LB8
8 134
8 134
P33A4 48 LB8 32 LB15 143 Existed O
24 135
YES >> GO TO 4.
EVB-153
and Installation".

JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-154
P33D4 BATT GRADUAL CAPA LOSS DIAG
A

BATTERY INTERNAL RESISTANCE DIAG When the battery charge lowers.
P33D4
(Battery internal resistance diagnosis) (The internal resistance of the battery increases.)
POSSIBLE CAUSES D
Li-ion battery
FAIL-SAFE
E
With CONSULT
2. Select “Self Diagnostic Result” of “HV BAT”. G
3. Check DTC.
Is P33D4 detected?
H
I
When this DTC is detected, replace Li-ion battery. Refer to EVB-213, "Removal and Installation".
J
EVB-155
P33D5 CURRENT SENSOR
DTC DETECTION LOGIC

CURRENT SENSOR Deviation in characteristics of battery current sensor signal voltage.
P33D5
(Current sensor) (Battery current sensor signal voltage is too high or too low.)
POSSIBLE CAUSES
• Current sensor
• System main relay
FAIL-SAFE
• Charge stop
With CONSULT
3. Check DTC.
Is P33D5 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS OF VCM
With CONSULT
1. Select “Self Diagnostic Result” of “EV/HEV”.
EVB-156
2. Check to see if “P0AA0”, “P0AA1” or “P0AA4” is detected.
YES >> Perform diagnosis on the detected DTC. Refer to EVB-55, "DTC Index".
NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Disconnect the high voltage. Refer to EVB-15, "How to Disconnect High Voltage". EVB
Installation".
D
>> GO TO 3.
3.CHECK CONNECTION STATUS E
Check connection status of Li-ion battery controller harness connector and current sensor harness connector.
YES >> GO TO 4. F
4.CHECK HARNESS BETWEEN CURRENT SENSOR AND LI-ION BATTERY CONTROLLER G
Check continuity between current sensor harness connector and Li-ion battery controller harness connector.
Current sensor Li-ion battery controller H

Continuity
S 10
I
LB5 V LB10 9 Exited
G 15
YES >> GO TO 5.
5.CHECK CURRENT SENSOR K
Check resistance of current sensor.
L
Current sensor Resistance val-
Connector Terminal Terminal ue
S G M
LB5 1 kΩ–10 MΩ
V G
N
YES >> GO TO 6.
NO >> Replace current sensor.
6.CHECK LI-ION BATTERY CONTROLLER O
Check resistance of Li-ion battery controller.
Li-ion battery controller Resistance val- P

LB10 10 15 Approx. 4.7 kΩ

YES >> Replace current sensor. Refer to EVB-234, "BATTERY JUNCTION BOX AND BATTERY HAR-
NESS : Exploded View".
EVB-157
and Installation".
EVB-158
A

CURRENT SENSOR
P33D6 Deviation from the specified voltage characteristics of battery current sensor.
(Current sensor)
POSSIBLE CAUSES D
FAIL-SAFE E
• Charge stop
F
G
With CONSULT
3. Check DTC. H
Is P33D6 detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". I
J
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of K
maintenance. L
WARNING:
ing inspection or maintenance of high voltage system harnesses and parts. M
before beginning work on the high voltage system. N
lating sheet except when using them. O
CAUTION:
instructed in the Service Manual. A malfunction may occur if this is not observed. P
1.PRECONDITIONING
WARNING:
Installation".
EVB-159
>> 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
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
LB10 9 LB5 V Existed
15 G
EVB-160
P33D7, P33D9, P33DB, P33DD TEMPERATURE SENSOR
A

P33D7 Battery temperature sensor rear center signal voltage is too high or too low.
P33D9 TEMPERATURE SENSOR Battery temperature sensor LH center signal voltage is too high or too low.
P33DB (Temperature sensor) Battery temperature sensor rear LH signal voltage is too high or too low. D
P33DD Battery temperature sensor LH rear signal voltage is too high or too low.
POSSIBLE CAUSES E
• Battery temperature sensor
• Harness or connector F
FAIL-SAFE
None
G
With CONSULT H
3. Check DTC. I
K
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of L
maintenance.
M
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in N
before beginning work on the high voltage system. O
• Refer to EVB-17, "High Voltage Precautions". P
CAUTION:
1.PRECONDITIONING
WARNING:
EVB-161
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 Li-ion battery controller harness connector or battery temperature sensor har-
ness connector and ground.
Front module stuck
Battery tem-
perature sen- Connector Terminal — Continuity
sor
LH center LB9 1
Ground No existed
LH rear LB9 3
Rear module stuck
Li-ion battery
Battery tem-
controller
perature sen- Terminal — Continuity
harness con-
sor
nector
Rear center LB11 25
Ground No existed
Rear LH LB11 27
and Installation".

1. Remove battery temperature sensor. Refer to EVB-242, "FRONT MODULE STACK : Exploded View"
(FRONT MODULE STACK) or EVB-259, "REAR MODULE STACK : Exploded View" (REAR MODULE
STACK).
2. Check resistance between Li-ion battery controller harness connector terminals or battery temperature
sensor terminals.
EVB-162
Front module stuck
Battery tem- A
perature
Battery temperature sensor Condition Resistance (kΩ)
sensor ter-
minals
B
LH center 1 and 2 10 (50) Approx. 7.4
Temperature °C (°F) 25 (77) Approx. 4.0
LH rear 3 and 4
40 (104) Approx. 2.3 EVB
Rear module stuck
Li-ion bat-
tery control-
D
Battery temperature sensor ler harness Condition Resistance (kΩ)
connector
terminals E
Rear center 25 and 29 10 (50) Approx. 7.4
Rear LH 27 and 31
40 (104) Approx. 2.3 F
G
NO >> Replace battery temperature sensor. Refer to EVB-242, "FRONT MODULE STACK : Exploded
View" (FRONT MODULE STACK) or EVB-259, "REAR MODULE STACK : Exploded View"
H
EVB-163
P33DF BAT VOLTAGE ISOLATION SEN
DTC DETECTION LOGIC

BAT VOLTAGE ISOLATION SEN Signal voltage of the on-board isolation resistance monitoring system is too
P33DF
(Battery voltage isolation sensor) high.
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P33DF detected?
EVB-164
P33E0 BAT VOLTAGE ISOLATION SEN
A
DTC Trouble diagnosis name DTC detecting condition

BATTERY VOLTAGE ISOLATION EVB
Signal Voltage of the on-board isolation resistance monitoring system is too
P33E0 SENSOR
low.
(Battery voltage isolation sensor)
POSSIBLE CAUSES D
FAIL-SAFE E
With CONSULT
3. Check DTC.
Is P33E0 detected?
H
I
J
EVB-165
DTC DETECTION LOGIC

BATTERY VOLTAGE ISOLATION
Signal voltage of the on-board isolation resistance monitoring system exhibits
P33E1 SENSOR
no amplitude variation.
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P33E1 detected?
When this DTC is detected, perform Li-ion battery insulation resistance loss check. Refer to EVB-180, "Com-
ponent Inspection".
EVB-166
P33E2 BATT PACK OVER TEMP
A

BATTERY PACK OVER TEMPERA-
P33E2 TURE When the battery (battery pack) temperature is excessively high.
(Battery pack over temperature)
D
POSSIBLE CAUSES
Overcharge caused by traction motor inverter/VCM malfunction
E
FAIL-SAFE
• No driving
• Charge stop
• EV system warning lamp illuminate F
With CONSULT
3. Check DTC.
Is P33E2 detected?
J

K
With CONSULT
2. Check to see if “P33E4” or “P33E5” is detected simultaneously with “P33E2”.
L
Is P33E4 or P33E5 detected?
YES >> Perform diagnosis on the detected “P33E4” or “P33E5”. Refer to EVB-168, "Diagnosis Proce-
dure".
NO >> GO TO 2. M

With CONSULT N
Using FREEZE FRAME DATA (FFD), check the values of four temperature sensors when DTC is detected.
Monitor item Condition Limit O

Battery temperature sensor 1
Power switch ON 55°C (131°F) or less P
Is there temperature increase?
Temperature increase is seen>>Replace Li-ion battery. Refer to EVB-213, "Removal and Installation".
Temperature increase is not seen>>Replace battery temperature sensors. Refer to EVB-242, "FRONT
MODULE STACK : Exploded View" (FRONT MODULE STACK) or EVB-259, "REAR MODULE
STACK : Exploded View" (REAR MODULE STACK).
EVB-167
P33E4, P33E5 TEMPERATURE SENSOR
DTC DETECTION LOGIC

Deviation in characteristics of Battery temperature sensor rear center or LH
P33E4 TEMPERATURE SENSOR center.
(Temperature sensor)
P33E5 Deviation in characteristics of Battery temperature sensor rear LH or LH rear.
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P33E4 or P33E5 DTC detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-168
>> GO TO 2. A
2.CHECK BATTERY TEMPARETURE SENSOR
Refer to EVB-169, "Component Inspection". B
YES >> Replace both battery temperature sensor.
NO >> Replace malfunction battery temperature sensor. EVB
1.CHECK BATTERY TEMPERATURE SENSOR D

STACK). E
sensor terminals.
Front module stuck F
Battery tem-
perature
sensor ter- G
minals
Temperature °C (°F) 25 (77) Approx. 4.0 H
LH rear 3 and 4
40 (104) Approx. 2.3
Rear module stuck

I
Li-ion bat-
tery control-
connector J
terminals
Temperature °C (°F) 25 (77) Approx. 4.0 K
Rear LH 27 and 31
40 (104) Approx. 2.3
M
EVB-169
P33E6 CELL CONTROLLER
DTC DETECTION LOGIC

CELL CONTROLLER With the power switch ON and no load condition, the difference between the
P33E6
(Cell controller) maximum voltage and minimum voltage exceeds the allowable range.
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge limit
With CONSULT
1. Turn power switch ON and wait for 10 seconds or more.
3. Check DTC.
Is P33E6 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS OF LI-ION BATTERY CONTROLLER
With CONSULT
2. Check to see if “P0A1F”, “P3062” or “P33ED” is detected simultaneously with “P33E6”.
Is P0A1F, P3062 or P33ED detected?
EVB-170
YES-1 >> When “P0A1F” or “P3062” are detected simultaneously, Replace Li-ion battery controller. Refer to
EVB-232, "LI-ION BATTERY CONTROLLER : Removal and Installation". A
YES-2 >> When “P33ED” is detected simultaneously, perform the diagnosis procedure of “P33ED”. Refer to
EVB-176, "Diagnosis Procedure".
NO >> GO TO 2.
B
2.CHECK FREEZE FRAME DATA (FFD)
With CONSULT
1. Check “FFD” when DTC is detected. EVB
2. Calculate the average value of cell voltage by dividing “TOTAL BATTERY VOLTAGE” by 96 (the number
of cells).
D
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. E
A = Maximum cell voltage − Average cell voltage

B = Average cell voltage − Minimum cell voltage F
Which voltage is larger, A or B?
A >> Replace module including a cell of the maximum cell voltage. Refer to EVB-824, "FRONT MOD-
ULE STACK : Exploded View" (FRONT MODULE STACK) or EVB-841, "REAR MODULE STACK G
: 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-824, "FRONT MOD-
ULE STACK : Exploded View" (FRONT MODULE STACK) or EVB-841, "REAR MODULE STACK H
3.PERFORM CELL VOLTAGE LOSS INSPECTION
I
With CONSULT
1. Select “WORK SUPPORT” of “HV BAT.”
2. Select “CELL VOLTAGE LOSS INSPECTION.” Touch “START.”
3. Check “MINIMUM CELL VOLTAGE.” J
Is “MINIMUM CELL VOLTAGE” 3,712 mV or less?
YES >> GO TO 5.
NO >> GO TO 4. K
4.DISCHARGE OF LI-ION BATTERY
With CONSULT L
2. Set the vehicle, according to the following conditions.
M
A/C set temperature : Full hot
A/C fan speed : Maximum speed
A/C air outlet : Defroster N
Headlamp : High beam ON
Door glass : Full open
O
3. Check “DATA MONITOR” and let the Li-ion battery discharge until the “MINIMUM CELL VOLTAGE”
reaches 3,712 mV or less.
NOTE:
P
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.
EVB-171
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
5 Approx. 70 minute
4 Approx. 40 minute
3 Approx. 20 minute
>> GO TO 5.
5.CHECK CELL OF VOLTAGE LOSS
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
VALUE” is displayed.
Is a cell displayed?
YES >> Record applicable cell No. and then GO TO 6.
NO >> Check the minimum cell voltage on the data monitor and replace a module which includes the
minimum cell voltage. Refer to EVB-824, "FRONT MODULE STACK : Exploded View" (FRONT
MODULE STACK) or EVB-841, "REAR MODULE STACK : Exploded View" (REAR MODULE
STACK).
6.PRECONDITIONING
WARNING:
2. Remove battery pack upper case. Refer to EVB-221, "BATTERY PACK UPPER CASE : Exploded View".
>> GO TO 7.
7.CHECK CONDENSATION
Check condensation in battery pack.
YES >> GO TO 8.
NO >> Replace Li-ion battery. Refer to EVB-213, "Removal and Installation".
8.CHECK CONNECTORS AND FIXING BOLTS
Check connection state, damage and dust of following;
• Li-ion battery controller (LBC) harness connector
• Module harness connector
• Module terminal fixing bolt
YES >> GO TO 9
EVB-172
Check module voltage within determined cell at step 3 and check the divergence of the voltage and cell volt-
age with “DATA MONITOR”. A
DANGER:
When check module voltage, be careful not to short.
Is Divergence within 40 mV? B
YES-1 >> When the determined cell at step 5 is in front module stack.: GO TO 10.
YES-2 >> When the determined cell at step 5 is in rear module stack.: GO TO 12.
NO >> Replace Li-ion battery controller. Refer to EVB-222, "BATTERY PACK UPPER CASE : Removal EVB
and Installation".
10.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE HARNESS CONNEC-
TOR D
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 5. E
Resistance val-
Terminal
ue F
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. G
YES >> GO TO 11
NO >> Repair or replace harness or connectors. H
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 5. I
P
JSCIA1229GB
EVB-173
Resistance val-
Terminal
ue
Module harness con-
Bus bar Approx. 0 Ω
nector
2. Check the divergence of the resistance and the resistance of other cell harness.
YES >> Replace module within the determined cell at step 5.
NO >> Repair or replace harness or connectors.
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.
JSCIA1228GB
Resistance val-
Terminal
ue
Li-ion battery control-
ler harness connector
EVB-174
P33ED BATTERY PARALLEL DIAGNOSIS
A

BATTERY PARALLEL DIAGNOSIS
P33ED When a sudden voltage fluctuation is detected in module.
(Battery parallel diagnosis)
POSSIBLE CAUSE D
Module
FAIL-SAFE E
• Charge limit
F
1.CHECK LI-ION BATTERY AVAILABLE CHARGE GAUGE
G
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? H
YES >> GO TO 3.
NO >> GO TO 2.
I
2. Set the vehicle, according to the following conditions. J

A/C fan speed : Maximum speed K
A/C air outlet : Defroster
L
3. Let the Li-ion battery discharge until the Li-ion battery available charge gauge shows segment 1 or below.
M
>> GO TO 3.
3.CHARGE OF LI-ION BATTERY N
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.
O
>> GO TO 4.
4.PERFORM DTC CONFIRMATION PROCEDURE P
With CONSULT
3. Check DTC.
Is P33ED detected?
EVB-175
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-246, "FRONT MODULE STACK : Removal and
Installation" (FRONT MODULE STACK) or EVB-263, "REAR MODULE STACK : Removal and
Installation" (REAR MODULE STACK).
NO >> GO TO 2.
2.DTC CONFIRMATION PROCEDURE OPERATION
1. If abnormal cell is not identified, perform DTC confirmation procedure. Refer to EVB-175, "DTC Descrip-
tion".
2. Check cell voltage again using “DATA MONITOR” or “FFD” to identify malfunctioning cell.
>> Replace corresponding Module. Refer to EVB-246, "FRONT MODULE STACK : Removal and
Installation" (FRONT MODULE STACK) orEVB-263, "REAR MODULE STACK : Removal and
EVB-176
A
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul- B
tiplex communication 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
with 2 communication lines (CAN-H, CAN-L) allowing a high rate of information transmission with less wiring. EVB
Each control unit transmits/receives data but selectively reads the required data only.
CAN communication signal chart. Refer to LAN-41, "CAN COMMUNICATION SYSTEM : CAN Communica-
tion Signal Chart". D
DTC DETECTION LOGIC
Trouble diagnosis name E

CAN COMM CIRCUIT When no CAN communication signal is received continuously for 2 seconds or
U1000
(CAN communication circuit) more. F
POSSIBLE CAUSE
CAN communication system
G
FAIL-SAFE
• Charge stop
H
I
EVB-177
HIGH VOLTAGE CIRCUIT
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK HIGH VOLTAGE FUSE
Check the continuity between and .
YES >> GO TO 2.
NO >> Replace the service plug (with high voltage fuse) after
repairing the applicable circuit. Refer to EVB-221, "BAT-
TERY PACK UPPER CASE : Exploded View".
JSCIA1251ZZ
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
Check connection status of each bus bar in high voltage circuit
YES >> GO TO 4.
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.
EVB-178
3. Check the continuity between battery junction box and rear module stack.
High voltage harness between battery junction box and rear module stack A
High voltage harness — Continuity
Terminal Battery pack ground Existed
B
High voltage harness between front module stack RH and battery junction box

EVB

NO >> Replace high voltage harness connector.
EVB-179
LI-ION BATTERY INSULATION RESISTANCE LOSS CHECK
DANGER:
maintenance.
WARNING:
CAUTION:
The following diagnosis procedure must be performed when “P0AA6 or P33E1” are detected and Li-ion
battery is judged that its insulation resistance is dropping.
1.CHECK MAXIMUM CELL VOLTAGE
With CONSULT
1. Power switch ON.
3. Record “MAXIMUM CELL VOLTAGE”.
NOTE:
It is used, when replace a malfunction module.
>> GO TO 2
2.CHECK LI-BATTERY INSULATION RESISTANCE-1
CAUTION:
2. Remove Li-ion battery controller. Refer to EVB-232, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
3. Remove service plug switch bracket (with service plug switch and bus bar that connects service plug and
front module stack RH). Refer to EVB-234, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Exploded View".
4. Measure voltages between terminal of voltage detection harness and battery pack ground, and
between terminal of voltage detection harness and battery pack ground..
EVB-180
EVB
H
JSCIA1340ZZ
: Battery pack front

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

K
YES >> GO TO 5.
NO >> GO TO 3. L
3.CHECK SERVICE PLUG SWITCH INSULATION RESISTANCE-1
1. Using insulation resistance tester, measure insulation resistance
M
between service plug switch terminal and service plug switch
bracket.
WARNING:
Unlike the ordinary tester, the insulation resistance tester N
applies 500 V when measuring. If used incorrectly, there is
the danger of electric shock. If used in the vehicle 12 V sys-
tem, there is the danger of damage to electronic devices. O
Read the insulation resistance tester instruction manual
carefully and be sure to work safely.
CAUTION: JSCIA1341ZZ
Be sure to set the insulation resistance tester to 500 V when P
performing this test. Using a setting 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.
EVB-181
+ — Resistance
Service plug switch terminal Service plug switch bracket 1,000 MΩ or more
NO >> GO TO 4.
1. Remove bus bar that connects service plug and front module
stack RH.
JSCIA1232ZZ

bracket.
WARNING:
Unlike the ordinary tester, the insulation resistance tester
tem, there is the danger of damage to electronic devices.
Be sure to set the insulation resistance tester to 500 V when
being inspected.
NOTE:
+ — Resistance
YES >> Replace bus bar that connects service plug and front module stack RH.
NO >> Replace service plug switch. Refer to EVB-234, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Exploded View".
1. Disconnect voltage detection harness connector of front module stack LH.
EVB-182
EVB
H
JSCIA1342ZZ

I
between terminal of voltage detection harness and battery pack ground.
J
JSCIA1340ZZ
EVB-183
+
Front module stack LH − Voltage
Terminal

YES >> Replace voltage detection harness of front module stack LH.
NO >> GO TO 6.
1. Disconnect voltage detection harness connector of front module stack RH.
JSCIA1343ZZ
EVB-184
EVB
H
JSCIA1340ZZ

I
+
Terminal

K
YES >> Replace voltage detection harness of front module stack RH.
NO-1 (When is malfunctioning)>>GO TO 7. L
NO-2 (When is malfunctioning)>>GO TO 15.
M
1. Remove bus bar that connects front module stack RH and front module stack LH.
EVB-185
JSCIA1344ZZ
2. Measure voltages between terminal of voltage detection harness and battery pack ground.
JSCIA1345ZZ
EVB-186
+ A
Terminal
B
Battery pack ground Approx. 0 V

YES >> GO TO 8. EVB
NO >> GO TO 10.
8.CHECK MODULE-1 D
1. Remove front module stack RH. Refer to EVB-246, "FRONT MODULE STACK : Removal and Installa-
tion".
NOTE:
Do not disassemble module stack. E
2. Measure voltages between terminal / of modules (MD13 -
MD24) in front module stack RH and module body.
F
H
JSCIA0740ZZ
I
+
Module − Voltage
J
Terminal
Module body Approx. 0 V

K

YES >> GO TO 9. L
NO >> Replace malfunctioning module. Refer to EVB-251, "FRONT MODULE STACK : Disassembly and
Assembly".
9.CHECK MODULE-2 M
Measure insulation resistance between terminal / of modules
(MD13 - MD24) in front module stack RH and module body.
WARNING: N
applies 500 V when measuring. If used incorrectly, there is the
danger of electric shock. If used in the vehicle 12 V system, O
there is the danger of damage to electronic devices. Read the
insulation resistance tester instruction manual carefully and be
sure to work safely.
CAUTION: P
Be sure to set the insulation resistance tester to 500 V when JSCIA1369ZZ
EVB-187
+
Module − resistance
Terminal
Module body 100 MΩ or more

YES >> Replace bus bar that connects front module stack RH and front module stack LH.
Assembly".
1. Remove bus bar that connects battery junction box and front module stack LH.
JSCIA1346ZZ
EVB-188
EVB
I
JSCIA1347ZZ

J
+
K
Terminal
Battery pack ground Approx. 0 V L
YES >> GO TO 13.
NO >> GO TO 11. M
11.CHECK BATTERY JUNCTION BOX INSULATION RESISTANCE-1
1. Using insulation resistance tester, measure insulation resistance between high voltage terminal / of N
battery junction box and battery pack ground.
EVB-189
JSCIA1348ZZ
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
CAUTION:
higher than 500 V can result in damage to the component being inspected.

— Resistance
Terminal
Battery pack ground 1,000 MΩ or more

YES >> Replace bus bar that connects battery junction box and front module stack LH.
NO >> GO TO 12.
1. Remove bus bar that connects battery junction box and terminal of voltage detection harness.
EVB-190
EVB
I
JSCIA1349ZZ

J
2. Using insulation resistance tester, measure insulation resistance between high voltage terminal / of
K
EVB-191
JSCIA1350ZZ
WARNING:
CAUTION:

— Resistance
Terminal

YES >> Replace bus bar that connects battery junction box and terminal of voltage detection harness.
NO >> Replace battery junction box. Refer to EVB-234, "BATTERY JUNCTION BOX AND BATTERY
13.CHECK MODULE-3
tion".
NOTE:
Do not disassemble module stack.
EVB-192
2. Measure voltages between terminal / of modules (MD1 and
MD12) in front module stack RH and module body. A
EVB
JSCIA0740ZZ
+
E
Module − Voltage
Terminal
F

G
YES >> GO TO 14.
Assembly".
H
14.CHECK MODULE-4
(MD1 and MD12) in front module stack RH and module body. I
WARNING:
applies 500 V when measuring. If used incorrectly, there is the J
danger of electric shock. If used in the vehicle 12 V system,
sure to work safely. K
CAUTION:
performing this test. Using a setting higher than 500 V can L
+ M
Terminal
N

Assembly". P
1. Remove bus bar that connects front module stack RH and rear module stack.
EVB-193
JSCIA1243ZZ
JSCIA1351ZZ
EVB-194
: Battery pack front A
+
B
Terminal
Battery pack ground Approx. 0 V EVB
YES >> GO TO 16.
D
NO >> GO TO 18.
16.CHECK MODULE-5
1. Remove front module stack RH. Refer to EVB-246, "FRONT MODULE STACK : Removal and Installa- E
tion".
NOTE:
Do not disassemble module stack. F
2. Measure voltages between terminal / of modules (MD25
and MD26) in front module stack RH and module body.
G
I
JSCIA0740ZZ
J
+
Module − Voltage
Terminal K

L
YES >> GO TO 17.
NO >> Replace malfunctioning module. Refer to EVB-251, "FRONT MODULE STACK : Disassembly and M
Assembly".
17.CHECK MODULE-6
N
(MD25 and MD26) in front module stack RH and module body.
WARNING:
Unlike the ordinary tester, the insulation resistance tester O
there is the danger of damage to electronic devices. Read the P
CAUTION:
EVB-195
+
Terminal

YES >> Replace bus bar that connects front module stack RH and rear module stack.
Assembly".
1. Remove bus bar that connects front module stack LH and rear module stack.
JSCIA1245ZZ
EVB-196
EVB
H
JSCIA1351ZZ

I
+
Terminal
K
YES >> GO TO 19.
NO >> GO TO 21. L
19.CHECK MODULE-7
1. Remove rear module stack. Refer to EVB-246, "FRONT MODULE STACK : Removal and Installation".
NOTE: M
2. Measure voltages between terminal / of all modules in rear
module stack and module body. N
JSCIA0740ZZ
EVB-197
+
Module − Voltage
Terminal

YES >> GO TO 20.
Assembly".
20.CHECK MODULE-8
Measure insulation resistance between terminal / of all modules
in rear module stack and module body.
WARNING:
CAUTION:
+
Terminal

YES >> Replace bus bar that connects front module stack LH and rear module stack.
Assembly".
EVB-198
EVB
H
JSCIA1352ZZ

I
JSCIA1353ZZ
EVB-199
+
Terminal

YES >> GO TO 22.
NO >> GO TO 24.
22.CHECK MODULE-9
1. Remove rear module stack. Refer to EVB-263, "REAR MODULE STACK : Removal and Installation".
NOTE:
and MD 48) in rear module stack and module body.
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 23.
NO >> Replace malfunctioning module. Refer to EVB-267, "REAR MODULE STACK : Disassembly and
Assembly".
23.CHECK MODULE-10
(MD47 and MD 48) in front module stack LH and module body.
WARNING:
CAUTION:
EVB-200
+ A
Terminal
B
EVB
Assembly". D

1. Using insulation resistance tester, measure insulation resistance between high voltage terminal / of E
JSCIA1354ZZ M

N
WARNING:
danger of damage to electronic devices. Read the insulation resistance tester instruction manual O
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting P

— Resistance
Terminal
EVB-201
NO >> GO TO 25.
JSCIA1355ZZ
EVB-202
EVB
H
JSCIA1357ZZ

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

— Resistance
Terminal
Battery pack ground 1,000 MΩ or more M

YES >> Replace bus bar that connects battery junction box and terminal of voltage detection harness. N
O
EVB-203
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK FUSE

Battery 43
57
Power switch ON
82
Is the fuse fusing?
NO >> GO TO 2.
2.CHECK LI-ION BATTERY CONTROLLER GROUND CIRCUIT
2. Disconnect Li-ion battery vehicle communication harness connector.
3. Check the continuity between Li-ion battery vehicle communication harness connector and ground.
+
Connector Terminal
6
8
YES >> GO TO 3.
3.CHECK BATTERY POWER SUPPLY
Check the voltage between Li-ion battery vehicle communication harness connector and ground.
EVB-204
+ A
Connector Terminal
B
12V battery power
E128 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
+
No.43 fuse ter-
E128 5 Existed
minal
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
E128 Ground 11 – 14 V
31
YES >> GO TO 8.
NO >> GO TO 6.
6.CHECK POWER SWITCH ON POWER SUPPLY CIRCUIT-1 M
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
P
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.
EVB-205
Li-ion battery
— Continuity
Connector Terminal
No.82 fuse ter-
E128 31 Existed
minal
8.PRECONDITIONING
WARNING:
Installation".
>> GO TO 9.
9.CHECK HARNESS BETWEEN LI-ION BATTERY AND LI-ION BATTERY CONTROLLER
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
LB10 LB1 Existed
2 8
3 6
14 7
EVB-206
EV BATTERY SYSTEM
< SYMPTOM DIAGNOSIS > [WITHOUT BATTERY COOLER]
SYMPTOM DIAGNOSIS A
EV BATTERY SYSTEM
B
NOTE:
• If any DTC is detected, perform the corresponding diagnosis. EVB
• Before performing diagnosis, check that it is not a symptom caused by normal operation. Refer to EVB-209,
"Description".
D
Symptom Confirmation item Possible cause/Reference page
Combination meter
Information display is functioning normally Refer to MWI-91, "On Board Diagnosis E
Reduction in the driving range Function"
Information display is not functioning nor-
mally
F
EVB-207
REDUCTION IN THE DRIVING RANGE
• The driving range is shorter than before.

• Sudden change (decrease/increase) in possible travel distance indicated on the combination meter.

NOTE:
Is the lighting status 1 Segment or none?

YES >> GO TO 3.
NO >> GO TO 2.

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
>> GO TO 4.
With CONSULT
3. Check DTC.
EVB-208
A
TURN ON THE BATTERY TEMPERATURE WARNING LAMP B

The battery temperature warning lamp may turn ON under the following conditions:
• Quick charge or high-load driving is repeatedly performed when ambient temperature is high
EVB
EVB-209
EV BATTERY USAGE REPORT
< PERIODIC MAINTENANCE > [WITHOUT BATTERY COOLER]
PERIODIC MAINTENANCE
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.
EVB-210
LI-ION BATTERY UNDERCOVER
< REMOVAL AND INSTALLATION > [WITHOUT BATTERY COOLER]
REMOVAL AND INSTALLATION A

B
EVB
N
JSCIA1081GB
Li-ion battery undercover (rear) Li-ion battery undercover (center) Li-ion battery undercover (front)
O
Clip
P
REMOVAL
WARNING:
Prepare for work on the high-voltage system. Refer to EVB-283, "How to Disconnect High Voltage".
1. Remove the mounting bolts, nuts and clips.
EVB-211
< REMOVAL AND INSTALLATION > [WITHOUT BATTERY COOLER]
2. Remove the Li-ion battery under covers.
INSTALLATION
1. Install the Li-ion battery undercover (rear).
2. Install the Li-ion battery undercover (center).
3. Install the Li-ion battery undercover (front).
JSCIA1080ZZ
Bolts for Li-ion battery undercover Clips for Li-ion battery undercover Bolts for Li-ion battery undercover
(rear) (rear) (center)
Clips for Li-ion battery undercover Bolts for Li-ion battery undercover Clips for Li-ion battery undercover
(center) (front) (front)
: Vehicle front
EVB-212
LI-ION BATTERY
< UNIT REMOVAL AND INSTALLATION > [WITHOUT BATTERY COOLER]

LI-ION BATTERY
B
EVB
K
JSCIA1359GB
Li-ion battery Recycle label Bonding plate

Service plug High voltage warning label
L
: Always replace after disassembly.

: N-m (kg-m ft-lb) M
N
DANGER:
O
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. P
WARNING:
• 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.
• 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.
EVB-213
LI-ION BATTERY
• 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 components with an anti-static cover sheet
or similar item to prevent contact with other persons.
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
so in the Service Manual.
REMOVAL
1. Remove the service plug. Refer to EVB-15, "How to Disconnect High Voltage".
WARNING:
Prepare for work on the high-voltage system.
2. Lift up the vehicle and remove the Li-ion battery undercover. Refer to EVB-211, "Removal and Installa-
tion".
DANGER:

tective gear.

JSCIA1328ZZ
4. Disconnect the PTC heater harness connector .

DANGER:

tective gear.

EVB-214
LI-ION BATTERY
• Follow the procedure below to disconnect the PTC heater harness connector.
A
EVB
JSCIA1329ZZ
5. Disconnect the Li-ion battery vehicle communications connector D

while rotating it in the counterclockwise direction.
WARNING:
E
To prevent electric shock, wear insulated protective
gear.
F
JSCIA1363ZZ G
6. Remove mounting bolts then remove bonding plates .

WARNING: H

gear.
I
JSCIA1074ZZ
K
7. Remove Li-ion battery mounting bolts .
WARNING:
L
gear.
CAUTION:
Do not remove the 4 bolts in this step. N
JSCIA1075ZZ
8. Set the pallet [SST: — (J-50583)] onto the lift table.

O
EVB-215
LI-ION BATTERY
• Align the pallet center mark and the lift table center
mark .
Front
Side
JSCIA0178ZZ
9. 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
10. Remove the Li-ion battery mounting bolts (4 bolts) .
JSCIA1076ZZ
WARNING:
To prevent electric shock, wear insulated protective gear.
EVB-216
LI-ION BATTERY
11. Lower the pallet, and remove the Li-ion battery from the vehicle.
WARNING: A

gear. B
EVB
JSCIA1077ZZ
D
12. Lower the Li-ion battery from the lift table together with the pallet.
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 Li-ion battery onto the vehicle body. M
3. Tighten the Li-ion battery mounting bolts (4 bolts) , then remove the pallet.
P
JSCIA1076ZZ
WARNING:
EVB-217
LI-ION BATTERY
4. Install the Li-ion battery mounting bolts .

WARNING:

gear.
NOTE:
4 bolts are installed in previous step.
JSCIA1075ZZ
5. Install mounting bolts and bonding plates .

WARNING:

gear.
JSCIA1074ZZ
6. After installing the bonding plate, perform an electric equipotential test. EVB-219, "Inspection".
7. Rotate the vehicle communications connector clockwise to
connect it.
WARNING:

gear.
JSCIA1362ZZ
8. Install the PTC heater harness connector .

DANGER:

tective gear.
JSCIA1361ZZ
EVB-218
LI-ION BATTERY
• Follow the procedure below to connect the heater harness connector.
A
EVB
JSCIA1330ZZ
9. Install the high-voltage harness connector and install the har- D

ness clamp .
WARNING:
E
gear.
F
JSCIA1360ZZ G
• Connect the high-voltage harness connector by the following procedure.

H
JSCIA1331ZZ
10. Install the Li-ion battery undercover. Refer to EVB-213, "Removal and Installation". K
11. Install the service plug. Refer to EVB-15, "How to Disconnect High Voltage".
L
ELECTRIC EQUIPOTENTIAL TEST

M
EVB-219
LI-ION BATTERY
After installing the Li-ion battery, measure the resistance between the battery pack ground bolt and the body
ground.
JSCIA1203ZZ
WARNING:

If the result deviates from the standard value, check the following and correct the malfunction location.
• Conditions of bonding plate connection
• Corrosion on bonding plate mounting surface
• Presence of paint, oil, dirt, or other substance on the bonding plate mounting surface
EVB-220
LI-ION BATTERY
< UNIT DISASSEMBLY AND ASSEMBLY > [WITHOUT BATTERY COOLER]
UNIT DISASSEMBLY AND ASSEMBLY A

LI-ION BATTERY
BATTERY PACK UPPER CASE
B
BATTERY PACK UPPER CASE : Exploded View INFOID:0000000011103604
EVB
JSCIA1364ZZ
EVB-221
LI-ION BATTERY
Breather Service plug Service plug retainer

Battery pack upper case Seal Cap
Seal Plug Plug washer
Battery pack case side
: Always replace after every disas-
sembly.
BATTERY PACK UPPER CASE : Removal and Installation INFOID:0000000011103605
DANGER:
maintenance.
WARNING:
• 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.
CAUTION:
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK
1. Must be an indoor environment.
• 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
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.
• 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.
• 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.
• 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
EVB-222
LI-ION BATTERY
1. Clean any dust or dirt adhered to the battery pack.
2. Remove the service plug retainer . A
WARNING:
To prevent electric shock, wear insulated protective B

gear and use insulated tools.
EVB
JSCIA1172ZZ
D
3. Remove the battery pack upper case mounting bolts and ground bolts .
E
JSCIA1173ZZ J
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools.
K
L
4. Cut the battery pack upper case adhesive according to the following procedure.
WARNING:
M
N
a. Prepare a windshield cutter.
NOTE:
• Sharpen the blade of the windshield cutter . O
• Apply a tape for preventing damage to the battery pack.
: 38 mm (1.50 in) P
JSCIA0572ZZ
EVB-223
LI-ION BATTERY
b. Use the windshield cutter and cut the adhesive in the order from 1 to 4 as shown in the figure.
JSCIA1174ZZ
JSCIA1175ZZ
Battery pack upper case Battery pack lower case

Paint sealant Adhesive
: Paint sealant mark
: Battery front
CAUTION:
• When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi-
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.
• 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: KE560-15090).
Paint sealant damage limit:

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.
EVB-224
LI-ION BATTERY
• Set the windshield cutter (A) at an angle of 90° to the surface of the battery case.
A
EVB
JSCIA0678ZZ
D
• 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. E
CAUTION:
When cutting the adhesive, be careful to avoid scratching
the battery pack coating and paint sealant to the maximum F
extent possible.
NOTE:
Press the piano wire against the adhesive at the battery pack
G
corner, and pull it in alternate directions for cutting of adhesive.
JSCIA0574ZZ
H
d. Use the windshield cutter (A) for cutting adhesive at the embossed locations.
K
JSCIA0679ZZ
i. Insert a plastic remover tool (B) into the embossed locations to open a clearance.
CAUTION: L
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. M
CAUTION:
When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi-
N
5. Remove the battery pack upper case.
WARNING:
To prevent electric shock, wear insulated protective gear. O
P
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.
EVB-225
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-
ness.
• Operation must be performed by 2 persons. Be careful that the battery pack upper case does not
contact the battery module.
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
adhesive behind.
JSCIA0576ZZ
CAUTION:
• Because airtightness leakage is likely to occur, cut the seal in such a way that burrs are not pro-
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
primer (adhesive primer: KE560-15090).

- If the paint sealant damage on a corner is damaged, repair by applying primer (adhesive primer:
KE560-15090).
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.
• 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 .
NOTE:
If primer surfacer (anti-corrosion primer) contacts the seal, the
adhesive strength is reduced.
b. Spray primer surfacer (anti-corrosion primer) (B) into the cracks
in the battery pack upper case.
JSCIA0577ZZ
EVB-226
LI-ION BATTERY
3. Install a carabiner (A) onto the bracket of the battery pack upper
case. A
NOTE:
This is to provide a handle for use after the adhesive is applied
and prevent adhesive from adhering to the operator's hands.
B
EVB
JSCIA1181ZZ
D
4. Apply dam rubber (KE390-00590) on the inside of the old adhesive on the battery pack lower case.
G
JSCIA0578ZZ
C : 10 mm (0.39 in)
H
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, I
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.
J
5. Apply adhesive (KE561-32090) to the battery pack lower case as shown in the figure.
WARNING:
K
EVB-227
LI-ION BATTERY
JSCIA1176ZZ
: Dam rubber : Old adhesive

A : 30 mm (1.18 in) or more B : 5 mm (0.20 in) C : 10 mm (0.39 in)
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
adhesive begins to harden in as little as 16 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
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:
EVB-228
LI-ION BATTERY
• For applying the adhesive in a triangle, cut the end of the nozzle as shown in the figure.
A
EVB
JSCIA0642ZZ
D
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 . E
JSCIA1177ZZ
H
WARNING:
To prevent electric shock, wear insulated protective gear. I
J
CAUTION:
• Operation must be performed by 2 persons. Be careful
that the battery pack upper case does not contact the bat-
tery module. K
• Moving the upper case after it is installed makes airtight-
ness leakage more likely. Therefore, position the upper
case carefully. L
M
JSCIA1182ZZ
EVB-229
LI-ION BATTERY
7. Tighten the mounting bolts in the order from 1 to 6 as shown in the figure.
JSCIA1178ZZ
WARNING:
8. Install the ground bolt .
JSCIA1179ZZ
WARNING:
EVB-230
LI-ION BATTERY
9. Install the service plug retainer .
WARNING: A

gear and use insulated tools. B
EVB
JSCIA1172ZZ
D
10. Perform a battery pack air leak inspection. Refer to EVB-275, "Inspection".
CAUTION:
If air leakage occurs, remove the battery pack upper case and wipe off the adhesive, then apply
E
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.
F
JSCIA1180ZZ
CAUTION: I
• 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. J
• 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-275, "Inspection". K
AIR LEAK INSPECTION
L
LI-ION BATTERY CONTROLLER
EVB-231
LI-ION BATTERY
LI-ION BATTERY CONTROLLER : Exploded View INFOID:0000000011103606
JSCIA1187GB
Li-ion battery controller Controller bracket
LI-ION BATTERY CONTROLLER : Removal and Installation INFOID:0000000011103607
DANGER:
maintenance.
WARNING:
CAUTION:
EVB-232
LI-ION BATTERY
rain, snow, dust, or other substances from entering. A
2. Metal powder, grease, and other foreign substances must not enter. B
vinyl curtain or an equivalent to shut out the outside environment. EVB
4. Work space D
such as by placing signs indicating that disassembly work is in progress. E
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin- F
guisher).
REMOVAL
1. Remove the battery pack upper case. Refer to EVB-222, "BATTERY PACK UPPER CASE : Removal and G
Installation".
2. Disconnect the low-voltage harness connector of the Li-ion
battery controller. H
WARNING:
To prevent electric shock, wear insulated protective I

gear.
JSCIA1188ZZ
K
3. Remove the Li-ion battery controller mounting nuts , then pull
toward the arrow direction.
WARNING: L

M
N
JSCIA1189ZZ
4. Disconnect the high-voltage harness connector , then remove O

: Low-voltage harness connector

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

gear.
JSCIA1190ZZ
EVB-233
LI-ION BATTERY
• Because there is a risk of electric shock, immediately protect the terminals of the discon-
nected high-voltage harness connector with insulating tape so that they are not exposed.
INSTALLATION
1. Install the Li-ion battery controller.
WARNING:
• To prevent electric shock, wear insulated protective gear and use insulated tools.
• 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
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.
: Battery front
JSCIA1190ZZ
2. Install the battery pack upper case. EVB-222, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-275, "Inspection".
AIR LEAK INSPECTION
BATTERY JUNCTION BOX AND BATTERY HARNESS
BATTERY JUNCTION BOX AND BATTERY HARNESS : Exploded View INFOID:0000000011103614
DISASSEMBLY AND ASSEMBLY
EVB-234
LI-ION BATTERY
EVB
JSCIA1339GB
P
Service plug switch Service plug switch bracket Bus bar
Support bracket Vehicle communications harness Snap ring
Bus bar nut cap Bus bar Battery current sensor (integrated
with bus bar)
Bus bar Battery junction box High-voltage harness connector
PTC heater harness connector Connector flange Seal
EVB-235
LI-ION BATTERY
sembly.
BUS BAR LAYOUT
JSCIA1186ZZ
DANGER:
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal.
EVB-236
LI-ION BATTERY
BATTERY JUNCTION BOX AND BATTERY HARNESS : Removal and Installation
INFOID:0000000011103615 A
DANGER:
maintenance. EVB
WARNING:
inspection or maintenance of high voltage system harnesses and parts. D
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not E
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the G
H
I
2. Metal powder, grease, and other foreign substances must not enter. J
• If there is a risk of the above substances entering, take appropriate countermeasures, such as use of a K
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow. L
4. Work space
M
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin- N
guisher).
DISASSEMBLY
O
1. Remove the battery pack upper case.Refer to EVB-222, "BATTERY PACK UPPER CASE : Removal and
Installation".
P
Installation".
3. Remove the service plug switch as follows
EVB-237
LI-ION BATTERY
a. Open the bus bar cover . And then remove the bus bar nuts
.
DANGER:

tective gear and use insulated tools.
JSCIA1211ZZ
• 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.
b. Remove the service plug switch bracket mounting bolts .

WARNING:

JSCIA1212ZZ
c. Invert the service plug switch bracket and disconnect the har-
ness connector , then remove the service plug switch bracket.
WARNING:

JSCIA1213ZZ
d. Remove the mounting bolts . And then remove the bus bar .
WARNING:

JSCIA1214ZZ
EVB-238
LI-ION BATTERY
e. Remove the bolts . And then remove service plug switch
from service plug switch bracket . A
WARNING:

EVB
JSCIA1215ZZ
D
4. Remove the support bracket as follows.
a. Disconnect the harness connectors , and the harness clips .
WARNING: E

F
JSCIA1216ZZ
H
b. Remove the bolts and nut . And then remove the bracket.
WARNING:
I
K
JSCIA1217ZZ
5. Remove the current sensor as follows.

L
a. Disconnect the current sensor harness connector.
b. Open the bus bar cover and remove the bus bar cap .
c. Remove the bus bar nuts . Then remove the current sensor M
.
DANGER:
N
tective gear and use insulated tools. JSCIA1218ZZ
O
P
nected high-voltage harness connector (high-voltage terminals) with insulating tape so that they
are not exposed.
EVB-239
LI-ION BATTERY
6. Open the bus bar cover and remove the bus bar caps . And
remove the bus bar bolts and nuts . Then remove the bus
bar (Junction box - Left front module stack) .
DANGER:

JSCIA1219ZZ

7. Disconnect the harness connectors .

WARNING:

gear.
JSCIA1220ZZ
8. Open the bus bar cover and remove the bus bar cap . And
bar (High-voltage connector - Junction box) .
DANGER:

JSCIA1221ZZ

9. Remove the mounting nuts and remove the junction box .

WARNING:

JSCIA1222ZZ
EVB-240
LI-ION BATTERY
10. Remove the mounting bolts . And then remove the high-volt-
age harness connector from the connector flange. A
WARNING:

EVB
JSCIA1224ZZ
D
11. Remove the mounting bolts and remove the PTC heater har-
ness connector from the connector flange.
WARNING: E

F
G
JSCIA1225ZZ
12. Remove the vehicle communications harness as follows. H

a. Disconnect the vehicle communications harness clips .
WARNING:
I
K
JSCIA1226ZZ
b. Remove the snap ring (in the direction shown by arrow 1).
L
Press the connector toward inside (in the direction shown by
arrow 2) to remove from battery pack lower case.
WARNING:
M
N
JSCIA1227ZZ
O
ASSEMBLY
Note the following items, and disassembly in the reverse order of disassembly.
P
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.
EVB-241
LI-ION BATTERY
• 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.
WARNING:
Install the Li-ion battery controller immediately before installing the battery pack upper case. Refer to
EVB-232, "LI-ION BATTERY CONTROLLER : Removal and Installation".
CAUTION:
• Perform the “LI-ION BATTERY JUNCTION BOX DATA CLEAR” when battery junction box is replaced.
Refer to EVC-124, "Work Procedure".
AIR LEAK INSPECTION
FRONT MODULE STACK
FRONT MODULE STACK : Exploded View INFOID:0000000011103618
EVB-242
LI-ION BATTERY
EVB
L
JSCIA1300GB
Rear module stack Bus bar Bus bar M

Bus bar Right front module stack Left front module stack
Plate Battery pack lower case
N

O

P
EVB-243
LI-ION BATTERY
JSCIA1184GB
End plate End plate bracket End plate

Sub frame Bus bar module Battery temperature sensor (front)
(Left front module stack only)
Bus bar module cover Bus bar Bus bar
Bus bar Bus bar module cover Module
EVB-244
LI-ION BATTERY

A
: Battery front
NOTE:
The figure shows the left front. B
MODULE LAYOUT
EVB
H
JSCIA1087ZZ
Left front module stack Right front module stack

I
Module No. Module name Cell No. Module No. Module name Cell No.
MD1 Module A 1&2 MD13 Module A 25 & 26
MD2 Module A 3&4 MD14 Module A 27 & 28 J
K
MD5 Module A 9 & 10 MD17 Module A 33 & 34
MD7 Module A 13 & 14 MD19 Module A 37 & 38 L
M
N
O
EVB-245
LI-ION BATTERY
BUS BAR LAYOUT
JSCIA1186ZZ
DANGER:
FRONT MODULE STACK : Removal and Installation INFOID:0000000011103619
DANGER:
EVB-246
LI-ION BATTERY
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
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. Refer to EVB-222, "BATTERY PACK UPPER CASE : Removal and N
Installation".
Installation". O
3. Remove the following parts.
×: Need to remove
Parts name Left front module stack Right front module stack Reference P
Service plug switch bracket × ×
EVB-237, "BATTERY JUNC-
Support bracket × × TION BOX AND BATTERY
HARNESS : Removal and In-
Vehicle communications har-
× stallation"
ness
EVB-247
LI-ION BATTERY
4. Remove the connecting plates .
: Battery front
WARNING:

JSCIA1252ZZ
5. Disconnect the voltage detection harness connectors and

battery temperature sensor harness (rear) harness connector
.
WARNING:

JSCIA1253ZZ
6. Open the bus bar cover and remove the bus bar nuts .
Then remove the bus bar (Right front – Rear module stack)
DANGER:

JSCIA1254ZZ

Then remove the bus bar (Left front – Rear module stack).
DANGER:

JSCIA1255ZZ

EVB-248
LI-ION BATTERY
Then remove the bus bar (Right front – Left front module A
stack)
DANGER:
B
EVB
JSCIA1268ZZ
D
E
9.
10. Remove the front module stack mounting nuts .

F
JSCIA1256ZZ
K
WARNING: L
11. Follow the procedure below and remove the front module stack from the battery pack. N
a. Attach a carabiner at position as shown in the figure, and attach a sling belt to it.
JSCIA1257ZZ
WARNING:
EVB-249
LI-ION BATTERY
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. JSCIA1258ZZ
c. Move the battery pack and place the workbench below the front module stack.
WARNING:
CAUTION:
Place the removed battery pack upper case onto the battery pack for storage.
d. Place the front module stack onto the workbench.

WARNING:

gear.
• Because there is a risk of electric shock, lay an anti-

static rubber sheet on the workbench. JSCIA1259ZZ
NOTE:
The figure shows the left front module stack.
INSTALLATION
DANGER:
minal.
WARNING:
EV Battery Tracking Identification Seal
EVB-250
LI-ION BATTERY
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 A
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”.
B
3. Enter the necessary information in the “Li-ion battery replacement history record”.
CAUTION:
replace it with a new clip before installing. EVB
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST D
FRONT MODULE STACK : Disassembly and Assembly INFOID:0000000011103620
DANGER: E
electric shock, electric leakage, or similar accidents if the vehicle is handled incorrectly. Be sure to fol- F
low the correct work procedures when performing inspection and maintenance.
WARNING:
G
• Be sure to put on insulating protective gear before beginning work on the high voltage system. H
or similar item to prevent contact with other persons. I
CAUTION: J
so in the Service Manual. K
• The environment must utilize a shutter or other means to shut out the outside environment and prevent L
due to high temperature or humidity. M
entering due to maintenance performed on other vehicles and other sources during disassembly work. N
• The floor must not be wet as a result of factors such as vehicle entry during rain or snow. O
4. Work space
• Take appropriate countermeasures so that persons other than the operator do not enter the work space, P
guisher).
DISASSEMBLY
EVB-251
LI-ION BATTERY
1. Remove the bus bars according to the numerical order 1→3 as shown in the figure. And note the follow-
ing.
JSCIA1269ZZ
a. Open the bus bar cover and remove the bus bar bolts .
b. Pic the tabs ( ) and then remove the bus bars.
DANGER:
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.
2. Remove the bus bar module cover as follows.
a. Disengage the pawls ( ) using insulated tool (A). And then remove the bus bar module cover and .
CAUTION:
Be careful never to apply excessive force, the pawls may be damaged.
JSCIA1270ZZ
DANGER:
EVB-252
LI-ION BATTERY
B
3. Remove the battery temperature sensor (front) if necessary. (Left front module stack)
NOTE:
Battery temperature sensor removal is not required for module stack disassembly. EVB
a. Remove the mounting bolts and disengage the pawls ( ).Then remove the battery temperature sensor
(front) .
D
JSCIA1271ZZ
I
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear J
shock if the operators contact one another. L
4. Follow the procedure below and remove the bus bar module from the front module stack.
a. Remove the module terminal mounting bolts .
M
JSCIA1272ZZ
DANGER: P
EVB-253
LI-ION BATTERY
b. Remove the voltage detection terminal mounting screws , then remove the bus bar module from the
front module stack.
JSCIA1273ZZ
DANGER:
c. Install a module terminal cover [SST: KV99111500 ( — )] (A) onto all module terminals.
JSCIA1274ZZ
WARNING:
5. Remove the end plate and disassemble the front module stack.
WARNING:
ASSEMBLY
1. When replacing the Li-ion battery with a new battery, perform the following operation.
b. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
2. Follow the procedure below to assemble the front module stack.
EVB-254
LI-ION BATTERY
DANGER:
A
There is the danger of electric shock caused by contact with the terminals. Be sure to wear
B
a. Assemble the module so that the module terminals are arranged as shown in the figure.
EVB
Right front module stack
F
JSCIA1275ZZ
: Battery front
G
Left front module stack
J
JSCIA1290ZZ
: Battery front
K
WARNING:
Be careful of the directions of the + terminal and – terminal when assembling the module. If L
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. M
+ terminal identification color : Red

N
− terminal identification color : Black
JSCIA0682ZZ
P
EVB-255
LI-ION BATTERY
• Install the module while aligning the position of the module col-
lar .
JSCIA0733ZZ
b. Install so that the end plate carabiner installation holes are in the positions shown in the figure.
JSCIA1257ZZ
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.
JSCIA1276ZZ
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.
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.
EVB-256
LI-ION BATTERY
a. Install the bus bar module , then use an insulated torque driver to tighten the voltage detection terminal
mounting screws . A
EVB
JSCIA1273ZZ D
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear E
shock if the operators contact one another. G
b. Install the battery temperature sensor (front) . if removed.

H
JSCIA1271ZZ
M
DANGER:
insulated protective gear and use insulated tools. N
O
CAUTION: P
Be sure to engage the pawls ( )
c. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
EVB-257
LI-ION BATTERY
JSCIA1277ZZ
: Battery front
NOTE:
The part is installed the bus bar in after step.
JSCIA1278ZZ
: Battery front
NOTE:
DANGER:
NOTE:
4. Install the bus bar module cover.
EVB-258
LI-ION BATTERY
ing. A
EVB
F
JSCIA1269ZZ
a. Engage the tabs ( ).

b. Tighten the bus bar bolts and close the bus bar cover . G
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear H
shock if the operators contact one another. J
REAR MODULE STACK
REAR MODULE STACK : Exploded View INFOID:0000000011103621 K

L
EVB-259
LI-ION BATTERY
JSCIA1300GB
Rear module stack Bus bar Bus bar

EVB-260
LI-ION BATTERY
EVB
JSCIA1185GB
P
Rear stack member Right end plate Bus bar module
Bus bar module cover Battery temperature sensor harness Front stack member
(rear)
Harness bracket Module Through-bolt
Left end plate
EVB-261
LI-ION BATTERY

: Battery front
MODULE LAYOUT
JSCIA1087ZZ
Rear module stack

MD28 Module B 55 & 56 MD38 Module B 75 & 76
NOTE:
• Module A: No bracket
• Module B: With bracket
BUS BAR LAYOUT
DANGER:
EVB-262
LI-ION BATTERY
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal. A
EVB
JSCIA1186ZZ P
REAR MODULE STACK : Removal and Installation INFOID:0000000011103622
DANGER:
EVB-263
LI-ION BATTERY
maintenance.
WARNING:
CAUTION:
4. Work space
guisher).
REMOVAL
1. Remove the battery pack upper case. Refer to EVB-222, "BATTERY PACK UPPER CASE : Removal and
Installation".
Installation".
.
WARNING:

JSCIA1253ZZ
EVB-264
LI-ION BATTERY
Then remove the bus bar (Right front – Rear module stack) A
WARNING:

EVB
JSCIA1254ZZ
D
WARNING: E

F
G
JSCIA1255ZZ
6. Remove the rear module stack mounting bolts . H

WARNING:

gear and use insulated tools. I
JSCIA1261ZZ
K
7. Follow the procedure below and remove the rear module stack from the battery pack.
a. Attach a carabiner to position as shown in the figure and con-
L
nect a lashing belt to it.
WARNING:
To prevent electric shock, wear insulated protective M

gear.
JSCIA1262ZZ
O
EVB-265
LI-ION BATTERY
b. Use the engine frame (A) and lift up the rear module stack .
WARNING:

gear.
CAUTION:
Do not move the engine crane when the rear module stack
c. Move the battery pack and place the workbench below the rear module stack.
WARNING:
CAUTION:
d. Place the rear module stack onto the workbench.

WARNING:
• To prevent electric shock, wear insulated protective gear.
• Because there is a risk of electric shock, lay an anti-static rubber sheet on the workbench.
INSTALLATION
DANGER:
minal.
WARNING:

1. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
CAUTION:
EVB-266
LI-ION BATTERY
AIR LEAK INSPECTION A
REAR MODULE STACK : Disassembly and Assembly INFOID:0000000011103623
B
DANGER:
Because hybrid vehicles and electric vehicles contain a high voltage battery, there is a risk of EVB
WARNING: D
• 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.
E
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet F
G
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do H
I
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur J
• The indoor environment must also prevent metal powder, grease, and other foreign substances from K
vinyl curtain or an equivalent to shut out the outside environment. L
4. Work space M
5. Standard fire fighting equipment N
guisher). O
DISASSEMBLY
1. Follow the following procedure and remove the bus bar from the rear module stack.
P
EVB-267
LI-ION BATTERY
a. Remove the left-side bus bar cover and open the bus bar
cover , then remove the module terminal mounting bolts .
DANGER:

JSCIA1279ZZ
• This work must not be performed by multiple opera-

tors because there is a risk of electric shock if the operators contact one another.
b. Remove the center bus bar cover , then remove the module
terminal mounting bolts .
DANGER:

JSCIA1280ZZ

CAUTION:
Do not remove all bus bar covers and all module terminal mounting bolts at the same time.
c. Remove the right-side us bar cover and open the bus bar
DANGER:

JSCIA1281ZZ

d. Remove the battery temperature sensor (rear) if necessary.

NOTE:
Battery temperature sensor removal is not required for module stack disassembly.
EVB-268
LI-ION BATTERY
i. Remove the mounting bolts and disengage the pawls ( ). Then remove the battery temperature sensor
(rear) . A
EVB
F
JSCIA1301ZZ
DANGER:
G
H
• This work must not be performed by multiple operators because there is a risk of electric I
e. Remove the voltage detection terminal mounting screws ,
then remove the bus bar from the rear module stack. J
DANGER:
• There is the danger of electric shock caused by K

L
JSCIA1282ZZ
• This work must not be performed by multiple opera- M
f. Install a module terminal cover [SST: KV99111500 ( — )] (A)

onto all module terminals. N
WARNING:
To prevent electric shock, wear insulated protective O

gear.
P
NOTE:
• Because “module B” interferes with the bracket and cover, cut JSCIA1283ZZ
the module terminal cover at the position shown in the figure.
EVB-269
LI-ION BATTERY
JSCIA0729ZZ
A : 7 mm (0.28 in) B : 5 mm (0.20 in)
2. Remove the front stack member and the harness bracket .

WARNING:

JSCIA1284ZZ
3. Remove the rear stack member .

WARNING:

JSCIA1285ZZ
4. Fasten the rear module stack with a lashing belt .

WARNING:

gear.
JSCIA0240ZZ
EVB-270
LI-ION BATTERY
5. Remove the through bolts and mounting nuts, then disassem-
ble the rear module stack . A
WARNING:

EVB
JPCIA0131ZZ
D
ASSEMBLY
E
(old) LI-ion battery and to the “Li-ion battery replacement history record”. F
2. Follow the procedure below to assemble the rear module.
G
WARNING:
H
a. Assemble the rear module so that the module terminals are arranged as shown in the figure. I
JSCIA1286ZZ L
WARNING:
Be careful of the directions of the + terminal and − terminal when assembling the module. If
M
NOTE:
figure. N

− terminal identification color : Black O
JSCIA0682ZZ
EVB-271
LI-ION BATTERY
b. Use a lashing belt and apply pressure to the rear module
stack .
WARNING:

gear.
JSCIA0240ZZ
c. Inspect the module installation condition, and correct it if it is skewed or a large distortion is found.
JSCIA0313ZZ
WARNING:
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.
JSCIA1287ZZ
CAUTION:
e. Install the remaining 2 through-bolts, and tighten the mounting nuts to the prescribed torque.
EVB-272
LI-ION BATTERY
• When installing, hold the end of the through bolt stationary and
tighten the installation nut. A
EVB
JSCIA0347ZZ
D
3. Install the rear stack member .
WARNING:
E
F
G
JSCIA1285ZZ
4. Install the front stack member and the harness bracket . H

WARNING:

JSCIA1284ZZ
K
5. Remove the module terminal cover [SST: KV99111500 ( — )]
(A).
WARNING: L

gear. M
N
6. Follow the procedure below and install the bus bar module onto
the rear module stack. JSCIA1283ZZ
a. Install the bus bar module onto the rear module stack.
O
WARNING:

P
EVB-273
LI-ION BATTERY
b. Install the battery temperature sensor (rear) if removed.
JSCIA1301ZZ
c. Use an insulated torque driver (A) and tighten the voltage detec-
tion terminal mounting screws to the prescribed torque.
DANGER:

JPCIA0135ZZ
d. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
• When tightening of 1 – 15 is completed, install the left-side bus bar cover.
• When tightening of 16 – 27 is completed, install the center bus bar cover.
• When tightening of 28 – 40 is completed, install the right-side bus bar cover.
JSCIA1288ZZ
DANGER:
EVB-274
LI-ION BATTERY
e. Install the bus bar covers.
A
EVB
JSCIA1289ZZ
WARNING: D

E
CAUTION:
• Be careful not to install with the top and bottom facing in the wrong directions. F
• After installation, check that the mating is not skewed.
CAUTION: G
Inspection INFOID:0000000011103624 H
AIR LEAK INSPECTION

1. Use vinyl tape or similar means (A) to prevent air leakage from I
the breather.
• Use wide vinyl tape that is capable of covering all of the
breather with one strip. J
• Apply carefully so that no wrinkles in the tape occur.
WARNING:
To prevent electric shock, wear insulated protective K

gear.
JSCIA1208ZZ
L
2. Use vinyl tape or similar means (A) for preventing air leakage
M
from the each harness connector.
• Use wide vinyl tape that is capable of covering all of the har-
ness connector with one strip.
• Apply carefully so that no wrinkles in the tape occur. N
WARNING:

gear.
JSCIA1337ZZ
P
EVB-275
LI-ION BATTERY
3. Remove the plug and install the adapter (A) of the air leak tester
[SST: KV99111400 ( — )].
WARNING:

gear.
JSCIA1205ZZ
4. Install the gauge of the air leak tester [SST: KV99111400 ( —

)].
WARNING:

gear.
CAUTION:
The gauge is a precision instrument. Be careful not to drop JSCIA1206ZZ
it when handling it.
5. Install the service plug as per the following step.
ALAIA0089ZZ
DANGER:
insulated protective gear.
NOTE:
Because the service plug location is open, install the service plug for sealing the case.
6. Follow the procedure below to check the battery case pressure.
WARNING:
EVB-276
LI-ION BATTERY
a. Open the cock on the air leak tester.
CAUTION: A
Do not operate the pump before opening the cock on the air
leak tester. Doing so may damage the gauge. If the pump is
operated before the cock is opened, first disconnect the air
B
pump hose to release the pressure.
EVB
JSCIA0638ZZ
D
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.
E
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 F
gauge, the gauge may be damaged.
• Do not apply pressure of 2.0 kPa (0.020 bar, 0.0204 kg/cm2, 0.290 psi) or more to the battery case
or air leak tester. G
c. Close the cock and wait for 1 minute.
d. Check that the air leak tester reading remains at or above the limit value.
H
Repair limit 2
: 1.4 kPa (0.014 bar, 0.0142 kg/cm , 0.203 psi)
e. If the pressure is below the limit value, check for the locations of air leakage.
I
NOTE:
Check for air leakage from the sound of air escaping when pressure is applied.
ELECTRIC EQUIPOTENTIAL TEST J
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) .
K
P
JSCIA1209ZZ
WARNING:
EVB-277
LI-ION BATTERY

• Ground bolt connection condition
• Corrosion on ground bolt mounting surface
• Presence of paint, oil, dirt, or other substance on ground bolt mounting surface
EVB-278
< SERVICE DATA AND SPECIFICATIONS (SDS) [WITHOUT BATTERY COOLER]
SERVICE DATA AND SPECIFICATIONS (SDS) A

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. 263.3 (580.6)
E
JSCIA1204ZZ
External dimension “a” [mm (in)] 1102 (43.39) M

“b” [mm (in)] 824 (32.44)
“c” [mm (in)] 266 (10.47)
N
“d” [mm (in)] 1578 (62.13)
EVB-279
PRECAUTIONS
< PRECAUTION > [WITH BATTERY COOLER]
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
WARNING:
EVB-280
PRECAUTIONS
B
connectors.
WARNING: EVB
D
injury.
windshield.
G
PIIB3706J
I
J
NOTE:
SEF289H
WORK PROCEDURE
NOTE:
tion. O
NOTE: P
detected.
CAUTION:
EVB-281
PRECAUTIONS
NOTE:
the power switch.
NOTE:
NOTE:
EVB-282
A

CAUTION:
from damage. E
JMJIB0266ZZ
H
I
: Pawl
K
JMJIB0267ZZ

: Metal clip
M
JMJIB0268ZZ
O
EVB-283
:Vehicle front
JSCIA1194ZZ
ALAIA0088ZZ
DANGER:
WARNING:
battery side.
DANGER:

JSCIA1303ZZ
EVB-284
A
EVB
ALAIA0089ZZ
DANGER: D
E
WARNING: F
H
DANGER:
maintenance. J
WARNING:
K
CAUTION: M
blow gun.
NOTE:
EVB-285
WARNING:
EVB-286
workers. A
EVB
JSAIA1600GB P
DANGER:
EVB-287
maintenance.
WARNING:
CAUTION:
INSPECTION
WARNING:
Installation".
DANGER:

tective gear.

JSCIA1328ZZ

DANGER:

tective gear.
JSCIA1071ZZ
EVB-288
EVB
JSCIA1329ZZ
E
DANGER: F
G
JSCIA1195ZZ
K
CAUTION:
EVB-289
JSAIA3647ZZ

PTC elements heater
Electric compressor
Li-ion battery
COOLER
Service plug
COOLER
COOLER
CAUTION:
EVB-290
A
B
DAILY INSPECTION
JPCIA0061ZZ H


INSULATING TOOLS
L
CAUTION:
N
CAUTION: O
P
EVB-291
PREPARATION
< PREPARATION > [WITH BATTERY COOLER]
PREPARATION
PREPARATION
Tool name
Palette
(—)
JPCIA0239ZZ
Air leak checker

KV99111400
(—)
JSCIA0257ZZ

KV99111500
24 pieces/set
(—)
JPCIA0069ZZ

NOTE:
—
(J-50346-A)
JPCIA0070ZZ

(—)
JPCIA0156ZZ
EVB-292
PREPARATION

B
nents
material.
JMCIA0149ZZ D

E
ponents
tight] F
JPCIA0066ZZ

nents
material. H
JPCIA0011ZZ
I

ponents J
to electric line
K
JPCIA0167ZZ
L
ponents
Safety glasses
to electric line M
JPCIA0012ZZ

Insulated helmet O
nents
JPCIA0013ZZ P
EVB-293
PREPARATION

nents
JPCIA0019ZZ

nents
JPCIA0018ZZ
JPCIA0024ZZ
JPCIA0015ZZ
JSCIA0083ZZ

JPCIA0014ZZ
JPCIA0067ZZ
EVB-294
PREPARATION
A
B
EVB
JPCIA0068ZZ

stack
D
NOTE:
Carabineer [small]
• D: 8.0 mm (0.31 in)
• L: 74.0 mm (2.91 in) E
• S: 10.0 mm (0.39 in)
JPCIA0016ZZ
• W: 22.5 mm (0.89 in)
F
NOTE:
• D: 14.0 mm (0.55 in)
• L: 204.0 mm (8.03 in)
• S: 47.0 mm (1.85 in)
• W: 105.0 mm (4.13 in)
JPCIA0017ZZ
H

Belt slinger NOTE:
Length: 2.0 m (6.562 ft)
J
JPCIA0021ZZ

L
JPCIA0020ZZ

Lashing belt
stack
JPCIA0022ZZ
O
P
(Cut the adhesive)
JSCIA0640ZZ
EVB-295
PREPARATION

(Cut the adhesive)
NOTE:
JSCIA0641ZZ

Scraper
JSCIA0643ZZ
JSCIA0639ZZ

NOTE:
Metal bar
• D: φ 7 mm (0.28 in)
• L: 1 m (3.28 ft)
JSCIA0735ZZ
Tool name
Description
Tool number
Adhesive
KE561-32090
Dam rubber
KE390-00590
KE560-15090
—
EVB-296
COMPONENT PARTS
< SYSTEM DESCRIPTION > [WITH BATTERY COOLER]
COMPONENT PARTS
B
EVB
JSCIA1082ZZ
EVB-297
COMPONENT PARTS

: Vehicle front

JSCIA1084ZZ
: Vehicle front
EVB-298
COMPONENT PARTS
No. Component Function A

Li-ion battery cooling unit EVB-301, "Li-ion Battery Coolong Unit"
Expansion valve
B
Duct

EVB
ion battery controller, battery junction box, and service plug in addi- D
F
JSCIA1085ZZ
G
J
JSCIA1086ZZ

K
• The LBC is the core of battery control. Li-ion battery controller L
state of charge. LBC also calculates possible input/output values, M
meter indication values, and chargeable values, and send this data
N
JSCIA1128ZZ
O
Main Role of Li-ion Battery Controller
• State of charge
• Possible output value P
• Temperature
2. Optimization of Li-ion battery voltage
5. Detection of decrease in insulation resistance of high-voltage circuit
EVB-299
COMPONENT PARTS

• There are two kinds of modules, according to the location of posi-
Positive terminal : Red

Negative terminal : Black
JSCIA0703ZZ
MODULE INTERNAL CIRCUIT

parallel-connected cell pairs are connected in series.
NOTE:
the parallel circuit.
JPCIA0197GB
MODULE LAYOUT
JSCIA1087GB
NOTE:
CELL
EVB-300
COMPONENT PARTS
A
EVB
JSCIA0274ZZ
D
life.
• Light and thin structure increases flexibility in layout. E
Li-ion Battery Coolong Unit INFOID:0000000011103160

F
• Li-ion battery cooling unit is installed in the battery pack.
• Cooling unit has a built-in device for cooling purposes.
• The evaporator for cooling purposes receives refrigerant from the interior air conditioning system. G
J
JSCIA1088ZZ
: Front view : Rear view

K
EVAPORATOR ASSEMBLY
• The evaporator assembly is built in the Li-ion battery cooling unit.
L
JSCIA1090ZZ
O
• The expansion valve transforms high pressure liquid refrigerant to mist form low pressure liquid refrigerant P
by drawing function.
• The evaporator assembly cools the inside of Li-ion battery by using refrigerant supplied from the interior
refrigerant cycle.
• The refrigerant supply is controlled by A/C auto amp.
BLOWER MOTOR
EVB-301
COMPONENT PARTS
• The blower motor is built in the Li-ion battery cooling unit.
• During cooler operation, the blower motor rotates with 100% duty
ratio.
• After cooling, when the power switch is turned ON first time after
the completion of charging, the blower motor rotates with 40% duty
ratio to evaporate the flocculated water accumulated around the
evaporator.
JSCIA1130ZZ
DUCT
Duct is installed in the center of battery pack. Cold air sent from the
Li-ion battery cooling unit is supplied to each module through the
duct.
JSCIA1131ZZ
JSCIA1091ZZ


according to changes in temperature. The electrical resistance of
JPCIA0295GB
EVB-302
COMPONENT PARTS
A
pack.
• The battery junction box includes: B
battery.
rent immediately after power switch ON. EVB
relay provides DC current to each high voltage part. In addition, the
system main relay provides DC current to the Li-ion battery during D
JSCIA0506ZZ
• When an error occurs in the system, the system main relay is
cle control module). E

F
junction box and front module stack LH.
• This sensor measures charge/discharge current sent to Li-ion bat- G
(LBC).
according to charge/discharge current and sends the data to VCM. H
I
JSCIA1092ZZ

J
maintenance. K
pack. The plug can be removed when the leg-room mounted ser-
vice plug cover is removed. L
• Always use insulating protective equipment when removing and
installing service plug.
M
JSCIA0706ZZ

N
label in the original position. O
Li-ion Battery
P
EVB-303
COMPONENT PARTS
JSCIA1093ZZ
: Vehicle front

JSCIA0111ZZ
Service Plug
JSCIA1095ZZ
EVB-304
SYSTEM
SYSTEM
A
B
SYSTEM DIAGRAM
EVB
JSCIA1368GB K
Input Signal Item L

Output Signal Item

N
EVB-305
SYSTEM

VCM EV system CAN
Charge type signal
Li-ion battery cooler evaporator temperature signal
A/C auto amp. EV system CAN Li-ion battery cooling fan speed signal
Li-ion battery cooling request signal
DESCRIPTION
charge/charge line.
BATTERY PROTECTION
EVB-306
SYSTEM
Control item Control Operating condition A

tion Cell voltage exceeds the voltage judged as overvoltage and B
proaches the lower limit of the voltage capable of discharging. EVB
Gradual control of charging/discharging energy as Li-ion bat- D
control
Excessive temperature rise pro- capable of use.
E
more than the specified time.
HOW TO ADJUST CELL CAPACITY F

system starts, and the capacities are adjusted so that they are all at the target level. The voltage of each cell is
G
of all cells to be fully utilized.
JPCIA0094GB
L
INSULATION RESISTANCE LOSS DETECTION FUNCTION

M
nication.
EVB-307
SYSTEM
tance value.
JSCIA0815GB

LI-ION BATTERY COOLER CONTROL SYSTEM : System Description INFOID:0000000011103168
SYSTEM DIAGRAM
JSCIA1108GB

Input Signal Item
EVB-308
SYSTEM
Transmit unit Signal name A

VCM Keep SOC request signal
EV system CAN communication
HVAC Ambient sensor signal
B
Output Signal Item
Receive unit Signal name EVB

VCM EV system CAN communication Next start time signal
Li-ion battery cooling fan speed sig-
HVAC
nal
D
EV system CAN communication Li-ion battery cooler evaporator

HVAC
temperature signal
E
HVAC Li-ion battery cooling request signal
DESCRIPTION
To prevent heat generation in the battery resulted from charging current, the Li-ion battery cooler control sys- F
tem operates during quick charge and normal charge (200 V). While interior air-conditioner is operating, refrig-
erant is not supplied to the battery pack, and in this case, only the fan operates.
During Quick Charge G
OPERATING CONDITIONS
ON : When battery temperature is more than approximately 20°C (68°F)
H
OFF : When battery temperature is approximately 15°C (59°F) or less
During Normal Charge (200V)
OPERATING CONDITIONS I
ON : When battery temperature is more than approximately 25°C (77°F) and is
5°C (41°F) or more higher than ambient temperature
OFF When any of the following conditions is satisfied: J
- Battery temperature is approximately 20°C (68°F) or less.
- Battery temperature is lower than ambient temperature.
- Battery cooler continues operating for 5 hours or more. K
DESCRIPTION
• When temperature rises in the battery pack, LBC judges that temperature is high in the battery pack, accord-
ing to a signal from the battery temperature sensor. L
• LBC transmits a fan duty request signal to the blow motor to rotate it.
• When the blow motor rotates, LBC receives a fan RPM signal from the blow motor.
• LBC transmits an Li-ion Battery cooling request signal to A/C auto amp. to request for supplying a part of M
refrigerant used for interior air conditioning to the evaporator of Li-ion battery. LBC transmits Li-ion battery
evaporator temperature and Li-ion Battery cooling request signal to A/C auto amp. A/C auto amp. then
adjusts A/C compressor revolutions according to the signal values.
N
• Since flocculated water accumulates in the evaporator of Li-ion battery heater & cooling unit when cooling
the battery, the blower motor is activated at a speed of 40% for evaporating the accumulated water at the
next power switch ON after the completion of charging. The blower motor operates until the total power
switch ON time reaches 25 minutes. If the power switch is turned OFF before the time reaches 25 minutes, O
the blower motor starts again when the power switch is turned ON and operates until the total power switch
ON time reaches 25 minutes.
• When temperature increases in the battery pack outside the time frame of timer charge set time, VCM trans-
P
mits a Keep SOC Request signal to LBC via EV system CAN communication and activates only Li-ion bat-
tery cooler without charging Li-Ion battery.
• During the timer charge operation, Li-ion battery is charged, and in addition, when temperature rises in the
battery pack, Li-ion battery cooler is activated according to operating conditions.
EVB-309
SYSTEM
JSCIA1294GB
EVB-310
SYSTEM
EVB
JSCIA1295GB
EVB-311
SYSTEM
JSCIA1292GB
Harness Layout
EVB-312
SYSTEM
EVB
L
JSCIA1296GB
: Vehicle front M
N
O
FAIL-SAFE PATTERN
P
• Pattern E: Li-ion battery cooler stops

EVB-313
SYSTEM
EVB-314
HANDLING PRECAUTION
HANDLING PRECAUTION
A
• To improve the Li-ion battery life, never perform quick charge heavily. B
EVB
D
4. Lay an anti-static rubber sheet underneath the battery. E
F
11. Prevent other objects from falling onto the battery. G
EVB-315
APPLICATION ITEM
Item Function
Data Monitor Input/Output data in LBC can be read.
Active test Activates the actuator via LBC.
Work Support
*: The following diagnosis information is cleared when the VCM memory is erased.
ECU IDENTIFICATION
SELF-DIAGNOSTIC RESULTS
How to Erase DTC
3. Touch “ERASE”. (DTC in LBC will be erased.)

BATT ELECTRIC CURRENT A Displays the Li-ion battery current value
IR SEN SHORT PULSE mV
OPEN /
CLOSE
FAN DUTY % Displays drive duty ratio of blower motor
FAN SPEED rpm Displays revolutions of blower motor
EVAPORATOR TEMPERA-
°C Displays evaporator temperature
TURE
EVB-316
A
BATTERY COOLER AVAIL-
On / Off Displays the ready condition of Li-ion battery cooler
ABILITY STATE
BATTERY COOLING RE-
On / Off Displays the ready request status of Li-ion battery cooler B
QUEST
DATA MONITOR
NOTE: EVB
×:Applicable
Monitor Item Selection D

NALS AL1 AL2 AL3 AL4 E
BATT ELECTRIC CUR-
RENT
12V BATTERY VOLT- F
AGE
Displays the maximum to minimum difference of volt-
IR SEN SHORT PULSE mV × × age magnitude of the on-board isolation resistance G
monitoring system
TERLOCK CLOSE H
TOTAL BATTERY
VOLTAGE I
MAXIMUM CELL VOLT-
AGE
MINIMUM CELL VOLT-
J
AGE
°C × ×
K
°C × ×
BATTERY TEMPERA- Displays the temperature calculated with a signal volt- L
°C × ×
°C × ×
M
°C × ×
N
signal frequency. O
PTC HEATER RELAY
STAT SIG
PTC HEAT RELAY P
CONT SIG
ACTIVE TEST
EVB-317
Operation
Test item Operation status
item
On Blower motor is activated*
BATTERY HEATER
Off Blower motor stops
*: Blower motor stops 60 seconds after the activation.
WORK SUPPORT

DATA replaced.
DATA replaced.
CLEAR BATTERY GRADUAL CA- Erases Li-ion battery capacity related information stored in
PACITY LOSS DATA LBC
CLEAR BATT CHARGE/DIS- Erases Li-ion battery charge/discharge related information
CHARGE INFORMATION DATA stored in LBC
TION cells.
EVB-318
EV BATTERY SYSTEM
< ECU DIAGNOSIS INFORMATION > [WITH BATTERY COOLER]

EV BATTERY SYSTEM
B

NOTE: EVB
D
E

L
EVB-319
EV BATTERY SYSTEM
EVB-320
EV BATTERY SYSTEM
A
D
H
K
O
EVB-321
EV BATTERY SYSTEM
EVB-322
EV BATTERY SYSTEM
A
D
H
K
M
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
(front side)]
20°C - 30°C (68°F - 86°F)
cle)
EVB-323
EV BATTERY SYSTEM
20°C - 30°C (68°F - 86°F)
side)]
20°C - 30°C (68°F - 86°F)
TURE cle)
around evaporator]
100%
ating
40%
the Li-ion battery.
600 - 8,000 rpm
ating
FAN SPEED READY
rpm

READY

READY
FAIL-SAFE PATTERN
FAIL-SAFE LIST
Pattern
A B C D E
EVB-324
EV BATTERY SYSTEM
Pattern
A B C D E
P303A CELL CONT ASIC10 × B
P303B CELL CONT ASIC11 ×
P303D CELL CONT ASIC13 × EVB
P303E CELL CONT ASIC14 ×
D
F
H
P304C CELL CONT ASIC4 VOLT × I
J

K
M
P3059 CELL CONT ASIC17 VOLT × N
O
P305E CELL CONT ASIC22 VOLT × P
P3062 BYPASS SW ×
EVB-325
EV BATTERY SYSTEM
Pattern
A B C D E
EVB-326
EV BATTERY SYSTEM
Pattern
A B C D E
P3309 CELL OVER VOLTAGE MODULE8 × B
P330C CELL OVER VOLTAGE MODULE11 × EVB
D
F
H
P331B CELL OVER VOLTAGE MODULE26 × I
J

K
M
O
P332D CELL OVER VOLTAGE MODULE44 × P
EVB-327
EV BATTERY SYSTEM
Pattern
A B C D E
EVB-328
EV BATTERY SYSTEM
Pattern
A B C D E
P33D4 BATT GRADUAL CAPA LOSS DIAG × EVB
D
P33DB TEMPERATURE SENSOR No fail-safe E
P33DD TEMPERATURE SENSOR No fail-safe
F
P33E2 BATT PACK OVER TEMP × G
H
P33ED BATTERY PARALLEL DIAGNOSIS ×
P33F2 EVAPORATOR TEMP SENSOR × I
P33F5 BATTERY FAN ×
J

K
EV system
lamp
L
P0A0D HV SYSTEM INTERLOCK ERROR × 1 EVB-358
P3030 CELL CONT LIN × 1 EVB-361 M
P3033 CELL CONT ASIC3 × 1 EVB-362 N
O
P3038 CELL CONT ASIC8 × 1 EVB-362 P
P303B CELL CONT ASIC11 × 1 EVB-362
EVB-329
EV BATTERY SYSTEM
EV system
lamp
EVB-330
EV BATTERY SYSTEM
EV system
lamp
P3091 CELL CONT ASIC7 OPEN × 1 EVB-373 B
EVB
E
P309B CELL CONT ASIC17 OPEN × 1 EVB-376 F
G

P30A0 CELL CONT ASIC22 OPEN × 1 EVB-376 H
P30E0 DLC DIAGNOSIS VCM × 1 EVB-380 I
J
P30E4 DLC DIAGNOSIS PD MODULE — 1 EVB-383
P318E COMMUNICATION ERROR × 1 EVB-385 K
L
P319C COMMUNICATION ERROR — 1 EVB-390 M
N
P3307 CELL OVER VOLTAGE MODULE6 × 1 EVB-393 P
EVB-331
EV BATTERY SYSTEM
EV system
lamp
EVB-332
EV BATTERY SYSTEM
EV system
lamp
P337C CELL OVER DISCHARGE MODULE8 × 1 EVB-411 B
EVB
P3381 CELL OVER DISCHARGE MODULE13 × 1 EVB-415 D
E
G

P338B CELL OVER DISCHARGE MODULE23 × 1 EVB-415 H
P338E CELL OVER DISCHARGE MODULE26 × 1 EVB-419 I
J
L
P3398 CELL OVER DISCHARGE MODULE36 × 1 EVB-419 M
N
P339D CELL OVER DISCHARGE MODULE41 × 1 EVB-424 O
P33A0 CELL OVER DISCHARGE MODULE44 × 1 EVB-424 P
EVB-333
EV BATTERY SYSTEM
EV system
lamp
P33F2 EVAPORATOR TEMP SENSOR × 1 EVB-451
P33F5 BATTERY FAN × 1 EVB-453
EVB-334
VCM
< WIRING DIAGRAM > [WITH BATTERY COOLER]
WIRING DIAGRAM A
VCM
B
EVB
JRCWC0704GB
EVB-335
VCM
JRCWC0705GB
EVB-336
VCM
EVB
JRCWC0706GB
EVB-337
VCM
JRCWC0707GB
EVB-338
VCM
EVB
JRCWC0708GB
EVB-339
VCM
JRCWC0709GB
EVB-340
VCM
EVB
JRCWC0710GB
EVB-341
VCM
JRCWC0711GB
EVB-342
VCM
EVB
JRCWC0712GB
EVB-343
VCM
JRCWC0713GB
EVB-344
VCM
EVB
JRCWC0714GB
EVB-345
VCM
JRCWC0715GB
EVB-346
< BASIC INSPECTION > [WITH BATTERY COOLER]
BASIC INSPECTION A
B
DETAILED FLOW
D
>> GO TO 2.
2.CHECK DTC E
1. Check DTC.
- Erase DTC.
H
J
K
>> GO TO 5.
>> GO TO 6. N
again. O
NOTE:
this check.
MATION PROCEDURE.
Is DTC detected?
YES >> GO TO 7.
EVB-347

YES >> GO TO 7.
YES >> GO TO 8.
ment.
>> GO TO 9.
9.FINAL CHECK
DESCRIPTION
tomer complaint.
NOTE:
JSCIA0412GB
WORKSHEET SAMPLE
Question Sheet
Incident Date VIN
Customer name
MR/MS
EVB-348
Question Sheet
A
lamp is on
B
Onomatopoeia
D

Weather
Not affected
conditions
Temp. [Approx. °C
( °F)]
road
Other
I
L
Other
Other N
EVB-349

With CONSULT
1. Power switch ON.
>> WORK END
EVB-350
A
EVB

With CONSULT
1. Power switch ON.
E
F
>> WORK END
EVB-351
NOTE:

With CONSULT
1. Power switch ON.
>> WORK END
EVB-352
A
NOTE: EVB
D
With CONSULT
E
1. Power switch ON.
>> WORK END G
EVB-353
LER
LBC to the new LBC.

With CONSULT
>> GO TO 2.
Installation".
>> GO TO 3.
With CONSULT
>> GO TO 4.
>> END
EVB-354
A
EVB
E
>> GO TO 2.
F
>> GO TO 3. G


With CONSULT J
>> WORK END

M
EVB-355
NOTE:
With CONSULT
1. Power switch ON.

>> GO TO 2.
CAUTION:

CAUTION:
>> GO TO 4.
CAUTION:


EVB-356
>> GO TO 6.
B
With CONSULT
range. D

E
>> WORK END

F
EVB-357
< DTC/CIRCUIT DIAGNOSIS > [WITH BATTERY COOLER]
DTC DETECTION LOGIC

P0A0D
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P0A0D detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-358
>> GO TO 2. A
EVB
LBC
— Continuity
Connector Terminal
YES >> GO TO 3.
LBC G
— Continuity
Connector Terminal
H
YES >> GO TO 4.
I
and Installation".
NO >> Replace service plug. K

M
JPCIA0347ZZ
EVB-359
DTC DETECTION LOGIC

P0A1F ULE
CPU.
POSSIBLE CAUSES
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
Is P0A1F detected?
EVB-360
A

CELL CONT LIN
ler.
work)
D
POSSIBLE CAUSES
• Module E
FAIL-SAFE
• Charge stop

With CONSULT H
3. Check DTC. I
Is P3030 detected?
K
With CONSULT
Is P3030 detected?
O
and Installation".
P
EVB-361
DTC DETECTION LOGIC

CELL CONT ASIC1
grated circuit1)
CELL CONT ASIC2
grated circuit2)
CELL CONT ASIC3
grated circuit3)
CELL CONT ASIC4
grated circuit4)
CELL CONT ASIC5
grated circuit5)
CELL CONT ASIC6
grated circuit7)
CELL CONT ASIC8
grated circuit8)
CELL CONT ASIC9
grated circuit9)
CELL CONT ASIC10
grated circuit10)
CELL CONT ASIC11
grated circuit11)
CELL CONT ASIC12
grated circuit12)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
With CONSULT
EVB-362
3. Check DTC.
With CONSULT
Is P3030 detected?
and Installation".
EVB-363
DTC DETECTION LOGIC

CELL CONT ASIC13
grated circuit13)
CELL CONT ASIC14
grated circuit14)
CELL CONT ASIC15
grated circuit15)
CELL CONT ASIC16
grated circuit16)
CELL CONT ASIC17
grated circuit17)
CELL CONT ASIC18
grated circuit19)
CELL CONT ASIC20
grated circuit20)
CELL CONT ASIC21
grated circuit21)
CELL CONT ASIC22
grated circuit22)
CELL CONT ASIC23
grated circuit23)
CELL CONT ASIC24
grated circuit24)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
With CONSULT
EVB-364
3. Check DTC.
With CONSULT
Is P3030 detected?
and Installation".
EVB-365
DTC DETECTION LOGIC

circuit1 voltage)
circuit2 voltage)
circuit3 voltage)
circuit4 voltage)
circuit5 voltage)
circuit6 voltage)
circuit7 voltage)
circuit8 voltage)
circuit9 voltage)
circuit10 voltage)
circuit11 voltage)
circuit12 voltage)
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge stop
With CONSULT
EVB-366
3. Check DTC.
EVB

D
With CONSULT
2. Check DTC.
E
J
EVB-367
DTC DETECTION LOGIC

circuit13 voltage)
circuit14 voltage)
circuit15 voltage)
circuit16 voltage)
circuit17 voltage)
circuit18 voltage)
circuit19 voltage)
circuit20 voltage)
circuit21 voltage)
circuit22 voltage)
circuit23 voltage)
circuit24 voltage)
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge stop
With CONSULT
EVB-368
3. Check DTC.
EVB

D
With CONSULT
2. Check DTC.
E
J
EVB-369
DTC DETECTION LOGIC

P3061
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P3061 detected?
EVB-370
P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
A

BYPASS SW
(Bypass switch)
POSSIBLE CAUSES D
• Module
FAIL-SAFE
F
DTC DETECTION LOGIC
G
With CONSULT
3. Check DTC. H
Is P3062 detected?
J
With CONSULT K
M
EVB-371
DTC DETECTION LOGIC

ler.
tegrated circuit)
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P3064 detected?
EVB-372
A

circuit1 open)
D
circuit2 open)
E
circuit3 open)
circuit4 open)
circuit5 open)
circuit7 open)
circuit8 open)
circuit9 open)
circuit10 open) L
circuit11 open) M
circuit12 open) N
POSSIBLE CAUSES
FAIL-SAFE
P
• Charge stop
DTC DETECTION LOGIC
With CONSULT
EVB-373
3. Check DTC.
Is P308B-P3096 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
OVER DISCHARGE related codes) is detected simultaneously with “P308B”-“P3096”.
Is P3049-P3060 or P3375-P33A4 detected?
YES-2 >> “P3375”-“P33A4” are detected simultaneously.
“P3381”-“P338C”. Refer to EVB-416, "Diagnosis Procedure".
“P338D”-“P3398”. Refer to EVB-420, "Diagnosis Procedure"
• When “P3399”-“P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399”-“P33A4”. Refer to EVB-425, "Diagnosis Procedure".
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
EVB-374
>> GO TO 3.

B
YES >> GO TO 4.
EVB
DTC.

DTC Continuity
1 25 50
2 10 51
3 26 52
4 11 53 G
5 27 54
6 12 55
H
7 28 56
8 13 57
9 29 58 I
10 14 59
11 30 60
12 15 61
13 33 62
14 49 63
K
15 34 77
16 50 78
17 35 80 L
18 51 81
19 36 82
20 52 83
21 37 84
22 53 85 N
23 38 86
24 54 87
O
and Installation".
EVB-375
DTC DETECTION LOGIC

circuit13 open)
circuit14 open)
circuit15 open)
circuit16 open)
circuit17 open)
circuit19 open)
circuit20 open)
circuit21 open)
circuit22 open)
circuit23 open)
circuit24 open)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
DTC DETECTION LOGIC
With CONSULT
EVB-376
3. Check DTC. A
EVB
DANGER:
maintenance.
E
WARNING:
CAUTION:
With CONSULT J
NO >> GO TO 2.
2.PRECONDITIONING P
WARNING:
Installation".
EVB-377
>> GO TO 3.
YES >> GO TO 4.
detected DTC.
JSCIA1223ZZ

DTC Continuity
25 40 110
26 56 111
EVB-378

DTC Continuity A
27 112
P3098 LB14 Existed
28 113 B
29 114
P3099 LB14 Existed
30 115
31 116 EVB
P309A LB14 Existed
32 117
33 118
34 119
35 120
P309C LB14 Existed
37 bar 122
P309D LB14 Existed
38 123
F
39 124
P309E LB14 Existed
40 125
41 127 G
P309F LB14 Existed
42 128
43 137
44 138
45 140
P30A1 LB15 Existed
46 141 I
47 16 142
48 32 143
J
and Installation".
EVB-379
DTC DETECTION LOGIC

DLC DIAGNOSIS VCM
seconds or more.
control module)
POSSIBLE CAUSES
• VCM
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P30E0 detected?

With CONSULT
Is P30E0 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-380
A

D
POSSIBLE CAUSES
FAIL-SAFE F
None
G
With CONSULT
3. Check DTC.
With CONSULT
Is P30E2 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
EVB-381
DTC DETECTION LOGIC

DLC DIAGNOSIS MC
controller)
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P30E3 detected?

With CONSULT
Is P30E3 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-382
A

module)
D
POSSIBLE CAUSES
FAIL-SAFE
None F
With CONSULT
3. Check DTC.
Is P30E4 detected?
J

K
With CONSULT
L
Is P30E4 detected?
NO >> GO TO 2.
M
With CONSULT
Is U1000 detected?
and Installation".
P
EVB-383
DTC DETECTION LOGIC

COMMUNICATION ERROR
POSSIBLE CAUSES
• VCM
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P318D detected?
EVB-384
A

NOTE:

D
COMMUNICATION ERROR
POSSIBLE CAUSES E
• VCM
F
FAIL-SAFE
With CONSULT H
I
7. Check DTC.
Is P318E detected?
L

M
With CONSULT
N
Is P318E detected?
NO >> GO TO 2.
O
With CONSULT
Is U1000 detected?
and Installation".
EVB-385
DTC DETECTION LOGIC

NOTE:

P3191
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
7. Check DTC.
Is P3191 detected?

With CONSULT
Is P3191 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-386
A

NOTE:

D
P3196
POSSIBLE CAUSES E
F
FAIL-SAFE
None
With CONSULT H
I
7. Check DTC.
Is P3196 detected?
L

M
With CONSULT
N
Is P3196 detected?
NO >> GO TO 2.
O
With CONSULT
Is U1000 detected?
and Installation".
EVB-387
DTC DETECTION LOGIC

COMMUNICATION ERROR
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P3198 detected?

With CONSULT
Is P3198 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-388
A

COMMUNICATION ERROR
POSSIBLE CAUSES D
• VCM
E
FAIL-SAFE
With CONSULT G
3. Check DTC.
H
Is P3199 detected?
J
EVB-389
DTC DETECTION LOGIC

COMMUNICATION ERROR
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P319C detected?
EVB-390
P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
A

P31A4
POSSIBLE CAUSES D
VCM
FAIL-SAFE E
With CONSULT
3. Check DTC.
Is P31A4 detected?
H
I
J
EVB-391
DTC DETECTION LOGIC

P31A7
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P31A7 detected?
EVB-392
A

P3302
P3303
P3304
E
P3305
P3306
P3307
G
P3308
P3309 H
P330A
I
P330B
P330C
J
P330D
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-393
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
1 33
17 34
17 34
2 35
2 35
18 36
EVB-394

DTC Continuity A
18 36
3 37
3 37
19 38
19 38
D
4 39
4 39 E
20 40
F
20 40
5 42 G
5 42
H
21 43
21 43
6 44
6 44
J
22 45
22 45
K
7 46
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-395
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-396
A

P330E
P330F
P3310
E
P3311
P3312
P3313
G
P3314
P3315 H
P3316
I
P3317
P3318
J
P3319
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-397
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
LB8 7 46
LB7
57 47
57 47
42 48
42 LB12 48
P3310 15 LB7 34 77 Existed
LB13
58 65
EVB-398

DTC Continuity A
58 65
P3311 16 LB7 50 LB13 78 Existed B
43 66
43 66
59 69
59 69
D
P3313 18 LB7 51 LB13 81 Existed
44 70
44 70 E
P3314 19 LB7 36 LB13 82 Existed
60 71
F
60 71
P3315 20 LB7 52 LB13 83 Existed
45 72 G
45 72
P3316 21 LB7 37 LB13 84 Existed
H
61 73
61 73
P3317 22 LB7 53 LB13 85 Existed I
46 74
46 74
P3318 23 LB7 38 LB13 86 Existed
J
62 75
62 75
K
P3319 24 LB7 54 LB13 87 Existed
47 76
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-399
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-400
A

P331A
P331B
P331C
E
P331D
P331E
P331F
G
P3320
P3321 H
P3322
I
P3323
P3324
J
P3325
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-401
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT
EVB-402
EVB
JSCIA1228GB

DTC Continuity
55 89
48 90 L
48 90
M
64 91
EVB-403

DTC Continuity
LB7 64 91
92
92
93
93
94
94
95
95
96
Bus bar 96
97
97
99
99
100
100
101
101
102
YES >> GO TO 4.
and Installation".
EVB-404
A
EVB
G
JSCIA0338ZZ
H
I
Terminals
Voltage
(+) (-)
(Approx.) J
Module
EVB-405
DTC DETECTION LOGIC

P3326
P3327
P3328
P3329
P332A
P332B
P332C
P332D
P332E
P332F
P3330
P3331
POSSIBLE CAUSES
• Module
• Bus bar
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
EVB-406
A
DANGER:
maintenance.
EVB
WARNING:
CAUTION:
With CONSULT
H
I
NO >> GO TO 2.
2.PRECONDITIONING J
WARNING:
Installation".
L
>> GO TO 3.
M
With CONSULT
EVB-407
JSCIA1228GB
EVB-408

DTC Continuity
102
B
103
103 EVB
104
D
104
105 E
105
106
F
106
G
107
Bus bar 107
108
LB14 108
I
LB15
130
130 J
131
K
131
132 L
132
M
133
133
P3330 47 16 LB15 142 Existed N
LB8
8 134
8 134
P3331 48 LB8 32 LB15 143 Existed O
24 135
YES >> GO TO 4.
EVB-409
and Installation".

JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-410
A

P3375
P3376
P3377
E
P3378
P3379
P337A
G
P337B
P337C H
P337D
I
P337E
P337F
J
P3380
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop

With CONSULT
3. Check DTC.
EVB-411
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
1 33
17 34
17 34
2 35
2 35
18 36
EVB-412

DTC Continuity A
18 36
3 37
3 37
19 38
19 38
D
4 39
4 39 E
20 40
F
20 40
5 42 G
5 42
H
21 43
21 43
6 44
6 44
J
22 45
22 45
K
P3380 12 LB8 15 LB12 61 Existed
7 46
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-413
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-414
A

P3381
P3382
P3383
E
P3384
P3385
P3386
G
P3387
P3388 H
P3389
I
P338A
P338B
J
P338C
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-415
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
LB8 7 46
P3381 13 33 LB12 62 Existed
LB7
57 47
57 47
P3382 14 LB7 49 LB12 63 Existed
42 48
42 LB12 48
P3383 15 LB7 34 77 Existed
LB13
58 65
EVB-416

DTC Continuity A
58 65
P3384 16 LB7 50 LB13 78 Existed B
43 66
43 66
59 69
59 69
D
P3386 18 LB7 51 LB13 81 Existed
44 70
44 70 E
P3387 19 LB7 36 LB13 82 Existed
60 71
F
60 71
P3388 20 LB7 52 LB13 83 Existed
45 72 G
45 72
P3389 21 LB7 37 LB13 84 Existed
H
61 73
61 73
46 74
46 74
J
62 75
62 75
K
47 76
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-417
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-418
A

P338D
P338E
P338F
E
P3390
P3391
P3392
G
P3393
P3394 H
P3395
I
P3396
P3397
J
P3398
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-419
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT
EVB-420
EVB
JSCIA1228GB

DTC Continuity
55 89
48 90 L
48 90
M
64 91
EVB-421

DTC Continuity
LB7 64 91
92
92
93
93
94
94
95
95
96
Bus bar 96
97
97
99
99
100
100
101
101
102
YES >> GO TO 4.
and Installation".
EVB-422
A
EVB
G
JSCIA0338ZZ
H
I
Terminals
Voltage
(+) (-)
(Approx.) J
Module
EVB-423
DTC DETECTION LOGIC

P3399
P339A
P339B
P339C
P339D
P339E
P339F
P33A0
P33A1
P33A2
P33A3
P33A4
POSSIBLE CAUSES
• Module
• Bus bar
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
EVB-424
A
DANGER:
maintenance.
EVB
WARNING:
CAUTION:
With CONSULT
H
I
NO >> GO TO 2.
2.PRECONDITIONING J
WARNING:
Installation".
L
>> GO TO 3.
M
With CONSULT
EVB-425
JSCIA1228GB
EVB-426

DTC Continuity
102
B
103
103 EVB
104
D
104
105 E
105
106
F
106
G
107
Bus bar 107
108
LB14 108
I
LB15
130
130 J
131
K
131
132 L
132
M
133
133
LB8
8 134
8 134
24 135
YES >> GO TO 4.
EVB-427
and Installation".

JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-428
A

P33D4
POSSIBLE CAUSES D
Li-ion battery
FAIL-SAFE
E
With CONSULT
3. Check DTC.
Is P33D4 detected?
H
I
J
EVB-429
DTC DETECTION LOGIC

P33D5
POSSIBLE CAUSES
• Current sensor
FAIL-SAFE
• Charge stop
With CONSULT
3. Check DTC.
Is P33D5 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
EVB-430
NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
YES >> GO TO 4. F

Continuity
S 10
I
LB5 V LB10 9 Exited
G 15
YES >> GO TO 5.
L
S G M
V G
N
YES >> GO TO 6.


EVB-431
and Installation".
EVB-432
A

CURRENT SENSOR
(Current sensor)
POSSIBLE CAUSES D
FAIL-SAFE E
• Charge stop
F
G
With CONSULT
3. Check DTC. H
Is P33D6 detected?
J
DANGER:
maintenance. L
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-433
>> GO TO 2.

Resistance value
Connector Terminal
10 9
9 15
and Installation".
NO >> GO TO 3.
RENT SENSOR)

Continuity
10 S
15 G
EVB-434
A

POSSIBLE CAUSES E
FAIL-SAFE
None
G
With CONSULT H
3. Check DTC. I
K
DANGER:
maintenance.
M
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
EVB-435
Installation".
>> GO TO 2.
2.CHECK HARNESS
YES >> GO TO 3.
YES >> GO TO 4.
Front module stuck
Battery tem-
sor
LH center LB9 1
Ground No existed
LH rear LB9 3
Rear module stuck
Li-ion battery
Battery tem-
controller
harness con-
sor
nector
Rear center LB11 25
Ground No existed
Rear LH LB11 27
and Installation".

STACK).
sensor terminals.
EVB-436
Front module stuck
Battery tem- A
perature
sensor ter-
minals
B
LH rear 3 and 4
40 (104) Approx. 2.3 EVB
Rear module stuck
Li-ion bat-
tery control-
D
connector
terminals E
Rear LH 27 and 31
40 (104) Approx. 2.3 F
G
H
EVB-437
DTC DETECTION LOGIC

P33DF
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P33DF detected?
EVB-438
A

P33E0 SENSOR
low.
POSSIBLE CAUSES D
FAIL-SAFE E
With CONSULT
3. Check DTC.
Is P33E0 detected?
H
I
J
EVB-439
DTC DETECTION LOGIC

P33E1 SENSOR
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P33E1 detected?
ponent Inspection".
EVB-440
A

D
POSSIBLE CAUSES
E
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
Is P33E2 detected?
J

K
With CONSULT
L
dure".
NO >> GO TO 2. M

With CONSULT N

EVB-441
DTC DETECTION LOGIC

POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-442
>> GO TO 2. A

STACK). E
sensor terminals.
Battery tem-
perature
sensor ter- G
minals
LH rear 3 and 4
40 (104) Approx. 2.3
Rear module stuck

I
Li-ion bat-
tery control-
connector J
terminals
Rear LH 27 and 31
40 (104) Approx. 2.3
M
EVB-443
DTC DETECTION LOGIC

P33E6
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge limit
With CONSULT
3. Check DTC.
Is P33E6 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
EVB-444
NO >> GO TO 2.
B
With CONSULT
of cells).
D

I
With CONSULT
YES >> GO TO 5.
NO >> GO TO 4. K
With CONSULT L
M
O
NOTE:
P
EVB-445

ing segments of Li-
Time to 2 segments
charge gauge
6 Approx. 90 minute
5 Approx. 70 minute
4 Approx. 40 minute
3 Approx. 20 minute
>> GO TO 5.
With CONSULT
STACK).
6.PRECONDITIONING
WARNING:
>> GO TO 7.
YES >> GO TO 8.
YES >> GO TO 9
EVB-446
DANGER:
NO >> Replace Li-ion battery controller. Refer to EVB-501, "BATTERY PACK UPPER CASE : Removal EVB
and Installation".
TOR D
Resistance val-
Terminal
ue F
Approx. 0 Ω
YES >> GO TO 11
P
JSCIA1229GB
EVB-447
Resistance val-
Terminal
ue
Module harness con-
nector
at step 5.
JSCIA1228GB
Resistance val-
Terminal
ue
EVB-448
A

POSSIBLE CAUSE D
Module
FAIL-SAFE E
• Charge limit
F
G
NOTE:
Is the lighting status 1 Segment or none? H
YES >> GO TO 3.
NO >> GO TO 2.
I
2. Set the vehicle, according to the following conditions. J

A/C fan speed : Maximum speed K
L
M
>> GO TO 3.
3.CHARGE OF LI-ION BATTERY N
O
>> GO TO 4.
4.PERFORM DTC CONFIRMATION PROCEDURE P
With CONSULT
3. Check DTC.
Is P33ED detected?
EVB-449
1.CHECK DATA MONITOR OR FREEZE FRAME DATA (FFD)

With CONSULT
1. Select “DATA MONITOR” or “FFD”.
YES >> Replace corresponding Module. Refer to EVB-530, "FRONT MODULE STACK : Removal and
NO >> GO TO 2.
2.DTC CONFIRMATION PROCEDURE OPERATION
tion".
>> Replace corresponding Module. Refer to EVB-530, "FRONT MODULE STACK : Removal and
EVB-450
P33F2 EVAPORATOR TEMP SENSOR
A

EVAPORATOR TEMP SENSOR
P33F2 Evaporator temperature sensor signal voltage is too high or too low.
(Evaporator temperature sensor)
POSSIBLE CAUSE D
• Evaporator temperature sensor
FAIL-SAFE
Li-ion battery cooler stops
F
G
With CONSULT
3. Check DTC. H
J
DANGER:
maintenance. L
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-451
>> GO TO 2.
2.CHECK HARNESS
YES >> GO TO 3.
3.CHECK EVAPORATOR TEMPERATURE SENSOR
YES >> GO TO 4.
NO >> Replace Li-ion battery cooling unit.
4.CHECK HARNESS BETWEEN EVAPORATOR TEMPERATURE SENSOR AND GROUND
1. Disconnect Li-ion battery cooling unit harness connector.
2. Check continuity between Li-ion battery cooling unit harness connector and ground.
Li-ion battery cooling unit

Continuity
Connector Terminal Ground
LB16 12 No existed
and Installation".

1. Remove Li-ion battery cooling unit harness connector.
2. Check resistance between Li-ion battery cooling unit terminals.
Terminals Condition Resistance (kΩ)

10 (50) Approx. 4.0
11 and 12 Temperature °C (°F) 25 (77) Approx. 2.2
40 (104) Approx. 1.3
NO >> Replace Li-ion battery cooling unit. Refer to EVB-522, "LI-ION BATTERY COOLING UNIT :
EVB-452
P33F5 BATTERY FAN
P33F5 BATTERY FAN
A
Trouble diagnosis
DTC Detecting condition
(Trouble diagnosis contents) EVB
• Li-ion battery cooling fan speed signal value is the specified value or more for
BATTERY FAN a certain period of time when blower motor is OFF
P33F5
(Battery fan) • Li-ion battery cooling fan speed signal value is the specified value or less for a
certain period of time when blower motor is ON D
POSSIBLE CAUSES
• Li-ion battery cooling unit E
FAIL-SAFE F
G
1.CHECK BLOWER MOTOR FUNCTION
WITH CONSULT
1. Turn power switch ON and wait at least 10 seconds. H
2. Record DTC and Freeze frame data.
3. Erase DTC.
4. Perform “BATTERY HEATER” with the “ACTIVE TEST” mode and wait at least 30 seconds.
5. Select “Self Diagnostic Result” mode of “HV BAT”. I
6. Check DTC.
Is P33F5 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 before beginning work on the high voltage system. O
lating sheet except when using them. P
CAUTION:
1.CHECK BLOWER MOTOR OPERATION
WITH CONSULT
EVB-453
P33F5 BATTERY FAN
2. Perform “BATTERY HEATER” with the “ACTIVE TEST” mode.
Is the blower motor activated?
and Installation".
NO >> GO TO 2.
2.CHECK FUSE
2. Pull out 10 A fuse (No.84) and check that the fuse is not fusing.
YES >> GO TO 3.
3.CHECK BLOWER MOTOR INPUT SIGNAL CIRCUIT-1
Check voltage between Li-ion battery harness connector terminal.
Li-ion battery
Terminal Voltage
Connector
(+) (−)
19 20
Battery volt-
LB1 24 22
age
33 36
YES >> GO TO 4.
NO >> GO TO 7.
4.PRECONDITIONING
WARNING:
1. Disconnect high voltage circuit. Refer to EVB-283, "How to Disconnect High Voltage".
2. Check voltage in high voltage circuit. Refer to EVB-287, "Check Voltage in High Voltage Circuit".
>> GO TO 5.
5.CHECK BLOWER MOTOR INPUT SIGNAL CIRCUIT-2
3. Check continuity between Li-ion battery harness connector and Li-ion battery cooling unit harness con-
nector.
Li-ion battery Li-ion battery cooling unit

Continuity
19 7
LB1 24 LB16 10 Existed
33 16
YES >> GO TO 6.
6.CHECK BLOWER MOTOR GROUND CIRCUIT
EVB-454
P33F5 BATTERY FAN
2. Check continuity between Li-ion battery harness connector and Li-ion battery cooling unit harness con-
nector. A
Li-ion battery cooling unit Li-ion battery

Continuity
Connector Terminal Connector Terminal B
13 20
EVB
22 36
YES >> Replace Li-ion battery cooling unit. Refer to EVB-522, "LI-ION BATTERY COOLING UNIT : D
7.CHECK LI-ION BATTERY POWER SUPPLY CIRCUIT E
3. Check voltage between Li-ion battery harness connector and ground. F
(+)
(−) Voltage G
Li-ion battery
Connector Terminal
19 H
Ground Battery voltage
LB1 24
33
I
YES >> GO TO 8.
J
8.CHECK LI-ION BATTERY GROUND CIRCUIT
1. Check continuity between Li-ion battery harness connector and ground.
K
Li-ion battery
Continuity
Connector Terminal
L
20 Ground
LB1 22 Existed
36 M
YES >> Refer to GI-47, "Intermittent Incident".
NO >> Repair harness or connector. N
EVB-455
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul-
with 2 communication lines (CAN-H, CAN-L) allowing a high rate of information transmission with less wiring.
tion Signal Chart".
DTC DETECTION LOGIC

U1000
(CAN communication circuit) more.
POSSIBLE CAUSE
FAIL-SAFE
• Charge stop
EVB-456
A
DANGER: B
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and EVB
maintenance.
WARNING:
CAUTION: G
1.CHECK HIGH VOLTAGE FUSE H
I
YES >> GO TO 2.
TERY PACK UPPER CASE : Exploded View". J
K
JSCIA1251ZZ
2.PRECONDITIONING L
WARNING:
1. Remove Li-ion battery. Refer to EVB-492, "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
CAUTION:
EVB-457
High voltage harness between battery junction box and rear module stack


EVB-458
A
DANGER: B
maintenance.
WARNING:
CAUTION: G
The following diagnosis procedure must be performed when “P0AA6 or P33E1” are detected and Li-ion H
I
With CONSULT
1. Power switch ON.
J
NOTE:
K
>> GO TO 2
2.CHECK LI-BATTERY INSULATION RESISTANCE-1 L
CAUTION:
found, replace damaged parts. M
Installation".
3. Remove battery cooler duct. Refer to EVB-522, "LI-ION BATTERY COOLING UNIT : Exploded view". N
4. Remove service plug switch bracket (with service plug switch and bus bar that connects service plug and
front module stack RH). Refer to EVB-513, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Exploded View". O
P
EVB-459
JSCIA1230ZZ
+
Terminal

YES >> GO TO 5.
NO >> GO TO 3.
bracket.
WARNING:
being inspected.
NOTE:
EVB-460
+ — Resistance A
B
NO >> GO TO 4.
4.CHECK SERVICE PLUG SWITCH INSULATION RESISTANCE-2 EVB
stack RH.
D
F
JSCIA1232ZZ
2. Using insulation resistance tester, measure insulation resistance G

bracket.
WARNING: H
the danger of electric shock. If used in the vehicle 12 V sys- I
CAUTION: J
JSCIA1233ZZ
being inspected. K
NOTE:
L
+ — Resistance
HARNESS : Exploded View". N
1. Disconnect voltage detection harness connector of front module stack LH. O
EVB-461
JSCIA1234ZZ
JSCIA1230ZZ
EVB-462
+ A
Terminal
B

YES >> Replace voltage detection harness of front module stack LH. EVB
NO >> GO TO 6.
6.CHECK LI-BATTERY INSULATION RESISTANCE-3 D
JSCIA1235ZZ L

M
EVB-463
JSCIA1230ZZ
+
Terminal

EVB-464
EVB
H
JSCIA1236ZZ

I
JSCIA1237ZZ
EVB-465
+
Terminal

YES >> GO TO 8.
NO >> GO TO 10.
8.CHECK MODULE-1
tion".
NOTE:
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 9.
Assembly".
9.CHECK MODULE-2
WARNING:
CAUTION:
EVB-466
+ A
Terminal
B
EVB
Assembly". D

1. Remove bus bar that connects battery junction box and front module stack LH. E
JSCIA1238ZZ
M
2. Measure voltages between terminal of voltage detection harness and battery pack ground. N
EVB-467
JSCIA1239ZZ
+
Terminal

YES >> GO TO 13.
NO >> GO TO 11.
EVB-468
EVB
I
JSCIA1240ZZ

J
WARNING:
incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the K
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting L
Battery junction box M

— Resistance
Terminal
N

O
NO >> GO TO 12.
12.CHECK BATTERY JUNCTION BOX INSULATION RESISTANCE-2 P
EVB-469
JSCIA1241ZZ
EVB-470
EVB
I
JSCIA1242ZZ

J
WARNING:
incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the K
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting L
Battery junction box M

— Resistance
Terminal
N

O
P
13.CHECK MODULE-3
tion".
NOTE:
EVB-471
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 14.
Assembly".
14.CHECK MODULE-4
WARNING:
CAUTION:
+
Terminal

Assembly".
EVB-472
EVB
I
JSCIA1243ZZ

J
JSCIA1244ZZ
EVB-473
+
Terminal

YES >> GO TO 16.
NO >> GO TO 18.
16.CHECK MODULE-5
tion".
NOTE:
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 17.
Assembly".
17.CHECK MODULE-6
WARNING:
CAUTION:
EVB-474
+ A
Terminal
B
EVB
Assembly". D

1. Remove bus bar that connects front module stack LH and rear module stack. E
JSCIA1245ZZ
N
2. Measure voltages between terminal of voltage detection harness and battery pack ground. O
EVB-475
JSCIA1244ZZ
+
Terminal

YES >> GO TO 19.
NO >> GO TO 21.
19.CHECK MODULE-7
NOTE:
module stack and module body.
JSCIA0740ZZ
EVB-476
+ A
Module − Voltage
Terminal
B
EVB
YES >> GO TO 20.
Assembly". D
20.CHECK MODULE-8
Measure insulation resistance between terminal / of all modules E
WARNING:
Unlike the ordinary tester, the insulation resistance tester F
insulation resistance tester instruction manual carefully and be G
CAUTION:
Be sure to set the insulation resistance tester to 500 V when JSCIA1369ZZ H
I
+
Terminal J

K
NO >> Replace malfunctioning module. Refer to EVB-535, "FRONT MODULE STACK : Disassembly and L
Assembly".
M
EVB-477
JSCIA1246ZZ
JSCIA1247ZZ
EVB-478
+ A
Terminal
B

YES >> GO TO 22. EVB
NO >> GO TO 24.
22.CHECK MODULE-9 D
NOTE:
2. Measure voltages between terminal / of modules (MD47 E
H
JSCIA0740ZZ
I
+
Module − Voltage
Terminal J

K
YES >> GO TO 23.
NO >> Replace malfunctioning module. Refer to EVB-551, "REAR MODULE STACK : Disassembly and L
Assembly".
23.CHECK MODULE-10
Measure insulation resistance between terminal / of modules M
WARNING:
there is the danger of damage to electronic devices. Read the O
CAUTION:
P
EVB-479
+
Terminal

Assembly".
JSCIA1248ZZ
WARNING:
CAUTION:

— Resistance
Terminal
EVB-480
YES >> Replace bus bar that connects battery junction box and front module stack LH. A
NO >> GO TO 25.
B
EVB
JSCIA1249ZZ J
K
EVB-481
JSCIA1250ZZ
WARNING:
CAUTION:

— Resistance
Terminal

EVB-482
A
DANGER: B
maintenance.
WARNING:
CAUTION: G
1.CHECK FUSE H

I
Battery 43
57 J
Power switch ON
82
Is the fuse fusing?
YES >> Replace the fuse after repairing the applicable circuit. K
NO >> GO TO 2.
2.CHECK LI-ION BATTERY CONTROLLER GROUND CIRCUIT L
M
+
Li-ion battery − Continuity N
Connector Terminal
6
E128 7 Ground Existed O
8
YES >> GO TO 3.
EVB-483
+
Connector Terminal
12V battery power
E128 5 Ground
supply
YES >> GO TO 5.
NO >> GO TO 4.
+
Connector Terminal
No.43 fuse ter-
E128 5 Existed
minal
+
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4
E128 Ground 11 – 14 V
31
YES >> GO TO 8.
NO >> GO TO 6.
3. Check the continuity between Li-ion battery vehicle communication harness and IPDM E/R harness con-
nector.
Li-ion battery IPDM E/R

Continuity
YES >> GO TO 7.
EVB-484
Li-ion battery A
— Continuity
Connector Terminal
No.82 fuse ter-
E128 31 Existed B
minal
8.PRECONDITIONING D
WARNING:
1. Remove Li-ion battery. Refer to EVB-492, "Removal and Installation". E
Installation".
F
>> GO TO 9.
9.CHECK HARNESS BETWEEN LI-ION BATTERY AND LI-ION BATTERY CONTROLLER G
H
LBC Li-ion battery
Continuity
5 31 I
7 4
12 5
LB10 LB1 Existed J
2 8
3 6
14 7 K
L
EVB-485
EV BATTERY SYSTEM
< SYMPTOM DIAGNOSIS > [WITH BATTERY COOLER]
SYMPTOM DIAGNOSIS
EV BATTERY SYSTEM
NOTE:
• If any DTC is detected, perform the corresponding diagnosis.
"Description".

Combination meter
Information display is functioning normally Refer to MWI-91, "On Board Diagnosis
mally
EVB-486
A
• The driving range is shorter than before. B

EVB
NOTE: D
Is the lighting status 1 Segment or none? E

YES >> GO TO 3.
NO >> GO TO 2.
2.DISCHARGE OF LI-ION BATTERY F
G
A/C fan speed : Maximum speed H
I
J
>> GO TO 3.
K
L
>> GO TO 4.
With CONSULT
3. Check DTC.
YES >> Perform diagnosis on the detected DTC. Refer to EVB-329, "DTC Index". O
EVB-487
TURN ON THE BATTERY TEMPERATURE WARNING LAMP

EVB-488
< PERIODIC MAINTENANCE > [WITH BATTERY COOLER]
B
tions needed to keep the Li-ion battery in the best possible condition. EVB
tion manual.
D
EVB-489
< REMOVAL AND INSTALLATION > [WITH BATTERY COOLER]

JSCIA1081GB
Clip
REMOVAL
WARNING:
EVB-490
< REMOVAL AND INSTALLATION > [WITH BATTERY COOLER]
A
INSTALLATION
2. Install the Li-ion battery undercover (center). B
EVB
JSCIA1080ZZ
J
Bolts for Li-ion battery undercover Clips for Li-ion battery undercover Bolts for Li-ion battery undercover K
(center) (front) (front) L
: Vehicle front
EVB-491
LI-ION BATTERY
< UNIT REMOVAL AND INSTALLATION > [WITH BATTERY COOLER]
UNIT REMOVAL AND INSTALLATION

LI-ION BATTERY
JSCIA1079GB
Cooler pipe O-ring Cooler pipe

: N-m (kg-m ft-lb)
DANGER:
WARNING:
EVB-492
LI-ION BATTERY
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet A
CAUTION:
B
EVB
REMOVAL
1. Discharge the refrigerant. Refer to HA-26, "Recycle Refrigerant" (For Europe) or HA-93, "Recycle Refrig-
erant" (Except for Europe).
D
WARNING:
Prepare for work on the high-voltage system. E
tion".
4. Disconnect the Li-ion battery high-voltage harness connector . F
DANGER:

G
tective gear.

I
J
JSCIA1328ZZ
M
DANGER:
N
tective gear. O
P
EVB-493
LI-ION BATTERY
JSCIA1329ZZ
6. Disconnect the Li-ion battery vehicle communications connector

WARNING:

gear.
JSCIA1078ZZ
7. Remove the bolt and disconnect the A/C pipe from Li-ion
battery.
DANGER:

tective gear.
JSCIA1073ZZ

WARNING:

gear.
JSCIA1074ZZ

WARNING:

gear.
CAUTION:
Do not remove the 4 bolts in this step.
JSCIA1075ZZ
EVB-494
LI-ION BATTERY
• Align the pallet center mark and the lift table center A
mark .
Front B
Side
EVB
G
JSCIA0178ZZ
11. Set the pallet onto the Li-ion battery. H

CAUTION:
battery with transport fastening bolts. I
JSCIA0179ZZ K

L
JSCIA1076ZZ
WARNING: O
EVB-495
LI-ION BATTERY
WARNING:

gear.
JSCIA1077ZZ
JPCIA0196ZZ

CAUTION:
Because there is the danger of tipping over, do not move the stacker while the Li-ion battery is
lifted up.
INSTALLATION
1. When replacing the Li-ion battery with a new battery, perform the work listed below.
b. Cut the EV battery tracking identification seal into 2 pieces and apply them to the body of the replaced
2. Install the Li-ion battery onto the vehicle body.
JSCIA1076ZZ
WARNING:
EVB-496
LI-ION BATTERY

A
WARNING:

gear. B
EVB
NOTE:
JSCIA1075ZZ
D
WARNING:
E
gear.
F
G
JSCIA1074ZZ
6. Install the A/C pipe and install the bolt . H

DANGER:
• There is the danger of electric shock caused by I

tective gear.
JSCIA1073ZZ K
8. Rotate the vehicle communications connector clockwise to L
connect it.
WARNING:
M
gear.
JSCIA1072ZZ
O
EVB-497
LI-ION BATTERY
DANGER:

tective gear.
JSCIA1071ZZ
JSCIA1330ZZ
10. Install the high-voltage harness connector and install the har-
ness clamp .
WARNING:

gear.
JSCIA1070ZZ
JSCIA1331ZZ
11. Install the Li-ion battery undercover. Refer to EVB-490, "Removal and Installation".
13. Charge the refrigerant. Refer to HA-27, "Charge Refrigerant" (For Europe) or HA-94, "Charge Refrigerant"
(Except for Europe).
EVB-498
LI-ION BATTERY
ground. A
EVB
F
JSCIA1203ZZ
WARNING:
G

I
• Presence of paint, oil, dirt, or other substance on the bonding plate mounting surface J
EVB-499
LI-ION BATTERY
< UNIT DISASSEMBLY AND ASSEMBLY > [WITH BATTERY COOLER]
UNIT DISASSEMBLY AND ASSEMBLY

LI-ION BATTERY
JSCIA1338GB
EVB-500
LI-ION BATTERY
Breather Service plug Service plug retainer A

Battery pack upper case Seal Plug
Plug washer
B
sembly.
EVB

D
DANGER: E
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and F
maintenance.
WARNING:
• 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
ing electric shock, fire, and damage to parts. J
CAUTION:
K
1. Must be an indoor environment. L
M
3. The floor must be dry. O
4. Work space
• The work space must be approximately the size of one entire vehicle. P
guisher).
REMOVAL
EVB-501
LI-ION BATTERY
2. Remove the service plug retainer .
WARNING:

JSCIA1172ZZ
JSCIA1173ZZ
WARNING:
WARNING:

NOTE:
• Sharpen the blade of the windshield cutter .
: 38 mm (1.50 in)
JSCIA0572ZZ
EVB-502
LI-ION BATTERY
A
EVB
JSCIA1174ZZ F
I
JSCIA1175ZZ

J
: Battery front K
CAUTION:
• When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi- L
sive. M
sealant damage is less than the limit, repair by applying primer (adhesive primer: KE560-15090). N

Continuous length of undamaged section: : 210 mm (8.27 in) or more O
NOTE:
P
EVB-503
LI-ION BATTERY
JSCIA0678ZZ
ners.
CAUTION:
the battery pack coating and paint sealant to the maximum
extent possible.
NOTE:
JSCIA0574ZZ
JSCIA0679ZZ
CAUTION:
upper case.
ii. Tilt the windshield cutter blade at an angle and cut the adhesive at the embossed locations.
CAUTION:
WARNING:
CAUTION:
battery pack.
EVB-504
LI-ION BATTERY
assembling so that no particles remain on the battery module, bus bar, and high-voltage har- A
ness.
B
INSTALLATION
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:
G
duced.
case must be replaced. If the paint sealant damage is less than the limit, repair by applying H
Paint sealant damage limit: I

KE560-15090). J
NOTE:
are not damaged. K
a. Protect the seal with masking tape . L
NOTE:
M
N
JSCIA0577ZZ O
EVB-505
LI-ION BATTERY
case.
NOTE:
JSCIA1181ZZ
JSCIA0578ZZ
C : 10 mm (0.39 in)
CAUTION:
NOTE:
Apply the dam rubber so that adhesive does not enter the inner side. If the adhesive enters the inner side,
WARNING:
EVB-506
LI-ION BATTERY
EVB
L
JSCIA1176ZZ
: Dam rubber : Old adhesive M

CAUTION: N
overlaps.
adhesive begins to harden in as little as 16 minutes. [Humidity: 80%, Temperature: 35°C (95°F)] O
than the height of the dam rubber, then the amount of adhesive is insufficient.) P
NOTE:
EVB-507
LI-ION BATTERY
JSCIA0642ZZ

alignment holes on the battery pack upper case and battery pack lower case .
JSCIA1177ZZ
WARNING:
CAUTION:
tery module.
case carefully.
JSCIA1182ZZ
EVB-508
LI-ION BATTERY
A
EVB
JSCIA1178ZZ F
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools. G
H
M
JSCIA1179ZZ
WARNING:
N
EVB-509
LI-ION BATTERY
WARNING:

JSCIA1172ZZ
CAUTION:
JSCIA1180ZZ
CAUTION:
which strains the vehicle body) for approximately 3 hours after installation.
AIR LEAK INSPECTION
EVB-510
LI-ION BATTERY
EVB
JSCIA1187GB
I

J
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:
EVB-511
LI-ION BATTERY
4. Work space
guisher).
REMOVAL
Installation".
battery controller.
WARNING:

gear.
JSCIA1188ZZ

WARNING:

JSCIA1189ZZ
4. Disconnect the high-voltage harness connector , then remove


: Battery front
WARNING:

gear.
JSCIA1190ZZ
EVB-512
LI-ION BATTERY
B
INSTALLATION
EVB
WARNING:
• To prevent electric shock, wear insulated protective gear and use insulated tools. D
E
nector . If the high-voltage harness connector is F
G
: Battery front
H
JSCIA1190ZZ
tion". I
CAUTION:
replace it with a new clip before installing. J
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST K
L

M
EVB-513
LI-ION BATTERY
JSCIA1210GB

with bus bar)
sembly.
EVB-514
LI-ION BATTERY
BUS BAR LAYOUT
A
EVB
JSCIA1186ZZ
DANGER: P
INFOID:0000000011103362
DANGER:
EVB-515
LI-ION BATTERY
maintenance.
WARNING:
CAUTION:
4. Work space
guisher).
DISASSEMBLY
Installation".
Installation".
EVB-516
LI-ION BATTERY
. A
DANGER:
• There is the danger of electric shock caused by B

EVB
JSCIA1211ZZ
• Because there is a risk of electric shock, immedi- D

E
WARNING:
To prevent electric shock, wear insulated protective F

H
JSCIA1212ZZ
ness connector , then remove the service plug switch bracket. I
WARNING:
To prevent electric shock, wear insulated protective J

JSCIA1213ZZ
L
WARNING:
M
N
O
JSCIA1214ZZ
EVB-517
LI-ION BATTERY
from service plug switch bracket .
WARNING:

JSCIA1215ZZ

WARNING:

JSCIA1216ZZ
WARNING:

JSCIA1217ZZ

c. Remove the bus bar nuts . Then remove the current sensor
.
DANGER:

are not exposed.
EVB-518
LI-ION BATTERY
remove the bus bar bolts and nuts . Then remove the bus A
DANGER:
B
EVB
JSCIA1219ZZ
D
terminals) with insulating tape so that they are not exposed. E
WARNING:
F
gear.
G
JSCIA1220ZZ
8. Open the bus bar cover and remove the bus bar cap . And I
DANGER: J

contact with the terminals. Be sure to wear insulated pro- K
JSCIA1221ZZ
L

ately protect the terminals of the disconnected high-voltage harness connector (high-voltage M
9. Remove the mounting nuts and remove the junction box . N

WARNING:

gear and use insulated tools. O
JSCIA1222ZZ
EVB-519
LI-ION BATTERY
age harness connector from the connector flange.
WARNING:

JSCIA1224ZZ
WARNING:

JSCIA1225ZZ
12. Remove the vehicle communications harness as follows.

WARNING:

JSCIA1226ZZ
WARNING:

JSCIA1227ZZ
ASSEMBLY
DANGER:
EVB-520
LI-ION BATTERY
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter- A
minal.
B
WARNING:
CAUTION: EVB
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged, D
AIR LEAK INSPECTION
E
LI-ION BATTERY COOLING UNIT
F
EVB-521
LI-ION BATTERY
LI-ION BATTERY COOLING UNIT : Exploded view INFOID:0000000011103363
JSCIA1196GB
Plate Gasket Li-ion battery cooling unit

Li-ion battery cooling duct (front) Li-ion battery cooling duct (rear)
sembly.
LI-ION BATTERY COOLING UNIT : Removal and Installation INFOID:0000000011103364
DANGER:
maintenance.
WARNING:
EVB-522
LI-ION BATTERY
ing inspection or maintenance of high voltage system harnesses and parts. A
• 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.
B
• To prevent electric shock hazards, ignition, and damage to parts, always remove Li-ion battery con-
troller before disassembling battery pack. EVB
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do D
WORK ENVIRONMENT FOR DISASSEMBLY OF LI-ION BATTERY
1. Must be an indoor environment. E
• 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 F
occurring as a result of high temperature and humidity.
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. G
• 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. H
• The floor must not become wet as a result of causes such as vehicles entering when it is raining or
snowing.
4. Work space I
• 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. J
guisher). K
REMOVAL
1. Remove the battery pack upper case. Refer to EVB-501, "BATTERY PACK UPPER CASE : Removal and L
Installation".
Installation". M
3. Remove service plug switch bracket and support bracket. Refer to EVB-515, "BATTERY JUNCTION BOX
AND BATTERY HARNESS : Removal and Installation".
N
EVB-523
LI-ION BATTERY
4. Remove mounting bolts and clips .then remove the plate .
JSCIA1197ZZ
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools.
5. Remove Li-ion battery cooling duct .

WARNING:
To prevent electric shock hazards, be sure to put on

JSCIA1198ZZ
6. Separate Li-ion battery cooling duct as shown in the figure if

necessary.
JSCIA1199ZZ
EVB-524
LI-ION BATTERY
7. Remove mounting bolts .
WARNING: A

insulated protective gear and use insulated tools. B
EVB
JSCIA1200ZZ
D
8. Remove mounting bolts and nut .
WARNING:
E
F
G
JSCIA1201ZZ
9. Remove Li-ion battery cooling unit and the gasket . H

WARNING:

insulated protective gear and use insulated tools. I
JSCIA1202ZZ
K
INSTALLATION
1. Instal Li-ion battery cooling unit and the gasket . L
WARNING:
To prevent electric shock hazards, be sure to put on M

JSCIA1202ZZ O
EVB-525
LI-ION BATTERY
2. Instal mounting bolts .
WARNING:

JSCIA1200ZZ
3. Instal mounting bolts and nut .

WARNING:

JSCIA1201ZZ
4. After install in the reverse order of removal.

WARNING:
lated tools.
CAUTION:
• Install Li-ion battery controller immediately before installing battery pack upper case. Refer to EVB-
501, "BATTERY PACK UPPER CASE : Removal and Installation".
AIR LEAK INSPECTION
FRONT MODULE STACK
EVB-526
LI-ION BATTERY
EVB
L
JSCIA1300GB

N

O

P
EVB-527
LI-ION BATTERY
JSCIA1184GB

EVB-528
LI-ION BATTERY

A
: Battery front
NOTE:
MODULE LAYOUT
EVB
H
JSCIA1087ZZ

I
K
M
N
O
EVB-529
LI-ION BATTERY
BUS BAR LAYOUT
JSCIA1186ZZ
DANGER:
DANGER:
EVB-530
LI-ION BATTERY
maintenance.
B
WARNING:
CAUTION:
4. Work space K
guisher).
REMOVAL
Installation".
Installation". O
EVB-531
LI-ION BATTERY
×: Need to remove
Parts name Left front module stack Right front module stack Reference
× stallation"
ness
EVB-522, "LI-ION BATTERY
Li-ion battery cooling unit × COOLING UNIT : Removal and
Installation"

.
WARNING:

JSCIA1253ZZ
DANGER:

JSCIA1254ZZ

DANGER:

JSCIA1255ZZ

EVB-532
LI-ION BATTERY
stack)
DANGER:
B
EVB
JSCIA1268ZZ
D
E
8.

F
JSCIA1256ZZ
K
WARNING: L
JSCIA1257ZZ
WARNING:
EVB-533
LI-ION BATTERY
WARNING:

gear.
CAUTION:
WARNING:
CAUTION:

WARNING:

gear.

NOTE:
INSTALLATION
DANGER:
minal.
WARNING:
EVB-534
LI-ION BATTERY
B
CAUTION:
AIR LEAK INSPECTION
DANGER: E
WARNING:
G
CAUTION: J
4. Work space
guisher).
DISASSEMBLY
EVB-535
LI-ION BATTERY
ing.
JSCIA1269ZZ
DANGER:
CAUTION:
JSCIA1270ZZ
DANGER:
EVB-536
LI-ION BATTERY
B
NOTE:
(front) .
D
JSCIA1271ZZ
I
DANGER:
M
JSCIA1272ZZ
DANGER: P
EVB-537
LI-ION BATTERY
front module stack.
JSCIA1273ZZ
DANGER:
JSCIA1274ZZ
WARNING:
WARNING:
ASSEMBLY
EVB-538
LI-ION BATTERY
DANGER:
A
B
EVB
F
JSCIA1275ZZ
: Battery front
G
J
JSCIA1290ZZ
: Battery front
K
WARNING:
NOTE:
figure. M

N
JSCIA0682ZZ
P
EVB-539
LI-ION BATTERY
lar .
JSCIA0733ZZ
JSCIA1257ZZ
NOTE:
JSCIA1276ZZ
CAUTION:
EVB-540
LI-ION BATTERY
mounting screws . A
EVB
JSCIA1273ZZ D
DANGER:

H
JSCIA1271ZZ
M
DANGER:
O
CAUTION: P
EVB-541
LI-ION BATTERY
JSCIA1277ZZ
: Battery front
NOTE:
JSCIA1278ZZ
: Battery front
NOTE:
DANGER:
NOTE:
EVB-542
LI-ION BATTERY
ing. A
EVB
F
JSCIA1269ZZ

DANGER:
REAR MODULE STACK

L
EVB-543
LI-ION BATTERY
JSCIA1300GB

EVB-544
LI-ION BATTERY
EVB
JSCIA1185GB
P
(rear)
Left end plate
EVB-545
LI-ION BATTERY

: Battery front
MODULE LAYOUT
JSCIA1087ZZ
Rear module stack

NOTE:
BUS BAR LAYOUT
DANGER:
EVB-546
LI-ION BATTERY
EVB
JSCIA1186ZZ P
DANGER:
EVB-547
LI-ION BATTERY
maintenance.
WARNING:
CAUTION:
4. Work space
guisher).
REMOVAL
Installation".
Installation".
3. Remove Li-ion battery cooling duct. Refer to EVB-522, "LI-ION BATTERY COOLING UNIT : Removal and
Installation".
.
WARNING:

JSCIA1253ZZ
EVB-548
LI-ION BATTERY
WARNING:

EVB
JSCIA1254ZZ
D
WARNING: E

gear and use insulated tools. F
G
JSCIA1255ZZ

WARNING:

JSCIA1261ZZ K
a. Attach a carabiner to position as shown in the figure and con- L
WARNING:
M
gear.
JSCIA1262ZZ
O
EVB-549
LI-ION BATTERY
WARNING:

gear.
CAUTION:
WARNING:
CAUTION:

WARNING:
INSTALLATION
DANGER:
minal.
WARNING:

CAUTION:
EVB-550
LI-ION BATTERY
B
DANGER:
WARNING: D
E
G
CAUTION:
I
4. Work space M
guisher). O
DISASSEMBLY
P
EVB-551
LI-ION BATTERY
DANGER:

JSCIA1279ZZ

DANGER:

JSCIA1280ZZ

CAUTION:
DANGER:

JSCIA1281ZZ


NOTE:
EVB-552
LI-ION BATTERY
(rear) . A
EVB
F
JSCIA1301ZZ
DANGER:
G
H
DANGER:

L
JSCIA1282ZZ

WARNING:

gear.
P
NOTE:
EVB-553
LI-ION BATTERY
JSCIA0729ZZ
A : 7 mm (0.28 in) B : 5 mm (0.20 in)

WARNING:

JSCIA1284ZZ

WARNING:

JSCIA1285ZZ

WARNING:

gear.
JSCIA0240ZZ
EVB-554
LI-ION BATTERY
WARNING:

EVB
JPCIA0131ZZ
D
ASSEMBLY
E
G
WARNING:
H
JSCIA1286ZZ L
WARNING:
M
NOTE:
figure. N

JSCIA0682ZZ
EVB-555
LI-ION BATTERY
stack .
WARNING:

gear.
JSCIA0240ZZ
JSCIA0313ZZ
WARNING:
JSCIA1287ZZ
CAUTION:
EVB-556
LI-ION BATTERY
EVB
JSCIA0347ZZ
D
WARNING:
E
F
G
JSCIA1285ZZ

WARNING:

JSCIA1284ZZ
K
(A).
WARNING: L

gear. M
N
O
WARNING:

P
EVB-557
LI-ION BATTERY
JSCIA1301ZZ
DANGER:

JPCIA0135ZZ
JSCIA1288ZZ
DANGER:
EVB-558
LI-ION BATTERY
A
EVB
JSCIA1289ZZ
WARNING: D

E
CAUTION:
CAUTION: G
AIR LEAK INSPECTION

the breather.
WARNING:

gear.
JSCIA1208ZZ
L
M
WARNING:

gear.
JSCIA1337ZZ
P
EVB-559
LI-ION BATTERY
[SST: KV99111400 ( — )].
WARNING:

gear.
JSCIA1205ZZ

)].
WARNING:

gear.
CAUTION:
ALAIA0089ZZ
DANGER:
NOTE:
WARNING:
EVB-560
LI-ION BATTERY
CAUTION: A
B
EVB
JSCIA0638ZZ
D
E
CAUTION:
H
Repair limit 2
: 1.4 kPa (0.014 bar, 0.0142 kg/cm , 0.203 psi)
I
NOTE:
K
P
JSCIA1209ZZ
WARNING:
EVB-561
LI-ION BATTERY

EVB-562
< SERVICE DATA AND SPECIFICATIONS (SDS) [WITH BATTERY COOLER]

B
Items Specification
EVB
Type Li-ion battery
E
JSCIA1204ZZ

“b” [mm (in)] 824 (32.44)
“c” [mm (in)] 266 (10.47)
N
“d” [mm (in)] 1578 (62.13)
EVB-563
PRECAUTIONS
< PRECAUTION > [WITH BATTERY HEATER & COOLER]
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
WARNING:
EVB-564
PRECAUTIONS
B
connectors.
WARNING: EVB
D
injury.
windshield.
G
PIIB3706J
I
J
NOTE:
SEF289H
WORK PROCEDURE
NOTE:
tion. O
NOTE: P
detected.
CAUTION:
EVB-565
PRECAUTIONS
NOTE:
the power switch.
NOTE:
NOTE:
EVB-566
A

CAUTION:
from damage. E
JMJIB0266ZZ
H
I
: Pawl
K
JMJIB0267ZZ

: Metal clip
M
JMJIB0268ZZ
O
EVB-567
:Vehicle front
JSCIA1194ZZ
ALAIA0088ZZ
DANGER:
WARNING:
battery side.
DANGER:

JSCIA1303ZZ
EVB-568
A
EVB
ALAIA0089ZZ
DANGER: D
E
WARNING: F
H
DANGER:
maintenance. J
WARNING:
K
CAUTION: M
blow gun.
NOTE:
EVB-569
WARNING:
EVB-570
workers. A
EVB
JSAIA1600GB P
DANGER:
EVB-571
maintenance.
WARNING:
CAUTION:
INSPECTION
WARNING:
Installation".
DANGER:

tective gear.

JSCIA1328ZZ

DANGER:

tective gear.
JSCIA1071ZZ
EVB-572
EVB
JSCIA1329ZZ
E
DANGER: F
G
JSCIA1195ZZ
K
CAUTION:
EVB-573
JSAIA3647ZZ

PTC elements heater
Electric compressor
Li-ion battery
COOLER
Service plug
COOLER
COOLER
CAUTION:
EVB-574
A
B
DAILY INSPECTION
JPCIA0061ZZ H


INSULATING TOOLS
L
CAUTION:
N
CAUTION: O
P
EVB-575
PREPARATION
< PREPARATION > [WITH BATTERY HEATER & COOLER]
PREPARATION
PREPARATION
Tool name
Palette
(—)
JPCIA0239ZZ
Air leak checker

KV99111400
(—)
JSCIA0257ZZ

KV99111500
24 pieces/set
(—)
JPCIA0069ZZ

NOTE:
—
(J-50346-A)
JPCIA0070ZZ

(—)
JPCIA0156ZZ
EVB-576
PREPARATION

B
nents
material.
JMCIA0149ZZ D

E
ponents
tight] F
JPCIA0066ZZ

nents
material. H
JPCIA0011ZZ
I

ponents J
to electric line
K
JPCIA0167ZZ
L
ponents
Safety glasses
to electric line M
JPCIA0012ZZ

Insulated helmet O
nents
JPCIA0013ZZ P
EVB-577
PREPARATION

nents
JPCIA0019ZZ

nents
JPCIA0018ZZ
JPCIA0024ZZ
JPCIA0015ZZ
JSCIA0083ZZ

JPCIA0014ZZ
JPCIA0067ZZ
EVB-578
PREPARATION
A
B
EVB
JPCIA0068ZZ

stack
D
NOTE:
Carabineer [small]
• D: 8.0 mm (0.31 in)
• L: 74.0 mm (2.91 in) E
• S: 10.0 mm (0.39 in)
JPCIA0016ZZ
• W: 22.5 mm (0.89 in)
F
NOTE:
• D: 14.0 mm (0.55 in)
• L: 204.0 mm (8.03 in)
• S: 47.0 mm (1.85 in)
• W: 105.0 mm (4.13 in)
JPCIA0017ZZ
H

Belt slinger NOTE:
Length: 2.0 m (6.562 ft)
J
JPCIA0021ZZ

L
JPCIA0020ZZ

Lashing belt
stack
JPCIA0022ZZ
O
P
(Cut the adhesive)
JSCIA0640ZZ
EVB-579
PREPARATION

(Cut the adhesive)
NOTE:
JSCIA0641ZZ

Scraper
JSCIA0643ZZ
JSCIA0639ZZ

NOTE:
Metal bar
• D: φ 7 mm (0.28 in)
• L: 1 m (3.28 ft)
JSCIA0735ZZ
Tool name
Description
Tool number
Adhesive
KE561-32090
Dam rubber
KE390-00590
KE560-15090
—
EVB-580
COMPONENT PARTS
< SYSTEM DESCRIPTION > [WITH BATTERY HEATER & COOLER]
COMPONENT PARTS
B
EVB
JSCIA1082ZZ
EVB-581
COMPONENT PARTS

: Vehicle front

EVB-582
COMPONENT PARTS
EVB
JSCIA1083ZZ
K
: Vehicle front
L

Li-ion battery heater & cooling unit EVB-586, "Li-ion Battery Heater & Cooling Unit" M
PTC heater EVB-586, "Li-ion Battery Heater & Cooling Unit"
Heater relay unit EVB-586, "Heater Relay Unit"

N
Duct EVB-586, "Li-ion Battery Heater & Cooling Unit"
EVB-583
COMPONENT PARTS

ion battery controller, battery junction box, and service plug in addi-
JSCIA1085ZZ
JSCIA1086ZZ

• The LBC is the core of battery control. Li-ion battery controller
state of charge. LBC also calculates possible input/output values,
meter indication values, and chargeable values, and send this data
JSCIA1128ZZ
Main Role of Li-ion Battery Controller

• State of charge
• Possible output value
• Temperature
2. Optimization of Li-ion battery voltage
5. Detection of decrease in insulation resistance of high-voltage circuit
EVB-584
COMPONENT PARTS
A
• There are two kinds of modules, according to the location of posi- B
Positive terminal : Red

Negative terminal : Black EVB
D
JSCIA0703ZZ
MODULE INTERNAL CIRCUIT

E
parallel-connected cell pairs are connected in series.
NOTE: F
the parallel circuit.
G
H
JPCIA0197GB
MODULE LAYOUT
I
N
JSCIA1087GB
NOTE:
O
CELL
P
EVB-585
COMPONENT PARTS
JSCIA0274ZZ

life.
• Light and thin structure increases flexibility in layout.
Heater Relay Unit INFOID:0000000010623818
• The heater relay unit is installed in the battery pack.

• 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 PTC heater.
JSCIA1129ZZ
Li-ion Battery Heater & Cooling Unit INFOID:0000000010623819
• Li-ion battery heater & cooling unit is installed in the battery pack.
• Heater & cooling unit has a built-in device for cooling and heating purposes.
• PTC heater for heating purposes receives voltage power from the heater relay unit.
• The evaporator for cooling purposes receives refrigerant from the interior air conditioning system.
JSCIA1088ZZ
PTC HEATER
EVB-586
COMPONENT PARTS
• PTC heater is built in the Li-ion battery heater & cooling unit.
• With the adoption of a forced convection type heater, the inside of A
Li-ion battery is heated by blower motor-generated convection.
• PTC heater operates from high voltage power supplied from the
heater relay unit.
B
EVB
JSCIA1089ZZ
D
EVAPORATOR ASSEMBLY
• The evaporator assembly is built in the Li-ion battery heater & cooling unit.
JSCIA1090ZZ
H
• The expansion valve transforms high pressure liquid refrigerant to mist form low pressure liquid refrigerant
by drawing function. I
• The evaporator assembly cools the inside of Li-ion battery by using refrigerant supplied from the interior
refrigerant cycle.
• The refrigerant supply is controlled by A/C auto amp. J
BLOWER MOTOR
• The blower motor is built in the Li-ion battery heater & cooling unit.
• During heater or cooler operation, the blower motor rotates with K
100% duty ratio.
• After cooling, when the power switch is turned ON first time after
the completion of charging, the blower motor rotates with 40% duty L
ratio to evaporate the flocculated water accumulated around the
evaporator.
M
JSCIA1130ZZ
N
DUCT
Duct is installed in the center of battery pack. Cold/warm air sent
from the Li-ion battery heater & cooling unit is supplied to each mod-
ule through the duct. O
JSCIA1131ZZ
EVB-587
COMPONENT PARTS
JSCIA1091ZZ


according to changes in temperature. The electrical resistance of
JPCIA0295GB
pack.
• The battery junction box includes:
battery.
rent immediately after power switch ON.
relay provides DC current to each high voltage part. In addition, the
system main relay provides DC current to the Li-ion battery during
JSCIA0506ZZ
• When an error occurs in the system, the system main relay is
cle control module).

junction box and front module stack LH.
• This sensor measures charge/discharge current sent to Li-ion bat-
(LBC).
according to charge/discharge current and sends the data to VCM.
JSCIA1092ZZ
EVB-588
COMPONENT PARTS
A
maintenance. B
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 EVB
installing service plug.
D
JSCIA0706ZZ

E
label in the original position. F
Li-ion Battery
G
JSCIA1093ZZ J
: Vehicle front
K
L
JSCIA0111ZZ
Service Plug O
EVB-589
COMPONENT PARTS
JSCIA1095ZZ
EVB-590
SYSTEM
SYSTEM
A
B
SYSTEM DIAGRAM
EVB
JSCIA1368GB K
Input Signal Item L

Output Signal Item

N
EVB-591
SYSTEM

VCM EV system CAN
Charge type signal
Li-ion battery cooler evaporator temperature signal
A/C auto amp. EV system CAN Li-ion battery cooling fan speed signal
Li-ion battery cooling request signal
DESCRIPTION
charge/charge line.
BATTERY PROTECTION
EVB-592
SYSTEM
Control item Control Operating condition A

tion Cell voltage exceeds the voltage judged as overvoltage and B
proaches the lower limit of the voltage capable of discharging. EVB
Gradual control of charging/discharging energy as Li-ion bat- D
control
Excessive temperature rise pro- capable of use.
E
more than the specified time.
HOW TO ADJUST CELL CAPACITY F

system starts, and the capacities are adjusted so that they are all at the target level. The voltage of each cell is
G
of all cells to be fully utilized.
JPCIA0094GB
L
INSULATION RESISTANCE LOSS DETECTION FUNCTION

M
nication.
EVB-593
SYSTEM
tance value.
JSCIA0815GB
LI-ION BATTERY HEATER CONTROL SYSTEM

LI-ION BATTERY HEATER CONTROL SYSTEM : System Description INFOID:0000000010623826
SYSTEM DIAGRAM
JSCIA1096GB

Input Signal Item

VCM EV system CAN communication Keep SOC request signal
Output Signal Item
EVB-594
SYSTEM
Receive unit Signal name A

DESCRIPTION B
• 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 EVB
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.
• The LBC judges the activation of the PTC heater and blower motor, according to a temperature in the battery D
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- E
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.
Activation of the Li-ion battery heater
F
Temperature in the battery pack
State of charge
Lower than −20°C [−40°F (approx.)] −20°C or higher [−40°F (approx.)]
30% or more (approx.) Active Inactive G
Less than 30% (approx.) Inactive* Inactive
*: The Li-ion battery heater is activated under the conditions listed below: H
- 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 PTC heater. I
• The blower motor is activated when the PTC heater is heated from high voltage power. Warm air is sent to
the inside of Li-ion battery via PTC heater.
• During heater operation, the blower motor rotates with 100% duty ratio. J
• 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
K
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), L
LBC activates the Li-ion battery heater.
When EVSE is connected (normal charge)
M
JSCIA1097ZZ
• 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.
EVB-595
SYSTEM
• 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)
JSCIA1098ZZ
• 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.
• 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
Li-ion battery heater operation even if the temperature in the battery pack is insufficient.
LI-ION BATTERY COOLER CONTROL SYSTEM : System Description INFOID:0000000010931272
SYSTEM DIAGRAM
JSCIA1108GB
EVB-596
SYSTEM
Input Signal Item
A
VCM Keep SOC request signal
EV system CAN communication B
HVAC Ambient sensor signal
Output Signal Item

EVB
Receive unit Signal name
D
Li-ion battery cooling fan speed sig-
HVAC
nal
EV system CAN communication Li-ion battery cooler evaporator
HVAC E
temperature signal
HVAC Li-ion battery cooling request signal
DESCRIPTION F
To prevent heat generation in the battery resulted from charging current, the Li-ion battery cooler control sys-
tem operates during quick charge and normal charge (200 V). While interior air-conditioner is operating, refrig-
erant is not supplied to the battery pack, and in this case, only the fan operates. G
During Quick Charge
H
ON : When battery temperature is more than approximately 20°C (68°F)
OFF : When battery temperature is approximately 15°C (59°F) or less
During Normal Charge (200V) I
ON : When battery temperature is more than approximately 25°C (77°F) and is
5°C (41°F) or more higher than ambient temperature J
OFF When any of the following conditions is satisfied:
- Battery temperature is approximately 20°C (68°F) or less.
- Battery temperature is lower than ambient temperature. K
- Battery cooler continues operating for 5 hours or more.
DESCRIPTION L
• When temperature rises in the battery pack, LBC judges that temperature is high in the battery pack, accord-
ing to a signal from the battery temperature sensor.
• LBC transmits a fan duty request signal to the blow motor to rotate it.
• When the blow motor rotates, LBC receives a fan RPM signal from the blow motor. M
• LBC transmits an Li-ion Battery cooling request signal to A/C auto amp. to request for supplying a part of
refrigerant used for interior air conditioning to the evaporator of Li-ion battery. LBC transmits Li-ion battery
evaporator temperature and Li-ion Battery cooling request signal to A/C auto amp. A/C auto amp. then N
adjusts A/C compressor revolutions according to the signal values.
• Since flocculated water accumulates in the evaporator of Li-ion battery heater & cooling unit when cooling
the battery, the blower motor is activated at a speed of 40% for evaporating the accumulated water at the
next power switch ON after the completion of charging. The blower motor operates until the total power O
switch ON time reaches 25 minutes. If the power switch is turned OFF before the time reaches 25 minutes,
the blower motor starts again when the power switch is turned ON and operates until the total power switch
ON time reaches 25 minutes. P
• When temperature increases in the battery pack outside the time frame of timer charge set time, VCM trans-
mits a Keep SOC Request signal to LBC via EV system CAN communication and activates only Li-ion bat-
tery cooler without charging Li-Ion battery.
• During the timer charge operation, Li-ion battery is charged, and in addition, when temperature rises in the
battery pack, Li-ion battery cooler is activated according to operating conditions.
EVB-597
SYSTEM
JSCIA1297GB
EVB-598
SYSTEM
EVB
JSCIA1298GB
EVB-599
SYSTEM
JSCIA1292GB
Harness Layout
EVB-600
SYSTEM
EVB
JSCIA1299GB
P
: Vehicle front
EVB-601
SYSTEM
FAIL-SAFE PATTERN
• Pattern A: No driving, Charge stop and EV system warning lamp illuminate
• Pattern F: Li-ion battery heater stops
EVB-602
HANDLING PRECAUTION
HANDLING PRECAUTION
A
• To improve the Li-ion battery life, never perform quick charge heavily. B
EVB
D
4. Lay an anti-static rubber sheet underneath the battery. E
F
11. Prevent other objects from falling onto the battery. G
EVB-603
APPLICATION ITEM
Item Function
Data Monitor Input/Output data in LBC can be read.
Active test Activates the actuator via LBC.
Work Support
*: The following diagnosis information is cleared when the VCM memory is erased.
ECU IDENTIFICATION
SELF-DIAGNOSTIC RESULTS
How to Erase DTC
3. Touch “ERASE”. (DTC in LBC will be erased.)

BATT ELECTRIC CURRENT A Displays the Li-ion battery current value
IR SEN SHORT PULSE mV
OPEN /
CLOSE
PTC HEAT RELAY CONT SIG On / Off Displays the ON/OFF request status of heater relay
PTC HEATER RELAY STAT
On / Off Displays the ON/OFF status of heater relay
SIG
FAN DUTY % Displays drive duty ratio of blower motor
EVB-604
A
FAN SPEED rpm Displays revolutions of blower motor
EVAPORATOR TEMPERA-
°C Displays evaporator temperature
TURE
B
BATTERY HEATER AVAIL-
OK / NG Displays the ready condition of Li-ion battery heater
ABILITY STATE
BATTERY HEATING RE-
QUEST
ON / OFF Displays the ready request status of Li-ion battery heater EVB
BATTERY COOLER AVAIL-
On / Off Displays the ready condition of Li-ion battery cooler
ABILITY STATE
D
BATTERY COOLING RE-
On / Off Displays the ready request status of Li-ion battery cooler
QUEST
DATA MONITOR E
NOTE:
×:Applicable F

SIG- SIGN SIGN SIGN SIGN G
BATT ELECTRIC CUR-
RENT H
12V BATTERY VOLT-
AGE
Displays the maximum to minimum difference of volt- I
IR SEN SHORT PULSE mV × × age magnitude of the on-board isolation resistance
monitoring system
J
TERLOCK CLOSE
TOTAL BATTERY K
VOLTAGE
MAXIMUM CELL VOLT-
AGE L
MINIMUM CELL VOLT-
AGE
BATTERY TEMPERA-
°C × ×
Displays the temperature calculated with a signal volt- M
°C × ×
N
°C × ×
BATTERY TEMPERA- Displays the temperature calculated with a signal volt- O
°C × ×
°C × ×
P
signal frequency.
EVB-605

PTC HEATER RELAY
STAT SIG
PTC HEAT RELAY
CONT SIG
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 PTC
On heater
• Blower motor is activated*
BATTERY HEATER
• Turns OFF the relay built into the heater relay unit to stop high voltage power supply to
Off the PTC heater
• Blower motor stops
*: Blower motor stops 60 seconds after the activation.
WORK SUPPORT

DATA replaced.
DATA replaced.
CLEAR BATTERY GRADUAL CA-
LBC-stored information on Li-ion battery capacity is erased. When all modules are replaced.
PACITY LOSS DATA
CLEAR BATT CHARGE/DIS- LBC-stored information on Li-ion battery charge/discharge in-
CHARGE INFORMATION DATA formation is erased.
TION cells.
EVB-606
EV BATTERY SYSTEM
< ECU DIAGNOSIS INFORMATION > [WITH BATTERY HEATER & COOLER]

EV BATTERY SYSTEM
B

NOTE: EVB
D
E

L
EVB-607
EV BATTERY SYSTEM
EVB-608
EV BATTERY SYSTEM
A
D
H
K
O
EVB-609
EV BATTERY SYSTEM
EVB-610
EV BATTERY SYSTEM
A
D
H
K
M
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
(front side)]
20°C - 30°C (68°F - 86°F)
cle)
EVB-611
EV BATTERY SYSTEM
20°C - 30°C (68°F - 86°F)
side)]
20°C - 30°C (68°F - 86°F)
TURE cle)
around evaporator]
100%
ating
40%
the Li-ion battery.
600 - 8,000 rpm
ating
FAN SPEED READY
rpm

READY

READY
FAIL-SAFE PATTERN
• Pattern A: No driving, Charge stop and EV system warning lamp illuminate
• Pattern F: Li-ion battery heater stops
FAIL-SAFE LIST
Pattern
A B C D E F
EVB-612
EV BATTERY SYSTEM
Pattern
A B C D E F
P303A CELL CONT ASIC10 × B
P303B CELL CONT ASIC11 ×
P303D CELL CONT ASIC13 × EVB
P303E CELL CONT ASIC14 ×
D
F
H
P304C CELL CONT ASIC4 VOLT × I
J

K
M
P3059 CELL CONT ASIC17 VOLT × N
O
P305E CELL CONT ASIC22 VOLT × P
P3062 BYPASS SW ×
EVB-613
EV BATTERY SYSTEM
Pattern
A B C D E F
EVB-614
EV BATTERY SYSTEM
Pattern
A B C D E F
P3309 CELL OVER VOLTAGE MODULE8 × B
P330C CELL OVER VOLTAGE MODULE11 × EVB
D
F
H
P331B CELL OVER VOLTAGE MODULE26 × I
J

K
M
O
P332D CELL OVER VOLTAGE MODULE44 × P
EVB-615
EV BATTERY SYSTEM
Pattern
A B C D E F
EVB-616
EV BATTERY SYSTEM
Pattern
A B C D E F
P33D4 BATT GRADUAL CAPA LOSS DIAG × EVB
D
P33DB TEMPERATURE SENSOR No fail-safe E
P33DD TEMPERATURE SENSOR No fail-safe
F
P33E2 BATT PACK OVER TEMP × G
H
P33EA BATTERY HEATER RELAY ×
P33ED BATTERY PARALLEL DIAGNOSIS × I
P33EE BATTERY HEATER CONTROL SYSTEM ×
P33F2 EVAPORATOR TEMP SENSOR ×
P33F5 BATTERY FAN × ×
J
DTC Index INFOID:0000000010623832 K
EV system L
lamp
P0A0D HV SYSTEM INTERLOCK ERROR × 1 EVB-648 M
P3030 CELL CONT LIN × 1 EVB-649
P3031 CELL CONT ASIC1 × 1 EVB-650 N
O
P3036 CELL CONT ASIC6 × 1 EVB-650 P
P303B CELL CONT ASIC11 × 1 EVB-650
EVB-617
EV BATTERY SYSTEM
EV system
lamp
EVB-618
EV BATTERY SYSTEM
EV system
lamp
P308F CELL CONT ASIC5 OPEN × 1 EVB-661 B
EVB
E
P3099 CELL CONT ASIC15 OPEN × 1 EVB-664 F
G

P309E CELL CONT ASIC20 OPEN × 1 EVB-664 H
P30A1 CELL CONT ASIC23 OPEN × 1 EVB-664 I
P30E0 DLC DIAGNOSIS VCM × 1 EVB-668
J
P30E4 DLC DIAGNOSIS PD MODULE — 1 EVB-671 K
P318E COMMUNICATION ERROR × 1 EVB-673
L
P3198 COMMUNICATION ERROR — 1 EVB-676 M
P319C COMMUNICATION ERROR — 1 EVB-678
N
P3305 CELL OVER VOLTAGE MODULE4 × 1 EVB-681 P
EVB-619
EV BATTERY SYSTEM
EV system
lamp
EVB-620
EV BATTERY SYSTEM
EV system
lamp
P337A CELL OVER DISCHARGE MODULE6 × 1 EVB-699 B
EVB
P337F CELL OVER DISCHARGE MODULE11 × 1 EVB-699 D
E
G

P3389 CELL OVER DISCHARGE MODULE21 × 1 EVB-703 H
P338C CELL OVER DISCHARGE MODULE24 × 1 EVB-703 I
J
L
P3396 CELL OVER DISCHARGE MODULE34 × 1 EVB-707 M
N
P339B CELL OVER DISCHARGE MODULE39 × 1 EVB-712 O
P339E CELL OVER DISCHARGE MODULE42 × 1 EVB-712 P
EVB-621
EV BATTERY SYSTEM
EV system
lamp
P33EA BATTERY HEATER RELAY × 1 EVB-737
P33EE BATTERY HEATER CONTROL SYSTEM × 1 EVB-742
P33F2 EVAPORATOR TEMP SENSOR × 1 EVB-744
P33F5 BATTERY FAN × 1 EVB-746
EVB-622
VCM
< WIRING DIAGRAM > [WITH BATTERY HEATER & COOLER]
WIRING DIAGRAM A
VCM
B
EVB
JRCWC0704GB
EVB-623
VCM
JRCWC0705GB
EVB-624
VCM
EVB
JRCWC0706GB
EVB-625
VCM
JRCWC0707GB
EVB-626
VCM
EVB
JRCWC0708GB
EVB-627
VCM
JRCWC0709GB
EVB-628
VCM
EVB
JRCWC0710GB
EVB-629
VCM
JRCWC0711GB
EVB-630
VCM
EVB
JRCWC0712GB
EVB-631
VCM
JRCWC0713GB
EVB-632
VCM
EVB
JRCWC0714GB
EVB-633
VCM
JRCWC0715GB
EVB-634
< BASIC INSPECTION > [WITH BATTERY HEATER & COOLER]
BASIC INSPECTION A
B
DETAILED FLOW
D
>> GO TO 2.
2.CHECK DTC E
1. Check DTC.
- Erase DTC.
H
J
K
>> GO TO 5.
>> GO TO 6. N
again. O
NOTE:
this check.
MATION PROCEDURE.
Is DTC detected?
YES >> GO TO 7.
EVB-635

YES >> GO TO 7.
YES >> GO TO 8.
ment.
>> GO TO 9.
9.FINAL CHECK
DESCRIPTION
tomer complaint.
NOTE:
JSCIA0412GB
WORKSHEET SAMPLE
Question Sheet
Incident Date VIN
Customer name
MR/MS
EVB-636
Question Sheet
A
lamp is on
B
Onomatopoeia
D

Weather
Not affected
conditions
Temp. [Approx. °C
( °F)]
road
Other
I
L
Other
Other N
EVB-637

With CONSULT
1. Power switch ON.
>> WORK END
EVB-638
A
EVB

With CONSULT
1. Power switch ON.
E
F
>> WORK END
EVB-639
NOTE:

With CONSULT
1. Power switch ON.
>> WORK END
EVB-640
A
NOTE: EVB
D
With CONSULT
E
1. Power switch ON.
>> WORK END G
EVB-641
LER
LBC to the new LBC.

With CONSULT
>> GO TO 2.
Installation".
>> GO TO 3.
With CONSULT
>> GO TO 4.
>> END
EVB-642
A
EVB
E
>> GO TO 2.
F
>> GO TO 3. G


With CONSULT J
>> WORK END

M
EVB-643
NOTE:
With CONSULT
1. Power switch ON.

>> GO TO 2.
CAUTION:

CAUTION:
>> GO TO 4.
CAUTION:


EVB-644
>> GO TO 6.
B
With CONSULT
range. D

E
>> WORK END

F
EVB-645
< DTC/CIRCUIT DIAGNOSIS > [WITH BATTERY HEATER & COOLER]
DTC DETECTION LOGIC

P0A0D
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P0A0D detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-646
>> GO TO 2. A
EVB
LBC
— Continuity
Connector Terminal
YES >> GO TO 3.
LBC G
— Continuity
Connector Terminal
H
YES >> GO TO 4.
I
YES >> Replace Li-ion battery controller. Refer to EVB-788, "Removal and Installation".
K

M
NO >> Replace service plug. N
O
JPCIA0347ZZ
EVB-647
DTC DETECTION LOGIC

P0A1F ULE
CPU.
POSSIBLE CAUSES
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
Is P0A1F detected?
EVB-648
A

CELL CONT LIN
ler.
work)
D
POSSIBLE CAUSES
• Module E
FAIL-SAFE
• Charge stop

With CONSULT H
3. Check DTC. I
Is P3030 detected?
K
With CONSULT
Is P3030 detected?
O
and Installation".
P
EVB-649
DTC DETECTION LOGIC

CELL CONT ASIC1
grated circuit1)
CELL CONT ASIC2
grated circuit2)
CELL CONT ASIC3
grated circuit3)
CELL CONT ASIC4
grated circuit4)
CELL CONT ASIC5
grated circuit5)
CELL CONT ASIC6
grated circuit7)
CELL CONT ASIC8
grated circuit8)
CELL CONT ASIC9
grated circuit9)
CELL CONT ASIC10
grated circuit10)
CELL CONT ASIC11
grated circuit11)
CELL CONT ASIC12
grated circuit12)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
With CONSULT
EVB-650
3. Check DTC.
With CONSULT
Is P3030 detected?
and Installation".
EVB-651
DTC DETECTION LOGIC

CELL CONT ASIC13
grated circuit13)
CELL CONT ASIC14
grated circuit14)
CELL CONT ASIC15
grated circuit15)
CELL CONT ASIC16
grated circuit16)
CELL CONT ASIC17
grated circuit17)
CELL CONT ASIC18
grated circuit19)
CELL CONT ASIC20
grated circuit20)
CELL CONT ASIC21
grated circuit21)
CELL CONT ASIC22
grated circuit22)
CELL CONT ASIC23
grated circuit23)
CELL CONT ASIC24
grated circuit24)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
With CONSULT
EVB-652
3. Check DTC.
With CONSULT
Is P3030 detected?
and Installation".
EVB-653
DTC DETECTION LOGIC

circuit1 voltage)
circuit2 voltage)
circuit3 voltage)
circuit4 voltage)
circuit5 voltage)
circuit6 voltage)
circuit7 voltage)
circuit8 voltage)
circuit9 voltage)
circuit10 voltage)
circuit11 voltage)
circuit12 voltage)
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge stop
With CONSULT
EVB-654
3. Check DTC.
EVB

D
With CONSULT
2. Check DTC.
E
J
EVB-655
DTC DETECTION LOGIC

circuit13 voltage)
circuit14 voltage)
circuit15 voltage)
circuit16 voltage)
circuit17 voltage)
circuit18 voltage)
circuit19 voltage)
circuit20 voltage)
circuit21 voltage)
circuit22 voltage)
circuit23 voltage)
circuit24 voltage)
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge stop
With CONSULT
EVB-656
3. Check DTC.
EVB

D
With CONSULT
2. Check DTC.
E
J
EVB-657
DTC DETECTION LOGIC

P3061
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P3061 detected?
EVB-658
P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
A

BYPASS SW
(Bypass switch)
POSSIBLE CAUSES D
• Module
FAIL-SAFE
F
DTC DETECTION LOGIC
G
With CONSULT
3. Check DTC. H
Is P3062 detected?
J
With CONSULT K
M
EVB-659
DTC DETECTION LOGIC

ler.
tegrated circuit)
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P3064 detected?
EVB-660
A

circuit1 open)
D
circuit2 open)
E
circuit3 open)
circuit4 open)
circuit5 open)
circuit7 open)
circuit8 open)
circuit9 open)
circuit10 open) L
circuit11 open) M
circuit12 open) N
POSSIBLE CAUSES
FAIL-SAFE
P
• Charge stop
DTC DETECTION LOGIC
With CONSULT
EVB-661
3. Check DTC.
Is P308B-P3096 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
OVER DISCHARGE related codes) is detected simultaneously with “P308B”-“P3096”.
Is P3049-P3060 or P3375-P33A4 detected?
YES-2 >> “P3375”-“P33A4” are detected simultaneously.
“P3381”-“P338C”. Refer to EVB-704, "Diagnosis Procedure".
“P338D”-“P3398”. Refer to EVB-708, "Diagnosis Procedure"
• When “P3399”-“P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399”-“P33A4”. Refer to EVB-713, "Diagnosis Procedure".
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
EVB-662
>> GO TO 3.

B
YES >> GO TO 4.
EVB
DTC.

DTC Continuity
1 25 50
2 10 51
3 26 52
4 11 53 G
5 27 54
6 12 55
H
7 28 56
8 13 57
9 29 58 I
10 14 59
11 30 60
12 15 61
13 33 62
14 49 63
K
15 34 77
16 50 78
17 35 80 L
18 51 81
19 36 82
20 52 83
21 37 84
22 53 85 N
23 38 86
24 54 87
O
and Installation".
EVB-663
DTC DETECTION LOGIC

circuit13 open)
circuit14 open)
circuit15 open)
circuit16 open)
circuit17 open)
circuit19 open)
circuit20 open)
circuit21 open)
circuit22 open)
circuit23 open)
circuit24 open)
POSSIBLE CAUSES
FAIL-SAFE
• Charge stop
DTC DETECTION LOGIC
With CONSULT
EVB-664
3. Check DTC. A
EVB
DANGER:
maintenance.
E
WARNING:
CAUTION:
With CONSULT J
NO >> GO TO 2.
2.PRECONDITIONING P
WARNING:
Installation".
EVB-665
>> GO TO 3.
YES >> GO TO 4.
detected DTC.
JSCIA1223ZZ

DTC Continuity
25 40 110
26 56 111
EVB-666

DTC Continuity A
27 112
P3098 LB14 Existed
28 113 B
29 114
P3099 LB14 Existed
30 115
31 116 EVB
P309A LB14 Existed
32 117
33 118
34 119
35 120
P309C LB14 Existed
37 bar 122
P309D LB14 Existed
38 123
F
39 124
P309E LB14 Existed
40 125
41 127 G
P309F LB14 Existed
42 128
43 137
44 138
45 140
P30A1 LB15 Existed
46 141 I
47 16 142
48 32 143
J
and Installation".
EVB-667
DTC DETECTION LOGIC

DLC DIAGNOSIS VCM
seconds or more.
control module)
POSSIBLE CAUSES
• VCM
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P30E0 detected?

With CONSULT
Is P30E0 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-668
A

D
POSSIBLE CAUSES
FAIL-SAFE F
None
G
With CONSULT
3. Check DTC.
With CONSULT
Is P30E2 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
EVB-669
DTC DETECTION LOGIC

DLC DIAGNOSIS MC
controller)
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P30E3 detected?

With CONSULT
Is P30E3 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-670
A

module)
D
POSSIBLE CAUSES
FAIL-SAFE
None F
With CONSULT
3. Check DTC.
Is P30E4 detected?
J

K
With CONSULT
L
Is P30E4 detected?
NO >> GO TO 2.
M
With CONSULT
Is U1000 detected?
and Installation".
P
EVB-671
DTC DETECTION LOGIC

COMMUNICATION ERROR
POSSIBLE CAUSES
• VCM
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P318D detected?
EVB-672
A

NOTE:

D
COMMUNICATION ERROR
POSSIBLE CAUSES E
• VCM
F
FAIL-SAFE
With CONSULT H
I
7. Check DTC.
Is P318E detected?
L

M
With CONSULT
N
Is P318E detected?
NO >> GO TO 2.
O
With CONSULT
Is U1000 detected?
and Installation".
EVB-673
DTC DETECTION LOGIC

NOTE:

P3191
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
7. Check DTC.
Is P3191 detected?

With CONSULT
Is P3191 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-674
A

NOTE:

D
P3196
POSSIBLE CAUSES E
F
FAIL-SAFE
None
With CONSULT H
I
7. Check DTC.
Is P3196 detected?
L

M
With CONSULT
N
Is P3196 detected?
NO >> GO TO 2.
O
With CONSULT
Is U1000 detected?
and Installation".
EVB-675
DTC DETECTION LOGIC

COMMUNICATION ERROR
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P3198 detected?

With CONSULT
Is P3198 detected?
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".
EVB-676
A

COMMUNICATION ERROR
POSSIBLE CAUSES D
• VCM
E
FAIL-SAFE
With CONSULT G
3. Check DTC.
H
Is P3199 detected?
J
EVB-677
DTC DETECTION LOGIC

COMMUNICATION ERROR
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P319C detected?
EVB-678
P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
A

P31A4
POSSIBLE CAUSES D
VCM
FAIL-SAFE E
With CONSULT
3. Check DTC.
Is P31A4 detected?
H
I
J
EVB-679
DTC DETECTION LOGIC

P31A7
POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
Is P31A7 detected?
EVB-680
A

P3302
P3303
P3304
E
P3305
P3306
P3307
G
P3308
P3309 H
P330A
I
P330B
P330C
J
P330D
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-681
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
1 33
17 34
17 34
2 35
2 35
18 36
EVB-682

DTC Continuity A
18 36
3 37
3 37
19 38
19 38
D
4 39
4 39 E
20 40
F
20 40
5 42 G
5 42
H
21 43
21 43
6 44
6 44
J
22 45
22 45
K
7 46
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-683
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-684
A

P330E
P330F
P3310
E
P3311
P3312
P3313
G
P3314
P3315 H
P3316
I
P3317
P3318
J
P3319
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-685
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
LB8 7 46
LB7
57 47
57 47
42 48
42 LB12 48
P3310 15 LB7 34 77 Existed
LB13
58 65
EVB-686

DTC Continuity A
58 65
P3311 16 LB7 50 LB13 78 Existed B
43 66
43 66
59 69
59 69
D
P3313 18 LB7 51 LB13 81 Existed
44 70
44 70 E
P3314 19 LB7 36 LB13 82 Existed
60 71
F
60 71
P3315 20 LB7 52 LB13 83 Existed
45 72 G
45 72
P3316 21 LB7 37 LB13 84 Existed
H
61 73
61 73
P3317 22 LB7 53 LB13 85 Existed I
46 74
46 74
P3318 23 LB7 38 LB13 86 Existed
J
62 75
62 75
K
P3319 24 LB7 54 LB13 87 Existed
47 76
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-687
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-688
A

P331A
P331B
P331C
E
P331D
P331E
P331F
G
P3320
P3321 H
P3322
I
P3323
P3324
J
P3325
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-689
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT
EVB-690
EVB
JSCIA1228GB

DTC Continuity
55 89
48 90 L
48 90
M
64 91
EVB-691

DTC Continuity
LB7 64 91
92
92
93
93
94
94
95
95
96
Bus bar 96
97
97
99
99
100
100
101
101
102
YES >> GO TO 4.
and Installation".
EVB-692
A
EVB
G
JSCIA0338ZZ
H
I
Terminals
Voltage
(+) (-)
(Approx.) J
Module
EVB-693
DTC DETECTION LOGIC

P3326
P3327
P3328
P3329
P332A
P332B
P332C
P332D
P332E
P332F
P3330
P3331
POSSIBLE CAUSES
• Module
• Bus bar
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
EVB-694
A
DANGER:
maintenance.
EVB
WARNING:
CAUTION:
With CONSULT
H
I
NO >> GO TO 2.
2.PRECONDITIONING J
WARNING:
Installation".
L
>> GO TO 3.
M
With CONSULT
EVB-695
JSCIA1228GB
EVB-696

DTC Continuity
102
B
103
103 EVB
104
D
104
105 E
105
106
F
106
G
107
Bus bar 107
108
LB14 108
I
LB15
130
130 J
131
K
131
132 L
132
M
133
133
P3330 47 16 LB15 142 Existed N
LB8
8 134
8 134
P3331 48 LB8 32 LB15 143 Existed O
24 135
YES >> GO TO 4.
EVB-697
and Installation".

JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-698
A

P3375
P3376
P3377
E
P3378
P3379
P337A
G
P337B
P337C H
P337D
I
P337E
P337F
J
P3380
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop

With CONSULT
3. Check DTC.
EVB-699
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
1 33
17 34
17 34
2 35
2 35
18 36
EVB-700

DTC Continuity A
18 36
3 37
3 37
19 38
19 38
D
4 39
4 39 E
20 40
F
20 40
5 42 G
5 42
H
21 43
21 43
6 44
6 44
J
22 45
22 45
K
P3380 12 LB8 15 LB12 61 Existed
7 46
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-701
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-702
A

P3381
P3382
P3383
E
P3384
P3385
P3386
G
P3387
P3388 H
P3389
I
P338A
P338B
J
P338C
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-703
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.

DTC Continuity
LB8 7 46
P3381 13 33 LB12 62 Existed
LB7
57 47
57 47
P3382 14 LB7 49 LB12 63 Existed
42 48
42 LB12 48
P3383 15 LB7 34 77 Existed
LB13
58 65
EVB-704

DTC Continuity A
58 65
P3384 16 LB7 50 LB13 78 Existed B
43 66
43 66
59 69
59 69
D
P3386 18 LB7 51 LB13 81 Existed
44 70
44 70 E
P3387 19 LB7 36 LB13 82 Existed
60 71
F
60 71
P3388 20 LB7 52 LB13 83 Existed
45 72 G
45 72
P3389 21 LB7 37 LB13 84 Existed
H
61 73
61 73
46 74
46 74
J
62 75
62 75
K
47 76
YES >> GO TO 4.
M
and Installation".
Assembly".
P
EVB-705
JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-706
A

P338D
P338E
P338F
E
P3390
P3391
P3392
G
P3393
P3394 H
P3395
I
P3396
P3397
J
P3398
K
POSSIBLE CAUSES
• Module L
• Bus bar
M
FAIL-SAFE
• No driving
• Charge stop
N
With CONSULT
3. Check DTC.
EVB-707
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT
EVB-708
EVB
JSCIA1228GB

DTC Continuity
55 89
48 90 L
48 90
M
64 91
EVB-709

DTC Continuity
LB7 64 91
92
92
93
93
94
94
95
95
96
Bus bar 96
97
97
99
99
100
100
101
101
102
YES >> GO TO 4.
and Installation".
EVB-710
A
EVB
G
JSCIA0338ZZ
H
I
Terminals
Voltage
(+) (-)
(Approx.) J
Module
EVB-711
DTC DETECTION LOGIC

P3399
P339A
P339B
P339C
P339D
P339E
P339F
P33A0
P33A1
P33A2
P33A3
P33A4
POSSIBLE CAUSES
• Module
• Bus bar
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
EVB-712
A
DANGER:
maintenance.
EVB
WARNING:
CAUTION:
With CONSULT
H
I
NO >> GO TO 2.
2.PRECONDITIONING J
WARNING:
Installation".
L
>> GO TO 3.
M
With CONSULT
EVB-713
JSCIA1228GB
EVB-714

DTC Continuity
102
B
103
103 EVB
104
D
104
105 E
105
106
F
106
G
107
Bus bar 107
108
LB14 108
I
LB15
130
130 J
131
K
131
132 L
132
M
133
133
LB8
8 134
8 134
24 135
YES >> GO TO 4.
EVB-715
and Installation".

JSCIA0338ZZ

Terminals
Voltage
(+) (-)
(Approx.)
Module
EVB-716
A

P33D4
POSSIBLE CAUSES D
Li-ion battery
FAIL-SAFE
E
With CONSULT
3. Check DTC.
Is P33D4 detected?
H
I
J
EVB-717
DTC DETECTION LOGIC

P33D5
POSSIBLE CAUSES
• Current sensor
FAIL-SAFE
• Charge stop
With CONSULT
3. Check DTC.
Is P33D5 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
EVB-718
NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
YES >> GO TO 4. F

Continuity
S 10
I
LB5 V LB10 9 Exited
G 15
YES >> GO TO 5.
L
S G M
V G
N
YES >> GO TO 6.


EVB-719
and Installation".
EVB-720
A

CURRENT SENSOR
(Current sensor)
POSSIBLE CAUSES D
FAIL-SAFE E
• Charge stop
F
G
With CONSULT
3. Check DTC. H
Is P33D6 detected?
J
DANGER:
maintenance. L
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-721
>> GO TO 2.

Resistance value
Connector Terminal
10 9
9 15
and Installation".
NO >> GO TO 3.
RENT SENSOR)

Continuity
10 S
15 G
EVB-722
A

POSSIBLE CAUSES E
FAIL-SAFE
None
G
With CONSULT H
3. Check DTC. I
K
DANGER:
maintenance.
M
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
EVB-723
Installation".
>> GO TO 2.
2.CHECK HARNESS
YES >> GO TO 3.
YES >> GO TO 4.
Front module stuck
Battery tem-
sor
LH center LB9 1
Ground No existed
LH rear LB9 3
Rear module stuck
Li-ion battery
Battery tem-
controller
harness con-
sor
nector
Rear center LB11 25
Ground No existed
Rear LH LB11 27
and Installation".

STACK).
sensor terminals.
EVB-724
Front module stuck
Battery tem- A
perature
sensor ter-
minals
B
LH rear 3 and 4
40 (104) Approx. 2.3 EVB
Rear module stuck
Li-ion bat-
tery control-
D
connector
terminals E
Rear LH 27 and 31
40 (104) Approx. 2.3 F
G
H
EVB-725
DTC DETECTION LOGIC

P33DF
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P33DF detected?
EVB-726
A

P33E0 SENSOR
low.
POSSIBLE CAUSES D
FAIL-SAFE E
With CONSULT
3. Check DTC.
Is P33E0 detected?
H
I
J
EVB-727
DTC DETECTION LOGIC

P33E1 SENSOR
POSSIBLE CAUSES
FAIL-SAFE
With CONSULT
3. Check DTC.
Is P33E1 detected?
ponent Inspection".
EVB-728
A

D
POSSIBLE CAUSES
E
FAIL-SAFE
• No driving
• Charge stop
With CONSULT
3. Check DTC.
Is P33E2 detected?
J

K
With CONSULT
L
dure".
NO >> GO TO 2. M

With CONSULT N

EVB-729
DTC DETECTION LOGIC

POSSIBLE CAUSES
FAIL-SAFE
None
With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-730
>> GO TO 2. A

STACK). E
sensor terminals.
Battery tem-
perature
sensor ter- G
minals
LH rear 3 and 4
40 (104) Approx. 2.3
Rear module stuck

I
Li-ion bat-
tery control-
connector J
terminals
Rear LH 27 and 31
40 (104) Approx. 2.3
M
EVB-731
DTC DETECTION LOGIC

P33E6
POSSIBLE CAUSES
• Module
FAIL-SAFE
• Charge limit
With CONSULT
3. Check DTC.
Is P33E6 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
With CONSULT
EVB-732
NO >> GO TO 2.
B
With CONSULT
of cells).
D

I
With CONSULT
YES >> GO TO 5.
NO >> GO TO 4. K
With CONSULT L
M
O
NOTE:
P
EVB-733

ing segments of Li-
Time to 2 segments
charge gauge
6 Approx. 90 minute
5 Approx. 70 minute
4 Approx. 40 minute
3 Approx. 20 minute
>> GO TO 5.
With CONSULT
STACK).
6.PRECONDITIONING
WARNING:
>> GO TO 7.
YES >> GO TO 8.
YES >> GO TO 9
EVB-734
DANGER:
NO >> Replace Li-ion battery controller. Refer to EVB-807, "LI-ION BATTERY CONTROLLER : Removal EVB
and Installation".
TOR D
Resistance val-
Terminal
ue F
Approx. 0 Ω
YES >> GO TO 11
P
JSCIA1229GB
EVB-735
Resistance val-
Terminal
ue
Module harness con-
nector
at step 5.
JSCIA1228GB
Resistance val-
Terminal
ue
EVB-736
P33EA BATTERY HEATER RELAY
A

Li-ion battery controller judges that the status of a relay control signal transmitted
BATTERY HEATER RELAY
P33EA from Li-ion battery controller and that of a relay status signal transmitted from
(Battery heater relay)
heater relay unit do not match.
D
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.
E
• 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.
F
POSSIBLE CAUSE
• Heater relay unit
• Harness or connector G
FAIL-SAFE
H
I
With CONSULT
1. Select “ACTIVE TEST” of “HV BAT.”
2. Select “HEATER RELAY UNIT.” Touch “START.”
J
>> GO TO 2.
2.PERFORM DTC CONFIRMATION PROCEDURE-2 K
With CONSULT
2. Check DTC. L
Is P33EA detected?
NO-1 >> To check malfunction symptom before repair: Refer toGI-47, "Intermittent Incident". M
N
DANGER:
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of O
maintenance. P
WARNING:
EVB-737
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.
2.CHECK CONTINUITYOF LI-ION BATTERY CONTROLLER AND HEATER RELAY UNIT
1. Remove service plug switch bracket. Refer to EVB-812, "BATTERY JUNCTION BOX AND BATTERY
2. Disconnect Li-ion battery controller harness connector and heater relay unit harness connector.
3. Check continuity Li-ion battery controller harness connector and heater relay unit harness connector.
Li-ion battery controller Heater relay unit

Continuity
20 3
LB10 LB17 Existed
18 6
YES >> GO TO 3.
3.CHECK CONTINUITY OF LI-ION BATTERY AND HEATER RELAY UNIT
Check continuity Li-ion battery harness connector and heater relay unit harness connector.
Li-ion battery Heater relay unit

Continuity
YES >> GO TO 4.
4.CHECK CONTINUITY OF HEATER RELAY UNIT AND LI-ION BATTERY CONTROLLER
Check continuity heater relay unit harness connector and Li-ion battery controller harness connector.
Heater relay unit Li-ion battery controller

Continuity
4 3
5 14
LB17 LB10 Existed
7
2
8
YES >> GO TO 5.
EVB-738
5.CHECK HEATER RELAY UNIT A

YES >> Replace Li-ion battery controller. Refer to EVB-807, "LI-ION BATTERY CONTROLLER : Removal B
and Installation".
NO >> Replace heater relay unit. Refer to EVB-810, "LI-ION BATTERY HEATER RELAY UNIT : Removal
and Installation".
EVB
1.CHECK HEATER RELAY UNIT D

1. Remove heater relay unit. Refer to EVB-810, "LI-ION BATTERY HEATER RELAY UNIT : Removal and
Installation".
2. Check the continuity between heater relay unit terminals. E
Terminals Continuity
11 and 10 Not existed F

YES >> INSPECTION END G
NO >> Replace heater relay unit. Refer to EVB-810, "LI-ION BATTERY HEATER RELAY UNIT : Removal
and Installation".
H
EVB-739
DTC DETECTION LOGIC

POSSIBLE CAUSE
Module
FAIL-SAFE
• Charge limit
NOTE:
YES >> GO TO 3.
NO >> GO TO 2.

>> GO TO 3.
>> GO TO 4.
With CONSULT
3. Check DTC.
Is P33ED detected?
EVB-740
1.CHECK DATA MONITOR OR FREEZE FRAME DATA (FFD) B
With CONSULT
1. Select “DATA MONITOR” or “FFD”. EVB
YES >> Replace corresponding Module. Refer to EVB-828, "FRONT MODULE STACK : Removal and D
NO >> GO TO 2.
E
2. DTC CONFIRMATION PROCEDURE OPERATION
tion". F
>> Replace corresponding Module. Refer to EVB-828, "FRONT MODULE STACK : Removal and G
H
EVB-741
P33EE BATTERY HEATER CONTROL SYSTEM
DTC DETECTION LOGIC

BATTERY HEATER CONTROL Under extremely low temperatures that PTC heater activates, Li-ion battery con-
P33EE SYSTEM troller judges that the temperature of Li-ion battery is still low after a lapse of spec-
(Battery heater control system) ified time.
POSSIBLE CAUSE
• Heater relay unit
• PTC heater
FAIL-SAFE
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.
2.CHECK CONNECTION STATUS OF LI-ION BATTERY HEATER & COOLING UNIT CONNECTOR
Check the connection status of the Li-ion battery heater & cooling unit connector.
YES >> GO TO 3.
NO >> Restore the connection status of the Li-ion battery heater & cooling unit connector.
3.CHECK RESISTANCE OF PTC HEATER
EVB-742
Check continuity of PTC heater.
A
Li-ion battery heater & cooling unit
Continuity
Terminal
B
2 3 Existed
YES >> GO TO 4. EVB
NO >> Replace applicable Li-ion battery heater & cooling unit. Refer to EVB-820, "LI-ION BATTERY
HEATER & COOLING UNIT : Removal and Installation".
4.CHECK CONTINUITY OF LI-ION BATTERY HEATER & COOLING UNIT AND BATTERY JUNCTION BOX D
1. Disconnect Li-ion battery heater & cooling unit and battery junction box harness connector.
2. Check continuity Li-ion battery heater & cooling unit and battery junction box harness connector.
E
Li-ion battery heater & cooling
unit Continuity
Connector Terminal Connector Terminal F
G
YES >> GO TO 5.
5.CHECK CONTINUITY OF LI-ION BATTERY HEATER & COOLING UNIT AND HEATER RELAY UNIT H
1. Disconnect Li-ion battery heater & cooling unit and heater relay unit harness connector harness connec-
tor.
2. Check continuity Li-ion battery heater & cooling unit and heater relay unit harness connector harness con- I
nector.

Heater relay unit
J
unit Continuity
LB19 2 LB18 11 Existed K
YES >> Replace Li-ion battery heater & cooling unit. Refer to EVB-810, "LI-ION BATTERY HEATER
RELAY UNIT : Removal and Installation". L
EVB-743
DTC DETECTION LOGIC

EVAPORATOR TEMP SENSOR
P33F2 Evaporator temperature sensor signal voltage is too high or too low.
(Evaporator temperature sensor)
POSSIBLE CAUSE
• Evaporator temperature sensor
FAIL-SAFE
With CONSULT
3. Check DTC.
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
EVB-744
>> GO TO 2. A
2.CHECK HARNESS
1. Power switch OFF. B
YES >> GO TO 3. EVB
Refer to EVB-745, "Component Inspection". D
YES >> GO TO 4.
NO >> Replace Li-ion battery heater & cooling unit. E
4.CHECK HARNESS BETWEEN EVAPORATOR TEMPERATURE SENSOR AND GROUND

1. Disconnect Li-ion battery heater & cooling unit harness connector. F
2. Check continuity between Li-ion battery heater & cooling unit harness connector and ground.
Li-ion battery heater & cool- G

ing unit Continuity
Ground
Connector Terminal
LB16 12 No existed H
and Installation". I
J

1. Remove Li-ion battery heater & cooling unit harness connector. K
2. Check resistance between Li-ion battery heater & cooling unit terminals.
Terminals Condition Resistance (kΩ) L

10 (50) Approx. 4.0
11 and 12 Temperature °C (°F) 25 (77) Approx. 2.2
40 (104) Approx. 1.3
M

NO >> Replace Li-ion battery heater & cooling unit. Refer to EVB-820, "LI-ION BATTERY HEATER &
COOLING UNIT : Removal and Installation".
O
EVB-745
P33F5 BATTERY FAN
P33F5 BATTERY FAN
DTC DETECTION LOGIC
Trouble diagnosis
DTC Detecting condition
(Trouble diagnosis contents)
• Li-ion battery cooling fan speed signal value is the specified value or more for
BATTERY FAN a certain period of time when blower motor is OFF
P33F5
(Battery fan) • Li-ion battery cooling fan speed signal value is the specified value or less for a
certain period of time when blower motor is ON
POSSIBLE CAUSES
• Li-ion battery heater & cooling unit
FAIL-SAFE
Li-ion battery cooler and heater stop
1.CHECK BLOWER MOTORN FUNCTION
WITH CONSULT
2. Record DTC and Freeze frame data.
3. Erase DTC.
4. Perform “BATTERY HEATER” with the “ACTIVE TEST” mode and wait at least 30 seconds.
5. Select “Self Diagnostic Result” mode of “HV BAT”.
6. Check DTC.
Is P33F5 detected?
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK BLOWER MOTOR OPERATION
WITH CONSULT
EVB-746
P33F5 BATTERY FAN
2. Perform “BATTERY HEATER” with the “ACTIVE TEST” mode. A
Is the blower motor activated?
and Installation". B
NO >> GO TO 2.
2.CHECK FUSE
EVB
2. Pull out 10 A fuse (No.84) and check that the fuse is not fusing.
D
YES >> GO TO 3.
3.CHECK BLOWER MOTOR INPUT SIGNAL CIRCUIT-1 E
Check voltage between Li-ion battery harness connector terminal.
Li-ion battery F
Terminal Voltage
Connector
(+) (−)
G
19 20
Battery volt-
LB1 24 22
age
33 36 H
YES >> GO TO 4.
NO >> GO TO 7. I
4.PRECONDITIONING
WARNING: J
1. Disconnect high voltage circuit. Refer to EVB-567, "How to Disconnect High Voltage".
2. Check voltage in high voltage circuit. Refer to EVB-571, "Check Voltage in High Voltage Circuit". K
>> GO TO 5.
5.CHECK BLOWER MOTOR INPUT SIGNAL CIRCUIT-2 L
3. Check continuity between Li-ion battery harness connector and Li-ion battery heater & cooling unit har- M
ness connector.
Li-ion battery heater & cooling N

Li-ion battery
unit Continuity
19 7 O
33 16
P
YES >> GO TO 6.
6.CHECK BLOWER MOTOR GROUND CIRCUIT
EVB-747
P33F5 BATTERY FAN
2. Check continuity between Li-ion battery harness connector and Li-ion battery heater & cooling unit har-
ness connector.

Li-ion battery
unit Continuity
13 20
22 36
YES >> Replace Li-ion battery heater & cooling unit. Refer to EVB-820, "LI-ION BATTERY HEATER &
COOLING UNIT : Removal and Installation".
7.CHECK LI-ION BATTERY POWER SUPPLY CIRCUIT
3. Check voltage between Li-ion battery harness connector and ground.
(+)
(−) Voltage
Li-ion battery
Connector Terminal
19
Ground Battery voltage
LB1 24
33
YES >> GO TO 8.
8.CHECK LI-ION BATTERY GROUND CIRCUIT
1. Check continuity between Li-ion battery harness connector and ground.
Li-ion battery
Continuity
Connector Terminal
20 Ground
LB1 22 Existed
36
YES >> Refer to GI-47, "Intermittent Incident".
EVB-748
A
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul- B
with 2 communication lines (CAN-H, CAN-L) allowing a high rate of information transmission with less wiring. EVB
tion Signal Chart". D
DTC DETECTION LOGIC
Trouble diagnosis name E

U1000
(CAN communication circuit) more. F
POSSIBLE CAUSE
G
FAIL-SAFE
• Charge stop
H
I
EVB-749
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK HIGH VOLTAGE FUSE
YES >> GO TO 2.
TERY PACK UPPER CASE : Exploded View".
JSCIA1251ZZ
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
Check connection status of each bus bar in high voltage circuit
YES >> GO TO 4.
CAUTION:
EVB-750
High voltage harness between battery junction box and rear module stack A
B

EVB

EVB-751
DANGER:
maintenance.
WARNING:
CAUTION:
The following diagnosis procedure must be performed when “P0AA6 or P33E1” are detected and Li-ion
With CONSULT
1. Power switch ON.
NOTE:
>> GO TO 2
CAUTION:
Installation".
3. Remove Li-ion battery cooling duct (front and rear). Refer to EVB-820, "LI-ION BATTERY HEATER &
COOLING UNIT : Exploded view".
4. Remove service plug switch bracket (with heater relay unit, service plug switch and bus bar that connects
service plug and front module stack RH). Refer to EVB-812, "BATTERY JUNCTION BOX AND BATTERY
EVB-752
EVB
H
JSCIA1230ZZ

I
+
Terminal

K
YES >> GO TO 5.
NO >> GO TO 3. L
M
bracket.
WARNING:
tem, there is the danger of damage to electronic devices. O
Be sure to set the insulation resistance tester to 500 V when P
being inspected.
NOTE:
EVB-753
+ — Resistance
NO >> GO TO 4.
stack RH.
JSCIA1232ZZ

bracket.
WARNING:
being inspected.
NOTE:
+ — Resistance
1. Disconnect voltage detection harness connector of front module stack LH.
EVB-754
EVB
H
JSCIA1234ZZ

I
J
JSCIA1230ZZ
EVB-755
+
Terminal

YES >> Replace voltage detection harness of front module stack LH.
NO >> GO TO 6.
JSCIA1235ZZ
EVB-756
EVB
H
JSCIA1230ZZ

I
+
Terminal

K
NO-1 (When is malfunctioning)>>GO TO 7. L
M
EVB-757
JSCIA1236ZZ
JSCIA1237ZZ
EVB-758
+ A
Terminal
B

YES >> GO TO 8. EVB
NO >> GO TO 10.
8.CHECK MODULE-1 D
tion".
NOTE:
Do not disassemble module stack. E
F
H
JSCIA0740ZZ
I
+
Module − Voltage
J
Terminal

K

YES >> GO TO 9. L
Assembly".
9.CHECK MODULE-2 M
WARNING: N
danger of electric shock. If used in the vehicle 12 V system, O
CAUTION: P
EVB-759
+
Terminal

Assembly".
JSCIA1238ZZ
EVB-760
EVB
I
JSCIA1239ZZ

J
+
K
Terminal
Battery pack ground Approx. 0 V L
YES >> GO TO 13.
NO >> GO TO 11. M
1. Using insulation resistance tester, measure insulation resistance between high voltage terminal / of N
EVB-761
JSCIA1240ZZ
WARNING:
CAUTION:

— Resistance
Terminal

NO >> GO TO 12.
EVB-762
EVB
I
JSCIA1241ZZ

J
K
EVB-763
JSCIA1242ZZ
WARNING:
CAUTION:

— Resistance
Terminal

13.CHECK MODULE-3
tion".
NOTE:
EVB-764
MD12) in front module stack RH and module body. A
EVB
JSCIA0740ZZ
+
E
Module − Voltage
Terminal
F

G
YES >> GO TO 14.
Assembly".
H
14.CHECK MODULE-4
(MD1 and MD12) in front module stack RH and module body. I
WARNING:
applies 500 V when measuring. If used incorrectly, there is the J
sure to work safely. K
CAUTION:
performing this test. Using a setting higher than 500 V can L
+ M
Terminal
N

Assembly". P
EVB-765
JSCIA1243ZZ
JSCIA1244ZZ
EVB-766
: Battery pack front A
+
B
Terminal
Battery pack ground Approx. 0 V EVB
YES >> GO TO 16.
D
NO >> GO TO 18.
16.CHECK MODULE-5
1. Remove front module stack RH. Refer to EVB-828, "FRONT MODULE STACK : Removal and Installa- E
tion".
NOTE:
Do not disassemble module stack. F
G
I
JSCIA0740ZZ
J
+
Module − Voltage
Terminal K

L
YES >> GO TO 17.
NO >> Replace malfunctioning module. Refer to EVB-833, "FRONT MODULE STACK : Disassembly and M
Assembly".
17.CHECK MODULE-6
N
WARNING:
Unlike the ordinary tester, the insulation resistance tester O
there is the danger of damage to electronic devices. Read the P
CAUTION:
EVB-767
+
Terminal

Assembly".
1. Remove bus bar that connects front module stack LH and rear module stack.
JSCIA1245ZZ
EVB-768
EVB
H
JSCIA1244ZZ

I
+
Terminal
K
YES >> GO TO 19.
NO >> GO TO 21. L
19.CHECK MODULE-7
NOTE: M
module stack and module body. N
JSCIA0740ZZ
EVB-769
+
Module − Voltage
Terminal

YES >> GO TO 20.
Assembly".
20.CHECK MODULE-8
Measure insulation resistance between terminal / of all modules
WARNING:
CAUTION:
+
Terminal

Assembly".
EVB-770
EVB
H
JSCIA1246ZZ

I
JSCIA1247ZZ
EVB-771
+
Terminal

YES >> GO TO 22.
NO >> GO TO 24.
22.CHECK MODULE-9
NOTE:
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 23.
Assembly".
23.CHECK MODULE-10
WARNING:
CAUTION:
EVB-772
+ A
Terminal
B
EVB
Assembly". D

1. Using insulation resistance tester, measure insulation resistance between high voltage terminal / of E
JSCIA1248ZZ M

N
WARNING:
danger of damage to electronic devices. Read the insulation resistance tester instruction manual O
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting P

— Resistance
Terminal
EVB-773
NO >> GO TO 25.
JSCIA1249ZZ
EVB-774
EVB
H
JSCIA1250ZZ

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

— Resistance
Terminal
Battery pack ground 1,000 MΩ or more M

YES >> Replace bus bar that connects battery junction box and terminal of voltage detection harness. N
O
EVB-775
LI-ION BATTERY HEATER SYSTEM INSULATION RESISTANCE CHECK
DANGER:
maintenance.
WARNING:
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.
Check the harness shield between the heater relay unit and the Li-ion battery heater for scratches and cracks.
YES >> GO TO 3.
NO >> Repair or replace error-detected parts and Li-ion battery controller.
3.CHECK HEATER RELAY UNIT INSULATION RESISTANCE
WARNING:
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully
1. Disconnect high voltage harness connector from heater relay unit.
NOTE:
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:
EVB-776
Heater relay unit A

Ground Resistance
Terminal
10
Battery pack lower case 1,000 MΩ or more B
11
YES >> GO TO 4. EVB
NO >> Replace heater relay unit and Li-ion battery controller.
4.CHECK LI-ION BATTERY HEATER
D
WARNING:
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully E
1. Disconnect high voltage harness connector from Li-ion battery heater.
NOTE: F
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
G
CAUTION:
H
Li-ion battery heater
Ground Resistance
Connector Terminal
I
2
LB16 Battery pack lower case 1,000 MΩ or more
3
YES >> GO TO 5.
NO >> Replace corresponding Li-ion battery heater and Li-ion battery controller.
5.CHECK HIGH VOLTAGE HARNESS INSULATION RESISTANCE K
WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used L
of damage to electronic devices. Read the insulation resistance tester instruction manual carefully
1. Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until M
CAUTION:
Be sure to set the insulation resistance tester to 500V when performing this test. Using a setting N
High voltage harness O

Ground Resistance
Connector Terminal
LB18 11 Battery pack lower case 1,000 MΩ or more
YES >> INSPECTION END.
NO >> Replace high voltage harness.
EVB-777
DANGER:
maintenance.
WARNING:
CAUTION:
1.CHECK FUSE

Battery 43
57
Power switch ON
82
Is the fuse fusing?
NO >> GO TO 2.
2.CHECK LI-ION BATTERY CONTROLLER GROUND CIRCUIT
+
Connector Terminal
6
8
YES >> GO TO 3.
EVB-778
+ A
Connector Terminal
B
12V battery power
E128 5 Ground
supply
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK BATTERY POWER SUPPLY CIRCUIT D
E
+
No.43 fuse ter-
E128 5 Existed
minal
+
J
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4 K
E128 Ground 11 – 14 V
31
YES >> GO TO 8.
NO >> GO TO 6.
6.CHECK POWER SWITCH ON POWER SUPPLY CIRCUIT-1 M
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
P
YES >> GO TO 7.
EVB-779
Li-ion battery
— Continuity
Connector Terminal
No.82 fuse ter-
E128 31 Existed
minal
8.PRECONDITIONING
WARNING:
Installation".
>> GO TO 9.
9.CHECK HARNESS BETWEEN LI-ION BATTERY AND LI-ION BATTERY CONTROLLER
LBC Li-ion battery

Continuity
5 31
7 4
12 5
LB10 LB1 Existed
2 8
3 6
14 7
EVB-780
EV BATTERY SYSTEM
< SYMPTOM DIAGNOSIS > [WITH BATTERY HEATER & COOLER]
SYMPTOM DIAGNOSIS A
EV BATTERY SYSTEM
B
NOTE:
• If any DTC is detected, perform the corresponding diagnosis. EVB
"Description".
D
Combination meter
Information display is functioning normally Refer to MWI-91, "On Board Diagnosis E
mally
F
Air conditioning control system
Refer to HAC-196, "Symptom Table" (AU-
Air conditioning control system is function-
TOMATIC AIR CONDITIONING) or HAC-
ing normally
Battery temperature warning lamp ON 327, "Symptom Table" (AUTOMATIC G
HEATER)
Air conditioning control system is not func-
tioning normally H
EVB-781
• The driving range is shorter than before.


NOTE:

YES >> GO TO 3.
NO >> GO TO 2.

>> GO TO 3.
>> GO TO 4.
With CONSULT
3. Check DTC.
EVB-782
BATTERY TEMPERATURE WARNING LAMP ON
BATTERY TEMPERATURE WARNING LAMP ON
A
Battery temperature warning lamp is ON B

NOTE:
Before performing diagnosis, check that it is not a symptom caused by normal operation. Refer to EVB-784,
"Description".
EVB
DANGER: D
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and E
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- F
G
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- H
CAUTION: I
1.PRECONDITIONING J
WARNING:
Installation".
L
>> GO TO 2.
2.CHECK HEATER RELAY UNIT
M
YES >> Replace Li-ion battery controller. Refer to EVB-807, "LI-ION BATTERY CONTROLLER : Removal N
and Installation".
NO >> Repair or replace malfunctioning parts.
EVB-783
TURN ON THE BATTERY TEMPERATURE WARNING LAMP

• Power switch is turned ON during Climate Ctrl. Timer operation
• Air conditioner is turned ON during charge
EVB-784
< PERIODIC MAINTENANCE > [WITH BATTERY HEATER & COOLER]
B
tions needed to keep the Li-ion battery in the best possible condition. EVB
tion manual.
D
EVB-785
< REMOVAL AND INSTALLATION > [WITH BATTERY HEATER & COOLER]

JSCIA1081GB
Clip
REMOVAL
WARNING:
EVB-786
< REMOVAL AND INSTALLATION > [WITH BATTERY HEATER & COOLER]
A
INSTALLATION
2. Install the Li-ion battery undercover (center). B
EVB
JSCIA1080ZZ
J
Bolts for Li-ion battery undercover Clips for Li-ion battery undercover Bolts for Li-ion battery undercover K
(center) (front) (front) L
: Vehicle front
EVB-787
LI-ION BATTERY
< UNIT REMOVAL AND INSTALLATION > [WITH BATTERY HEATER & COOLER]
UNIT REMOVAL AND INSTALLATION

LI-ION BATTERY
JSCIA1079GB
Cooler pipe O-ring Cooler pipe

: N-m (kg-m ft-lb)
DANGER:
WARNING:
EVB-788
LI-ION BATTERY
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet A
CAUTION:
B
EVB
REMOVAL
1. Discharge the refrigerant. Refer to HA-26, "Recycle Refrigerant" (For Europe) or HA-93, "Recycle Refrig-
erant" (Except for Europe).
D
WARNING:
Prepare for work on the high-voltage system. E
tion".
4. Disconnect the Li-ion battery high-voltage harness connector . F
DANGER:

G
tective gear.

I
J
JSCIA1328ZZ
M
DANGER:
N
tective gear. O
P
EVB-789
LI-ION BATTERY
JSCIA1329ZZ
6. Disconnect the Li-ion battery vehicle communications connector

WARNING:

gear.
JSCIA1078ZZ
7. Remove the bolt and disconnect the A/C pipe from Li-ion
battery.
DANGER:

tective gear.
JSCIA1073ZZ

WARNING:

gear.
JSCIA1074ZZ

WARNING:

gear.
CAUTION:
Do not remove the 4 bolts in this step.
JSCIA1075ZZ
EVB-790
LI-ION BATTERY
• Align the pallet center mark and the lift table center A
mark .
Front B
Side
EVB
G
JSCIA0178ZZ
11. Set the pallet onto the Li-ion battery. H

CAUTION:
battery with transport fastening bolts. I
JSCIA0179ZZ K

L
JSCIA1076ZZ
WARNING: O
EVB-791
LI-ION BATTERY
WARNING:

gear.
JSCIA1077ZZ
JPCIA0196ZZ

CAUTION:
Because there is the danger of tipping over, do not move the stacker while the Li-ion battery is
lifted up.
INSTALLATION
1. When replacing the Li-ion battery with a new battery, perform the work listed below.
b. Cut the EV battery tracking identification seal into 2 pieces and apply them to the body of the replaced
2. Install the Li-ion battery onto the vehicle body.
JSCIA1076ZZ
WARNING:
EVB-792
LI-ION BATTERY

A
WARNING:

gear. B
EVB
NOTE:
JSCIA1075ZZ
D
WARNING:
E
gear.
F
G
JSCIA1074ZZ
6. Install the A/C pipe and install the bolt . H

DANGER:
• There is the danger of electric shock caused by I

tective gear.
JSCIA1073ZZ K
8. Rotate the vehicle communications connector clockwise to L
connect it.
WARNING:
M
gear.
JSCIA1072ZZ
O
EVB-793
LI-ION BATTERY
DANGER:

tective gear.
JSCIA1071ZZ
JSCIA1330ZZ
10. Install the high-voltage harness connector and install the har-
ness clamp .
WARNING:

gear.
JSCIA1070ZZ
JSCIA1331ZZ
11. Install the Li-ion battery undercover. Refer to EVB-786, "Removal and Installation".
13. Charge the refrigerant. Refer to HA-27, "Charge Refrigerant" (For Europe) or HA-94, "Charge Refrigerant"
(Except for Europe).
EVB-794
LI-ION BATTERY
ground. A
EVB
F
JSCIA1203ZZ
WARNING:
G

I
• Presence of paint, oil, dirt, or other substance on the bonding plate mounting surface J
EVB-795
LI-ION BATTERY
< UNIT DISASSEMBLY AND ASSEMBLY > [WITH BATTERY HEATER & COOLER]
UNIT DISASSEMBLY AND ASSEMBLY

LI-ION BATTERY
JSCIA1171GB
EVB-796
LI-ION BATTERY
Breather Service plug Service plug retainer A

Battery pack upper case Seal Plug
Plug washer
B
sembly.
EVB

D
DANGER: E
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and F
maintenance.
WARNING:
• 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
ing electric shock, fire, and damage to parts. J
CAUTION:
K
1. Must be an indoor environment. L
M
3. The floor must be dry. O
4. Work space
• The work space must be approximately the size of one entire vehicle. P
guisher).
REMOVAL
EVB-797
LI-ION BATTERY
2. Remove the service plug retainer .
WARNING:

JSCIA1172ZZ
JSCIA1173ZZ
WARNING:
WARNING:

NOTE:
• Sharpen the blade of the windshield cutter .
: 38 mm (1.50 in)
JSCIA0572ZZ
EVB-798
LI-ION BATTERY
A
EVB
JSCIA1174ZZ F
I
JSCIA1175ZZ

J
: Battery front K
CAUTION:
• When cutting the adhesive, be careful to avoid scratching the battery pack coating to the maxi- L
sive. M
sealant damage is less than the limit, repair by applying primer (adhesive primer: KE560-15090). N

Continuous length of undamaged section: : 210 mm (8.27 in) or more O
NOTE:
P
EVB-799
LI-ION BATTERY
JSCIA0678ZZ
ners.
CAUTION:
the battery pack coating and paint sealant to the maximum
extent possible.
NOTE:
JSCIA0574ZZ
JSCIA0679ZZ
CAUTION:
upper case.
ii. Tilt the windshield cutter blade at an angle and cut the adhesive at the embossed locations.
CAUTION:
WARNING:
CAUTION:
battery pack.
EVB-800
LI-ION BATTERY
assembling so that no particles remain on the battery module, bus bar, and high-voltage har- A
ness.
B
INSTALLATION
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:
G
duced.
case must be replaced. If the paint sealant damage is less than the limit, repair by applying H
Paint sealant damage limit: I

KE560-15090). J
NOTE:
are not damaged. K
a. Protect the seal with masking tape . L
NOTE:
M
N
JSCIA0577ZZ O
EVB-801
LI-ION BATTERY
case.
NOTE:
JSCIA1181ZZ
JSCIA0578ZZ
C : 10 mm (0.39 in)
CAUTION:
NOTE:
Apply the dam rubber so that adhesive does not enter the inner side. If the adhesive enters the inner side,
WARNING:
EVB-802
LI-ION BATTERY
EVB
L
JSCIA1176ZZ
: Dam rubber : Old adhesive M

CAUTION: N
overlaps.
adhesive begins to harden in as little as 16 minutes. [Humidity: 80%, Temperature: 35°C (95°F)] O
than the height of the dam rubber, then the amount of adhesive is insufficient.) P
NOTE:
EVB-803
LI-ION BATTERY
JSCIA0642ZZ

alignment holes on the battery pack upper case and battery pack lower case .
JSCIA1177ZZ
WARNING:
CAUTION:
tery module.
case carefully.
JSCIA1182ZZ
EVB-804
LI-ION BATTERY
A
EVB
JSCIA1178ZZ F
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools. G
H
M
JSCIA1179ZZ
WARNING:
N
EVB-805
LI-ION BATTERY
WARNING:

JSCIA1172ZZ
CAUTION:
JSCIA1180ZZ
CAUTION:
which strains the vehicle body) for approximately 3 hours after installation.
AIR LEAK INSPECTION
EVB-806
LI-ION BATTERY
EVB
JSCIA1187GB
I

J
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:
EVB-807
LI-ION BATTERY
4. Work space
guisher).
REMOVAL
Installation".
battery controller.
WARNING:

gear.
JSCIA1188ZZ

WARNING:

JSCIA1189ZZ
4. Disconnect the high-voltage harness connector , then remove


: Battery front
WARNING:

gear.
JSCIA1190ZZ
EVB-808
LI-ION BATTERY
B
INSTALLATION
EVB
WARNING:
• To prevent electric shock, wear insulated protective gear and use insulated tools. D
E
nector . If the high-voltage harness connector is F
G
: Battery front
H
JSCIA1190ZZ
tion". I
CAUTION:
replace it with a new clip before installing. J
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST K
LI-ION BATTERY HEATER RELAY UNIT
L
EVB-809
LI-ION BATTERY
LI-ION BATTERY HEATER RELAY UNIT : Exploded view INFOID:0000000010623967
JSCIA1191GB
Li-ion battery heater relay harness Li-ion battery heater relay unit
LI-ION BATTERY HEATER RELAY UNIT : Removal and Installation INFOID:0000000010623968
DANGER:
maintenance.
WARNING:
troller before disassembling battery pack.
CAUTION:
EVB-810
LI-ION BATTERY
• The environment must prevent the entry of sweat during work, and also prevent condensation from
occurring as a result of high temperature and humidity. A
metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles. B
EVB
snowing.
4. Work space
• Space approximately the size of one vehicle must be secured as the disassembly space. D
than the workers do not enter the work space.
5. Standard fire fighting equipment E
guisher). F
DISASSEMBLY
Installation". G
Installation".
3. Remove the Li-ion battery heater relay unit as follows. H
a. Disconnect harness connector and heater harness connector
.
I
b. Remove mounting nuts and then remove the Li-ion battery
heater relay unit .
WARNING:
J
JSCIA1192ZZ
K
L
4. Disconnect harness connector and the harness clips . And
then remove heater relay harness .
WARNING:
M
N
O
JSCIA1193ZZ
ASSEMBLY
Assemble in the reverse order of disassembly. P
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated
tools.
EVB-811
LI-ION BATTERY
CAUTION:
AIR LEAK INSPECTION
• Install Li-ion battery controller immediately before installing battery pack upper case.
JSCIA1210GB

with bus bar)
EVB-812
LI-ION BATTERY
sembly. A
BUS BAR LAYOUT B
EVB
JSCIA1186ZZ
DANGER:
EVB-813
LI-ION BATTERY
INFOID:0000000010623964
DANGER:
maintenance.
WARNING:
CAUTION:
4. Work space
guisher).
DISASSEMBLY
Installation".
Installation".
3. Remove battery heater relay unit and the harness. Refer to EVB-810, "LI-ION BATTERY HEATER RELAY
UNIT : Removal and Installation".
EVB-814
LI-ION BATTERY
. A
DANGER:
• There is the danger of electric shock caused by B

EVB
JSCIA1211ZZ
• Because there is a risk of electric shock, immedi- D

E
WARNING:
To prevent electric shock, wear insulated protective F

H
JSCIA1212ZZ
ness connector , then remove the service plug switch bracket. I
WARNING:
To prevent electric shock, wear insulated protective J

JSCIA1213ZZ
L
WARNING:
M
N
O
JSCIA1214ZZ
EVB-815
LI-ION BATTERY
from service plug switch bracket .
WARNING:

JSCIA1215ZZ

WARNING:

JSCIA1216ZZ
WARNING:

JSCIA1217ZZ

c. Remove the bus bar nuts . Then remove the current sensor
.
DANGER:

are not exposed.
EVB-816
LI-ION BATTERY
remove the bus bar bolts and nuts . Then remove the bus A
DANGER:
B
EVB
JSCIA1219ZZ
D
terminals) with insulating tape so that they are not exposed. E
WARNING:
F
gear.
G
JSCIA1220ZZ
9. Open the bus bar cover and remove the bus bar cap . And I
DANGER: J

contact with the terminals. Be sure to wear insulated pro- K
JSCIA1221ZZ
L

ately protect the terminals of the disconnected high-voltage harness connector (high-voltage M
10. Remove the mounting nuts and remove the junction box . N
WARNING:

gear and use insulated tools. O
JSCIA1222ZZ
EVB-817
LI-ION BATTERY
age harness connector from the connector flange.
WARNING:

JSCIA1224ZZ
WARNING:

JSCIA1225ZZ
13. Remove the vehicle communications harness as follows.

WARNING:

JSCIA1226ZZ
WARNING:

JSCIA1227ZZ
ASSEMBLY
DANGER:
EVB-818
LI-ION BATTERY
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter- A
minal.
B
WARNING:
CAUTION: EVB
• Be sure to reinstall the high voltage harness clips in their original positions. If a clip is damaged, D
AIR LEAK INSPECTION
E
LI-ION BATTERY HEATER & COOLING UNIT
F
EVB-819
LI-ION BATTERY
LI-ION BATTERY HEATER & COOLING UNIT : Exploded view INFOID:0000000010711497
JSCIA1196GB
Plate Gasket Li-ion battery heater and cooling unit

Li-ion battery cooling duct (front) Li-ion battery cooling duct (rear)
sembly.
LI-ION BATTERY HEATER & COOLING UNIT : Removal and Installation INFOID:0000000010711498
DANGER:
maintenance.
WARNING:
EVB-820
LI-ION BATTERY
ing inspection or maintenance of high voltage system harnesses and parts. A
B
troller before disassembling battery pack. EVB
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do D
1. Must be an indoor environment. E
• The environment must prevent the entry of sweat during work, and also prevent condensation from F
occurring as a result of high temperature and humidity.
metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles. G
3. The floor must be dry. H
snowing.
4. Work space I
• Space approximately the size of one vehicle must be secured as the disassembly space.
than the workers do not enter the work space. J
guisher). K
REMOVAL
1. Remove the battery pack upper case. Refer to EVB-797, "BATTERY PACK UPPER CASE : Removal and L
Installation".
Installation". M
3. Remove Li-ion battery heater relay unit. Refer to EVB-810, "LI-ION BATTERY HEATER RELAY UNIT :
4. Remove service plug switch bracket and support bracket. Refer to EVB-814, "BATTERY JUNCTION BOX N
AND BATTERY HARNESS : Removal and Installation".
EVB-821
LI-ION BATTERY
5. Remove mounting bolts and clips .then remove the plate .
JSCIA1197ZZ
WARNING:
lated tools.
6. Remove Li-ion battery cooling duct .

WARNING:

JSCIA1198ZZ
7. Separate Li-ion battery cooling duct as shown in the figure if

necessary.
JSCIA1199ZZ
EVB-822
LI-ION BATTERY
8. Remove mounting bolts .
WARNING: A

insulated protective gear and use insulated tools. B
EVB
JSCIA1200ZZ
D
9. Remove mounting bolts and nut .
WARNING:
E
F
G
JSCIA1201ZZ
10. Remove Li-ion battery heater and cooling unit and the gasket H
.
WARNING:
To prevent electric shock hazards, be sure to put on I

JSCIA1202ZZ
K
INSTALLATION
1. Instal Li-ion battery heater and cooling unit and the gasket . L
WARNING:
To prevent electric shock hazards, be sure to put on M

JSCIA1202ZZ O
EVB-823
LI-ION BATTERY
2. Instal mounting bolts .
WARNING:

JSCIA1200ZZ
3. Instal mounting bolts and nut .

WARNING:

JSCIA1201ZZ
4. After install in the reverse order of removal.

WARNING:
lated tools.
CAUTION:
• Install Li-ion battery controller immediately before installing battery pack upper case. Refer to EVB-
807, "LI-ION BATTERY CONTROLLER : Removal and Installation".
AIR LEAK INSPECTION
FRONT MODULE STACK
EVB-824
LI-ION BATTERY
EVB
L
JSCIA1300GB

N

O

P
EVB-825
LI-ION BATTERY
JSCIA1184GB

EVB-826
LI-ION BATTERY

A
: Battery front
NOTE:
MODULE LAYOUT
EVB
H
JSCIA1087ZZ

I
K
M
N
O
EVB-827
LI-ION BATTERY
BUS BAR LAYOUT
JSCIA1186ZZ
DANGER:
DANGER:
EVB-828
LI-ION BATTERY
maintenance.
B
WARNING:
CAUTION:
4. Work space K
guisher).
REMOVAL
Installation".
Installation". O
×: Need to remove
Parts name Left front module stack Right front module stack Reference P
Li-ion battery heater relay unit × × HEATER RELAY UNIT : Re-
moval and Installation"
EVB-829
LI-ION BATTERY
Parts name Left front module stack Right front module stack Reference
× stallation"
ness
Li-ion battery cooling unit × HEATER & COOLING UNIT :
Removal and Installation"

.
WARNING:

JSCIA1253ZZ
DANGER:

JSCIA1254ZZ

DANGER:

JSCIA1255ZZ

EVB-830
LI-ION BATTERY
stack)
DANGER:
B
EVB
JSCIA1268ZZ
D
E
8.

F
JSCIA1256ZZ
K
WARNING: L
JSCIA1257ZZ
WARNING:
EVB-831
LI-ION BATTERY
WARNING:

gear.
CAUTION:
WARNING:
CAUTION:

WARNING:

gear.

NOTE:
INSTALLATION
DANGER:
minal.
WARNING:
EVB-832
LI-ION BATTERY
B
CAUTION:
AIR LEAK INSPECTION
DANGER: E
WARNING:
G
CAUTION: J
4. Work space
guisher).
DISASSEMBLY
EVB-833
LI-ION BATTERY
ing.
JSCIA1269ZZ
DANGER:
CAUTION:
JSCIA1270ZZ
DANGER:
EVB-834
LI-ION BATTERY
B
NOTE:
(front) .
D
JSCIA1271ZZ
I
DANGER:
M
JSCIA1272ZZ
DANGER: P
EVB-835
LI-ION BATTERY
front module stack.
JSCIA1273ZZ
DANGER:
JSCIA1274ZZ
WARNING:
WARNING:
ASSEMBLY
EVB-836
LI-ION BATTERY
DANGER:
A
B
EVB
F
JSCIA1275ZZ
: Battery front
G
J
JSCIA1290ZZ
: Battery front
K
WARNING:
NOTE:
figure. M

N
JSCIA0682ZZ
P
EVB-837
LI-ION BATTERY
lar .
JSCIA0733ZZ
JSCIA1257ZZ
NOTE:
JSCIA1276ZZ
CAUTION:
EVB-838
LI-ION BATTERY
mounting screws . A
EVB
JSCIA1273ZZ D
DANGER:

H
JSCIA1271ZZ
M
DANGER:
O
CAUTION: P
EVB-839
LI-ION BATTERY
JSCIA1277ZZ
: Battery front
NOTE:
JSCIA1278ZZ
: Battery front
NOTE:
DANGER:
NOTE:
EVB-840
LI-ION BATTERY
ing. A
EVB
F
JSCIA1269ZZ

DANGER:
REAR MODULE STACK

L
EVB-841
LI-ION BATTERY
JSCIA1300GB

EVB-842
LI-ION BATTERY
EVB
JSCIA1185GB
P
(rear)
Left end plate
EVB-843
LI-ION BATTERY

: Battery front
MODULE LAYOUT
JSCIA1087ZZ
Rear module stack

NOTE:
BUS BAR LAYOUT
DANGER:
EVB-844
LI-ION BATTERY
EVB
JSCIA1186ZZ P
DANGER:
EVB-845
LI-ION BATTERY
maintenance.
WARNING:
CAUTION:
4. Work space
guisher).
REMOVAL
Installation".
Installation".
3. Remove Li-ion battery cooling duct. Refer to EVB-820, "LI-ION BATTERY HEATER & COOLING UNIT :
.
WARNING:

JSCIA1253ZZ
EVB-846
LI-ION BATTERY
WARNING:

EVB
JSCIA1254ZZ
D
WARNING: E

gear and use insulated tools. F
G
JSCIA1255ZZ

WARNING:

JSCIA1261ZZ K
a. Attach a carabiner to position as shown in the figure and con- L
WARNING:
M
gear.
JSCIA1262ZZ
O
EVB-847
LI-ION BATTERY
WARNING:

gear.
CAUTION:
WARNING:
CAUTION:

WARNING:
INSTALLATION
DANGER:
minal.
WARNING:

CAUTION:
EVB-848
LI-ION BATTERY
B
DANGER:
WARNING: D
E
G
CAUTION:
I
4. Work space M
guisher). O
DISASSEMBLY
P
EVB-849
LI-ION BATTERY
DANGER:

JSCIA1279ZZ

DANGER:

JSCIA1280ZZ

CAUTION:
DANGER:

JSCIA1281ZZ


NOTE:
EVB-850
LI-ION BATTERY
(rear) . A
EVB
F
JSCIA1301ZZ
DANGER:
G
H
DANGER:

L
JSCIA1282ZZ

WARNING:

gear.
P
NOTE:
EVB-851
LI-ION BATTERY
JSCIA0729ZZ
A : 7 mm (0.28 in) B : 5 mm (0.20 in)

WARNING:

JSCIA1284ZZ

WARNING:

JSCIA1285ZZ

WARNING:

gear.
JSCIA0240ZZ
EVB-852
LI-ION BATTERY
WARNING:

EVB
JPCIA0131ZZ
D
ASSEMBLY
E
G
WARNING:
H
JSCIA1286ZZ L
WARNING:
M
NOTE:
figure. N

JSCIA0682ZZ
EVB-853
LI-ION BATTERY
stack .
WARNING:

gear.
JSCIA0240ZZ
JSCIA0313ZZ
WARNING:
JSCIA1287ZZ
CAUTION:
EVB-854
LI-ION BATTERY
EVB
JSCIA0347ZZ
D
WARNING:
E
F
G
JSCIA1285ZZ

WARNING:

JSCIA1284ZZ
K
(A).
WARNING: L

gear. M
N
O
WARNING:

P
EVB-855
LI-ION BATTERY
JSCIA1301ZZ
DANGER:

JPCIA0135ZZ
JSCIA1288ZZ
DANGER:
EVB-856
LI-ION BATTERY
A
EVB
JSCIA1289ZZ
WARNING: D

E
CAUTION:
CAUTION: G
AIR LEAK INSPECTION

the breather.
WARNING:

gear.
JSCIA1208ZZ
L
M
WARNING:

gear.
JSCIA1337ZZ
P
EVB-857
LI-ION BATTERY
[SST: KV99111400 ( — )].
WARNING:

gear.
JSCIA1205ZZ

)].
WARNING:

gear.
CAUTION:
ALAIA0089ZZ
DANGER:
NOTE:
WARNING:
EVB-858
LI-ION BATTERY
CAUTION: A
B
EVB
JSCIA0638ZZ
D
E
CAUTION:
H
Repair limit 2
: 1.4 kPa (0.014 bar, 0.0142 kg/cm , 0.203 psi)
I
NOTE:
K
P
JSCIA1209ZZ
WARNING:
EVB-859
LI-ION BATTERY

EVB-860
< SERVICE DATA AND SPECIFICATIONS (SDS) [WITH BATTERY HEATER & COOLER]

B
Items Specification
EVB
Type Li-ion battery
E
JSCIA1204ZZ

“b” [mm (in)] 824 (32.44)
“c” [mm (in)] 266 (10.47)
N
“d” [mm (in)] 1578 (62.13)
EVB-861
LI-ION BATTERY
BUS BAR LAYOUT
JSCIA1186ZZ
DANGER:
INFOID:0000000010623964
DANGER:
EVB-862
LI-ION BATTERY
maintenance.
B
WARNING:
CAUTION:
4. Work space K
guisher).
DISASSEMBLY
1. Remove the battery pack upper case. EVB-845, "BATTERY PACK UPPER CASE : Removal and Installa- N
tion".
Installation". O
3. Remove battery heater relay unit and the harness. Refer to EVB-858, "LI-ION BATTERY HEATER RELAY
UNIT : Removal and Installation".
4. Remove the service plug switch as follows P
EVB-863
LI-ION BATTERY
.
DANGER:

JSCIA1211ZZ


WARNING:

JSCIA1212ZZ
ness connector , then remove the service plug switch bracket.
WARNING:

JSCIA1213ZZ
d. Remove the mounting bolts And then remove the bus bar .
WARNING:

JSCIA1214ZZ
EVB-864
VEHICLE CHARGING SYSTEM

SECTION VC B
VC
E
CONTENTS
PRECAUTION ............................................... 4 POWER VOLTAGE VARIABLE CONTROL SYS- F
TEM : System Description .......................................20
PRECAUTIONS ................................................... 4
Precaution for Technicians Using Medical Electric...... 4 AUTOMATIC 12V BATTERY CHARGE CONTROL
G
Precaution for Supplemental Restraint System ....20
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- AUTOMATIC 12V BATTERY CHARGE CON-
SIONER" ................................................................... 4 TROL : System Description .....................................20
H
Precaution for Procedure without Cowl Top Cover...... 5 WARNING/INDICATOR/CHIME LIST ........................20
Precautions for Removing Battery Terminal ............. 5 WARNING/INDICATOR/CHIME LIST : Warning
High Voltage Precautions .......................................... 6
Lamp/Indicator Lamp ...............................................20
I
PREPARATION ............................................ 8 OPERATION ..................................................... 21
PREPARATION ................................................... 8 Switch Name and Function ......................................21
Special Service Tools ................................................ 8 J
HANDLING PRECAUTION ............................... 22
Commercial Service Tools ........................................ 9 Vehicle Charging System ........................................22
Sealant or/and Lubricant ......................................... 10
ON BOARD DIAGNOSTIC (OBD) SYSTEM .... 24 K
SYSTEM DESCRIPTION ............................. 11 Diagnosis Description ..............................................24
Counter System .......................................................24
COMPONENT PARTS .......................................11
DTC and Freeze Frame Data ..................................24 L
Component Parts Location ...................................... 11
PDM (Power Delivery Module) ................................ 13 DIAGNOSIS SYSTEM [PDM(POWER DELIV-
Normal Charge Cable ............................................. 13 ERY MODULE)] ................................................ 25
Charge Port ............................................................. 15 CONSULT Function .................................................25 M
Immediate Charging Switch .................................... 15
Charging Status Indicator ........................................ 16 ECU DIAGNOSIS INFORMATION .............. 28
High Voltage Warning Label ................................... 17 N
PDM(POWER DELIVERY MODULE) ............... 28
SYSTEM .............................................................18 Reference Value ......................................................28
Fail-Safe ..................................................................30
VEHICLE CHARGING SYSTEM ............................... 18 O
DTC Index ...............................................................31
VEHICLE CHARGING SYSTEM : System De-
DTC Sub Type Index ...............................................32
scription ................................................................... 18
VEHICLE CHARGING SYSTEM : Circuit Diagram WIRING DIAGRAM ...................................... 34 P
.... 18
VEHICLE CHARGING SYSTEM ....................... 34
LI-ION BATTERY CHARGE CONTROL ................... 18
Wiring Diagram ........................................................34
LI-ION BATTERY CHARGE CONTROL : System
Description .............................................................. 19 BASIC INSPECTION ................................... 41
POWER VOLTAGE VARIABLE CONTROL SYS- DIAGNOSIS AND REPAIR WORK FLOW ....... 41
TEM ............................................................................ 20
VC-1
Work Flow ............................................................... 41 B2820 QUICK CHARGER ................................. 68
Diagnostic Work Sheet ........................................... 43 DTC Description ...................................................... 68
PERIODIC MAINTENANCE ........................ 46
B2830 QUICK CHARGE VOLTAGE SENSOR... 69
CHARGE PORT ................................................. 46 DTC Description ...................................................... 69
Inspection ............................................................... 46 Diagnosis Procedure ............................................... 69
DTC/CIRCUIT DIAGNOSIS ......................... 48 B2840 PDM(POWER DELIVERY MODULE) ... 71
DTC Description ...................................................... 71
POWER SUPPLY AND GROUND CIRCUIT ..... 48
TYPE A AND B .......................................................... 73
PDM (POWER DELIVERY MODULE) ...................... 48
TYPE A AND B : Diagnosis Procedure ................... 73
PDM (POWER DELIVERY MODULE) : Diagnosis
Procedure ............................................................... 48 TYPE C ...................................................................... 74
TYPE C : Diagnosis Procedure ............................... 74
U1000 CAN COMMUNICATION ........................ 50
DTC Description ..................................................... 50 B2850 PDM(POWER DELIVERY MODULE) ... 75
Diagnosis Procedure .............................................. 50 DTC Description ...................................................... 75
U1008, U100B QUICK CHARGER COMMU-
NICATION .......................................................... 51 B2880 F/S CHG RELAY .................................... 76
TYPE A ...................................................................... 51 TYPE A ...................................................................... 76

TYPE A : Diagnosis Procedure .............................. 51 TYPE A : Diagnosis Procedure ............................... 76
TYPE B ...................................................................... 52 TYPE B ...................................................................... 78

TYPE B : Diagnosis Procedure .............................. 53 TYPE B : Diagnosis Procedure ............................... 78
B2890 DC/DC CONVERTER ............................. 80
U100A CAN COMMUNICATION ....................... 54 DTC Description ...................................................... 80
DTC Description ..................................................... 54
Diagnosis Procedure .............................................. 54 TYPE A ...................................................................... 81
TYPE A : Diagnosis Procedure ............................... 81
U1010 CONTROL MODULE (CAN) .................. 55
DTC Description ..................................................... 55 TYPE B ...................................................................... 81
Diagnosis Procedure .............................................. 55 TYPE B : Diagnosis Procedure ............................... 81
TYPE C ...................................................................... 82
B2801 QUICK CHARGE CONNECTOR ........... 56
TYPE C : Diagnosis Procedure ............................... 82
DTC Description ..................................................... 56
TYPE D ...................................................................... 82
TYPE A ...................................................................... 56
TYPE D : Diagnosis Procedure ............................... 82
TYPE A : Diagnosis Procedure .............................. 56
TYPE B ...................................................................... 58
B2900, B2902 PDM(POWER DELIVERY
TYPE B : Diagnosis Procedure .............................. 58 MODULE) .......................................................... 84
Component Inspection ............................................ 59 DTC Description ...................................................... 84
B2802 QUICK CHARGER ................................. 60
DTC Description ..................................................... 60 B2980 QUICK CHARGE PORT ........................ 85
Component Inspection ............................................ 61 Diagnosis Procedure ............................................... 85
B2803 QUICK CHARGER ................................. 63
DTC Description ..................................................... 63 B29A0 NORMAL CHARGE PORT .................... 89
Component Inspection ............................................ 65 TYPE A ...................................................................... 89
B2814 QUICK CHARGE RELAY ...................... 66 TYPE A : Diagnosis Procedure ............................... 90
DTC Description ..................................................... 66 TYPE B ...................................................................... 91
Diagnosis Procedure .............................................. 66 TYPE B : Diagnosis Procedure ............................... 91
VC-2
B29C1 EVSE ......................................................93 PDM(POWER DELIVERY MODULE) ............. 105
DTC Description ...................................................... 93 Exploded View ....................................................... 105 A
TYPE A, B AND E ..................................................... 94 Disassembly and Assembly ................................... 114
TYPE A, B AND E : Diagnosis Procedure ............... 94 Inspection .............................................................. 119 B
TYPE C AND D .......................................................... 96 QUICK CHARGE PORT .................................. 121
TYPE C AND D : Diagnosis Procedure ................... 96 Exploded View ....................................................... 121
Component Inspection ............................................ 96 Removal and Installation ....................................... 122 VC
PDM(POWER DELIVERY MODULE) ................98 Disassembly and Assembly ................................... 124
Diagnosis Procedure ............................................... 98 NORMAL CHARGE PORT ............................. 126 D
SYMPTOM DIAGNOSIS .............................. 99 Exploded View ....................................................... 126
VEHICLE CHARGING SYSTEM ........................99 Disassembly and Assembly ................................... 129
E
Symptom Table ....................................................... 99
IMMEDIATE CHARGING SWITCH ................. 132
NORMAL OPERATING CONDITION ............... 100 Removal and Installation ....................................... 132
Description ............................................................ 100 F
CHARGING STATUS INDICATOR ................. 133
REMOVAL AND INSTALLATION ............. 105 Removal and Installation ....................................... 133
VC-3
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
WARNING:
VC-4
PRECAUTIONS
< PRECAUTION >
B
connectors.
WARNING: VC
D
injury.
windshield.
G
PIIB3706J
I
J
NOTE:
SEF289H
WORK PROCEDURE
NOTE:
tion. O
NOTE: P
detected.
CAUTION:
VC-5
PRECAUTIONS
< PRECAUTION >
NOTE:
the power switch.
NOTE:
NOTE:
DANGER:
maintenance.
WARNING:
CAUTION:
blow gun.
NOTE:
WARNING:
VC-6
PRECAUTIONS
< PRECAUTION >
metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage A
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT” B
workers.
VC
JSAIA1600GB
VC-7
PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
The actual shape of the tools may differ from those illustrated here.
(TechMate No.)
Tool name
KV99112300 Removing and installing the PDM (Power
(J - 51050) Delivery Module)
Guide pin 3 pins/set
A: 106 mm (4.17 in) / 1 pin
96 mm (3.78 in) / 2 pins
JPCIA0332ZZ
KV99111400 When checking air leaks after disassem-

(J - 50378) bling/assembling Li-ion battery.
Air leak tester
JSCIA0257ZZ
KV99112400 Air leak test following disassembly and re-

(J - 51051) assembly of the PDM (Power Delivery
Air leak tester Module)
A: Attachment
B: 25 kPa pressure gauge
C: Male coupler
D: Female coupler for base mounting
JPCIA0351ZZ
KV10120900 Removing liquid gasket

(J - 51053)
Acrylic scraper
JPCIA0335ZZ
KV99112200 Supporting and hoisting the PDM (Power

(J - 51049) Delivery Module)
Slinger
NOTE:
The slinger comes as a set with 2
shackles.
JPCIA0373ZZ
VC-8
PREPARATION
< PREPARATION >

B
Removing and installing high voltage com-
ponents
Insulated gloves • Use protective gloves made of insulating VC
material.
• The protective gloves must be capable of
resisting the voltage of 600 or more.
JMCIA0149ZZ D
• Removing and installing high voltage

E
components
tight] F
JPCIA0066ZZ
• Gloves for preventing static electricity

Anti-static gloves • Disassembly and reassembly of the PDM
(Power Delivery Module) H
JMCIA0149ZZ
I
ponents
Comply with EN60903: J
material.
• The protective shoes must be capable of
resisting the voltage of 600 or more. K
JPCIA0011ZZ
• Removing and installing high voltage L

components
Face shield • To protect face from the spatter on the
work to electric line
[Comply with EN166.] M
JPCIA0167ZZ

components
Safety glasses O
• To protect face from the spatter on the
JPCIA0012ZZ P
VC-9
PREPARATION
< PREPARATION >

Insulated helmet
ponents
JPCIA0013ZZ
Installing PDM (Power Delivery Module)

Tube presser [Gasket material appli-
cover
cator]
(Apply the liquid gasket)
JSCIA0639ZZ
Insulation resistance tester Measuring insulation resistance, voltage,

(Multi tester) and resistance
JPCIA0014ZZ
Name Description Note

Three bond 1217H or equivalent PDM (Power Delivery Module) —
VC-10
COMPONENT PARTS
COMPONENT PARTS
B
LHD MODELS
VC
M
JSCIA1144ZZ
Charge lid (Vehicle front side) Instrument lower panel LH N

Charging status indicator VC-16, "Charging Status Indicator"
O

VCM is performed integrated control for vehicle charging system. P
VCM
Refer to EVC-15, "Component Parts Location", for detailed installation location.
Quick charge port* VC-15, "Charge Port"
*: Model with quick charge port.
VC-11
COMPONENT PARTS
RHD MODELS
JSCIA1099ZZ
Instrument lower panel RH Charge lid (Vehicle front side)

Charging status indicator VC-16, "Charging Status Indicator"

VCM is performed integrated control for vehicle charging system.
VCM
Refer to EVC-15, "Component Parts Location", for detailed installation location.
Quick charge port* VC-15, "Charge Port"
*: Model with quick charge port.
VC-12
COMPONENT PARTS
PDM (Power Delivery Module) INFOID:0000000010415136
A
The PDM (Power Delivery Module) is installed to the upper part of
drive motor in the motor room together with drive motor inverter and
consists of a charger and DC/DC converter. B
The charger converts external AC power source to DC power source
(260 – 410 V), and charges the Li-ion battery according to the type of
charging. The DC/DC converter charges the auxiliary 12V battery
according to the VCM command. VC
D
JSCIA1100ZZ
Normal Charge Cable INFOID:0000000010415137

E
Normal charge cable has Mode2 EVSE with control box, and Mode3 cable to use in charging station.
MODE2 EVSE
F
JSCIA0786GB
NOTE: I
The shape of plug varies by region.
The Mode2 EVSE (Electric Vehicle Supply Equipment) is manufactured based on the specifications pre-
scribed in SAE-J1772, and is for charging by connecting a commercial power source to the vehicle. The J
Mode2 EVSE consists of a plug, cable, control box, and a normal charge connector and supplies power to the
vehicle using commercial power. By conducting PWM communication with the PDM (Power Delivery Module),
the Mode2 EVSE performs safe and suitable charging for the vehicle.
K
Normal Charge Connector
The normal charge connector is equipped with a release switch
to maintain the connection between the normal charge port and the L
charge connector.
JSCIA0604ZZ
VC-13
COMPONENT PARTS
A circuit for detecting the hold status is incorporated into the release
switch, which stops the charging temporarily if the release switch is
pressed during charging.
NOTE:
When the release switch is pressed, the contacts turn OFF.
JSCIA1304GB
Control Box
The control box is equipped with an indicator that can be used
to check the charging status and malfunction detection status. The
indicator operates in the following cases when a commercial power
supply is connected to the Mode2 EVSE.
JSCIA0787ZZ
<List of Operations>
Illumination status
Vehicle condition
READY CHARGE FAULT
When there is no AC power supply input OFF OFF OFF
When AC power source is connected ON (Approx.0.5 s) ON (Approx.0.5 s) ON (Approx.0.5 s)
When there is AC power supply input and the Mode2
EVSE can communicate with the vehicle charger (when ON OFF OFF
not charging)
Charging ON ON OFF
When the Mode2 EVSE is not operating OFF OFF OFF
When the Mode2 EVSE detects electric leakage ON OFF Blink
When the Mode2 EVSE detects a malfunction in itself ON OFF ON
When ground is not connected Blink OFF OFF
When the plug is high temperature Blink OFF/Blink/ON Blink
MODE3 CABLE
The Mode3 cable is manufactured based on the specifications pre-
scribed in SAE-J1772, and is for charging by connecting a commer-
cial power source to the vehicle via charging station. The Mode3
cable consists of a plug , cable , and a normal charge connector
and supplies power to the vehicle using commercial power. By
conducting PWM communication with the PDM (Power Delivery
Module), the charging station performs safe and suitable charging
for the vehicle using Mode3 cable.
NOTE:
The shape of plug varies by region.
JSCIA1305ZZ
Normal Charge Connector
VC-14
COMPONENT PARTS
The normal charge connector is equipped with a release switch
to maintain the connection between the normal charge port and the A
charge connector.
VC
JSCIA0604ZZ
D
A circuit for detecting the hold status is incorporated into the release
switch, which stops the charging temporarily if the release switch is
pressed during charging. E
NOTE:
When the release switch is pressed, the contacts turn OFF.
F
G
JSCIA1304GB
Charge Port INFOID:0000000010415138

H
The charge port is installed at the front of the vehicle and is equipped
with a normal charge port and a quick charge port (with quick
charge port models). For charging, connect the normal charge cable I
or quick charge connector to the charge port according to the type of
charging, and then start charging.
J
JSCIA1101ZZ
Immediate Charging Switch INFOID:0000000010415142 L
The immediate charging switch is a switch that can be used to start

charging immediately when timer charging is set.
M
JSCIA1102ZZ
VC-15
COMPONENT PARTS
Charging Status Indicator INFOID:0000000010415143
Charging status indicator is mounted at the upper part of the instru-

ment panel. It indicates the charge status of the Li-ion battery.
Charging status indicator 1

: Vehicle front
JSCIA1103ZZ
Charging status indicator illuminates and blinks as per the following:

Indicator illuminating pattern
JSCIA1104GB
VC-16
COMPONENT PARTS
A
The high voltage warning labels are affixed to the up side of PDM
B
: Vehicle front
CAUTION:
After replacing PDM (Power Delivery Module), check that the VC
labels are affixed in the original position.
D
JSCIA0611ZZ
VC-17
SYSTEM
SYSTEM
VEHICLE CHARGING SYSTEM : System Description INFOID:0000000010415145
DESCRIPTION
This section describes the controls related to the vehicle charging system.
Item Description Refer to

Automatically selects a charge mode that is suitable for the ex-
Li-ion battery charge control VC-19
ternal power source and controls Li-ion battery charging.
Changes the DC/DC converter output inside the PDM (Power
Power voltage variable control system VC-20
Delivery Module) according to the VCM commands.
Controls the DC/DC converter inside the PDM (Power Delivery
Automatic 12V battery charge control Module) according to the VCM commands, and charges the 12V VC-20
battery.
PDM (POWER DELIVERY MODULE)

Description
The charger uses a 2-converter system which consists of the PFC circuit and the DC/DC converter. It
improves charging efficiency, charge level accuracy, and the service life of the Li-ion battery. PDM (Power
Delivery Module) judges whether external power supply is 100 V or 200 V, and automatically switches to
charging that is appropriate for the power supply.
NOTE:
PFC (Power Factor Correction) circuit is a power factor improvement circuit. It is a device that efficiently con-
verts AC power supply input from an external power source to a DC power supply.
Basic Charger Principle
JSCIA0612GB
1. AC power supply which is externally input is rectified to DC power with rectifier circuit 1.
2. The power factor of the rectified DC power supply is improved by the PFC circuit, and is boosted at the
same time.
3. The boosted DC power supply is converted again to AC power supply by the inverter.
4. The voltage of the AC power supply from the inverter is converted by the insulated transformer, and is rec-
tified to high-voltage DC power by rectifier circuit 2.
5. The rectified high-voltage DC power is output by the output circuit.
VEHICLE CHARGING SYSTEM : Circuit Diagram INFOID:0000000010415146
For information regarding the circuit diagram, refer to EVC-26, "ELECTRIC POWER TRAIN SYSTEM : Circuit
Diagram".
LI-ION BATTERY CHARGE CONTROL
VC-18
SYSTEM
LI-ION BATTERY CHARGE CONTROL : System Description INFOID:0000000010415147
A
OVERVIEW OF CHARGING FUNCTIONS
There are two types of Li-ion battery charging. Normal charging converts a commercial power supply to DC
power, and quick charging uses a special charger. B
For information about the charging sound system, refer to EVC-41, "LI-ION BATTERY CHARGE CONTROL :
System Description".
CHARGE MODE VC
Time required for charge

Charge mode Remaining charge level
[25°C (77°F)] D
Immediate AC 200 V: Approx. 8 hours
charge AC 100 V: Approx. 28 hours
Normal
charge mode Timer charge 80% or 100%*1 (selectable) (When charged from the point
E
where the battery level warning
Remote charge lamp turns ON to 100%.)
Approx. 30 minutes
(When charged from the point F
80% or 100%*1 (selectable) where the battery level warning
NOTE: lamp turns ON to 80%.)
Quick charge mode
When the specified time is passed, charging stops even if the NOTE:
When the battery temperature is G
charge level is not full.*2
low or high, approx. 60 – 90 min
or more may be required.
*1: Depending on the battery state, 100% may not be reached. H
*2: After charging stops, additional charging by quick charge is possible.
NORMAL CHARGE MODE

I
In this mode, the normal charge cable is connected for charging. Normal charging includes immediate charge
mode, timer charge mode, and remote charge mode. In all modes, the charge level can be set to either 80% or
100%.
NOTE: J
The method of setting the charge level varies according to the vehicle specifications.
×: Setting available
Charge level setting K
Setting operation Reference
Immediate charge Timer charge Remote charge
AV control unit
× × × AV-86
[Models with navigation system (7 inch display)] L
Combination meter
× × — MWI-74
[Models without navigation system (7 inch display)]
M
Immediate Charge Mode
This mode immediately starts charging when the normal charge cable is connected. When timer charge is not
set, the system enters immediate charge mode when the normal charge cable is connected. When timer
charge is set, immediate charge mode can be selected by pressing the immediate charge switch. N
Timer Charge Mode
This mode starts and stops charging according to the timer that is set on VCM.
NOTE: O
The timer setting method varies according to vehicle specifications.
• Models with navigation system (7 inch display): AV-86, "MULTI AV SYSTEM : System Description".
• Models without navigation system (7 inch display): MWI-74, "TIMER CHARGE AND A/C-HEATER TIMER P
(CLIMATE CTRL. TIMER) [WITHOUT NAVIGATION (7 INCH DISPLAY)] : System Description".
Remote Charge Mode
This mode starts charging by remote control with a mobile device.
NOTE:
For information about operation, refer to AV-314, "TELEMATICS SYSTEM : System Description".
QUICK CHARGE MODE
VC-19
SYSTEM
Mode that performs charging with quick charger. Even if charging is not completed, when the charge time set
on the quick charger or the time-out (approximately 30 - 60 minutes) set on the vehicle passes, charging
stops.
NOTE:
• When the battery temperature is ambient temperature, charging stops after approximately 30 minutes.
• When the battery temperature is low or high, charging stops after a maximum of 60 minutes.
• If charging stops before charging is complete, additional charging by quick charge can be performed again.
CHARGING STATUS INDICATOR AND CHARGING SOUND SYSTEM
The charge connector connection status and charge receiving status can be checked with the charging status
indicator lamp and the electronic sound from the Vehicle Sound for Pedestrians (VSP).
• For charging status indicator, refer to VC-16, "Charging Status Indicator".
• For charging sound system, refer to VSP-16, "CHARGE SOUND SYSTEM : System Description".
POWER VOLTAGE VARIABLE CONTROL SYSTEM
POWER VOLTAGE VARIABLE CONTROL SYSTEM : System Description INFOID:0000000010415149
DESCRIPTION
Power voltage variable control reduces the electric power consumption from the Li-ion battery by varying the
DC/DC converter output in a range from 13 V to 15 V according to the use status of electric equipment and the
12V battery status.
For control, refer to EVC-49, "POWER VOLTAGE VARIABLE CONTROL SYSTEM : System Description".
AUTOMATIC 12V BATTERY CHARGE CONTROL
AUTOMATIC 12V BATTERY CHARGE CONTROL : System Description INFOID:0000000010415150
DESCRIPTION
The 12V battery automatic charge control reduces the frequency with which the 12V battery becomes fully dis-
charged by automatically charging the 12V battery if the 12V battery voltage is low when the power switch is
turned to ON or the vehicle being left to sit for a long time.
The PDM (Power Delivery Module) controls the internal DC/DC converter by using commands from the VCM,
and charges the 12V battery using power from the Li-ion battery.
For control, refer toEVC-49, "AUTOMATIC 12V BATTERY CHARGE CONTROL : System Description".
WARNING/INDICATOR/CHIME LIST : Warning Lamp/Indicator Lamp INFOID:0000000010415151

12 V battery charge warning lamp For function, refer to MWI-66, "WARNING LAMPS/INDICATOR LAMPS : 12V
Battery Charge Warning Lamp".
Low battery charge warning lamp For function, refer to MWI-45, "WARNING LAMPS/INDICATOR LAMPS : Low
Battery Charge Warning Lamp".
Plug in indicator lamp For function, refer to MWI-48, "WARNING LAMPS/INDICATOR LAMPS : Plug In
Indicator Lamp".
VC-20
OPERATION
OPERATION
A
Switch Name and Function INFOID:0000000010415154
VC
JSCIA1105GB
Instrument lower panel RH G
No. Switch name Operation Function H

The immediate charging switch is a switch that can be used to start
Immediate charging switch Pressed
charging immediately when timer charging is set.
NOTE: I
For normal charge control, refer to VC-19, "LI-ION BATTERY CHARGE CONTROL : System Description".
VC-21
HANDLING PRECAUTION
HANDLING PRECAUTION
Vehicle Charging System INFOID:0000000010415155
HANDLING OF CHARGE CABLE, CHARGE PORT, AND CHARGE CONNECTOR

• Never touch metal terminals of the charge port or the charge connector.
• Never modify or disassemble control box, socket, charge cable, charge connector, or charge port.
• Never apply excessive force to the charge cable.
- Never pull.
- Never twist.
- Never drag.
- Never place a heavy item on charge cable.
- Never place near a heating device (heater, etc.).
• Never drop or subject to strong impact.
• When storing, be sure to attach the cap to the connector before storing.
• When storing, store in a location away from direct sunlight, not exposed to rain or wind, and where dust and
dirt do not enter.
• Use only with a designated socket especially wired for EV/PHEV with NISSAN recommended work or equiv-
alent means. (This is because there is an extremely high risk of electric shock if the ground line is connected
incorrectly.)
• Never allow the control box to be submerged in water.
• Maximum service temperature: 45°C (113°F)
PRECAUTIONS FOR CHARGING
• Use genuine NISSAN normal charge cable only.
• Never use an extension cord or conversion adapter.
• Never touch the plug with wet hands.
• If the plug is dirty or wet, wipe it with a clean, dry cloth.
• Check that there is no foreign material such as water or dust in the charge port or the charge connector.
WARNING:
• Since there may be a risk of electric shock, never touch the charge gun or charge port if they
contain foreign material.
• Since there may be a risk of electric shock or electric leakage, never connect the charge gun
or charge port if they contain foreign material.
• Never use the charge cable if it is worn, or if there are any deep scratches or other damage where the core
wires are visible.
• Never use the charge connector or plug (or control box in case of Mode2 EVSE) if it is broken, scratched,
cracked, or otherwise damaged.
• Check that there is no rust, corrosion, or damage on the charge port or charge gun. Check that there is no
loosening at the time of connection.
WARNING:
Since electric leakage, electric shock, short-circuit, or fire may occur, never charge if any mal-
function is found.
• Never perform charging when the connection is heavily exposed to water.
• Never perform charging with the body cover attached.
• Never perform charging when there may be a risk of lightning.
• Stop charging immediately when an unusual odor or smoke is found during charging.
• Never place hand near the cooling fan during charging.
NOTE:
The cooling fan may automatically start operation during charging when the power switch is turned OFF.
• After charging, securely close the cover and lid of the charge port to prevent entry of water or dust.
• To turn on READY after charging, operate after disconnecting the charge connector from the charge port.
NOTE:
When the charge connector is connected to the charge port, READY is disabled.
• To prevent electric shock or fire arising from electric leakage, use a waterproof plug with grounding con-
nected to the ground fault interrupter.
• Never connect to a socket providing other than the rated voltage.
VC-22
HANDLING PRECAUTION
• For charging with AC 100 V, use 15 A rating or more plug. For charging with AC 200 V, use 20 A rating or
more plug. A
WARNING:
If a plug with a low current rating is used or if a plug adapter is installed and used in combination
with another device, the plug may cause abnormal heating, resulting in a fire. B
• For charging, never use a generator or any other power source other than specified.
NOTE:
Charging may not be performed correctly or a malfunction may occur.
• When quick charging is performed, be sure to use a quick charger compatible with the vehicle. VC
VC-23
Diagnosis Description INFOID:0000000010415156
This system is an on board diagnostic system that detects a malfunction automatically. A malfunction is stored
in PDM (Power Delivery Module) memory as a DTC. The diagnostic information can be obtained with CON-
SULT.
Counter System INFOID:0000000010415157
Counter system counts up at every operation of power switch from OFF to ON under condition that the same
malfunction is not detected. On the other hand, if the same DTC as memorized one is detected again, the
count is reset and the counter system counts up again from “0”.
DTC and Freeze Frame Data INFOID:0000000010415158
The PDM (Power Delivery Module) can save multiple DTC but can only save one freeze frame data.
After the PDM (Power Delivery Module) has detected a malfunction and saves the DTC and freeze frame
data, if a different malfunction is detected, multiple DTC are confirmed, but only the freeze frame data that is
saved first can be confirmed.
The DTC and freeze frame data can be deleted when the self-diagnostic is deleted.
VC-24
DIAGNOSIS SYSTEM [PDM(POWER DELIVERY MODULE)]
A
ON BOARD DIAGNOSIS ITEM B
Diagnostic test mode Function

This mode enables a technician to adjust some devices faster and more accurately by following the VC
Work Support
Self-diagnostic result Self-diagnostic results and freeze frame data can be read and erased quickly.*
Data monitor Input/Output data in the PDM (Power Delivery Module) can be read. D
Operable under the condition that the actuator is activated by CONSULT via the PDM (Power Deliv-
Active Test
ery Module) or within the range that a (some of) command value is designated.
E
ECU Identification PDM (Power Delivery Module) part number can be read.
*: The following diagnosis information is cleared when the PDM (power delivery module) memory is erased.
F
WORK SUPPORT MODE

G
Work item Description
Displays the previous 10 charging current readings during normal charging, allowing the history of
Charging current limit history
current limits and charging stops resulting from normal charge cable commands to be checked. H
NOTE:
If the minimum value is 7.2 A or less, the current limit display reads “Yes”, indicating that the current is limited
or charging is stopped during charging. A possible cause is insufficient contact due to damage or wear of the I
normal charge cable plug or socket.
Change the combination of socket and normal charge cable that are used and perform normal charging. The
malfunctioning component can be identified by checking “CHARGE CURRENT LIMITATION HISTORY” again.
J
SELF-DIAG RESULTS MODE
• Regarding items of DTC, refer to VC-31, "DTC Index". K
• Regarding items of DTC sub type, refer to VC-32, "DTC Sub Type Index".
IGN Counter
IGN counter is displayed in Freeze Frame Data (FFD). It displays the number of operations of power switch L
from OFF to ON after DTC recovery to normal.
• CAN malfunction (U1000)
- The number is 0 when a malfunction is detected now. M
- The displayed number counts up at each operation of power switch from OFF to ON after recovery to nor-
mal, such as 1 → 2 → 3...38 → 39.
- The number is fixed to 39 until the self-diagnosis results are erased if it is over 39.
• Other than CAN malfunction (Other than U1000) N
- The number is 0 when a malfunction is detected now.
- The displayed number counts up at each operation of power switch from OFF to ON after recovery to nor-
mal, such as 1 → 2 → 3...254 → 255. O
- The number is fixed to 255 until the self-diagnosis results are erased if it is over 255.
Freeze Frame Data
The Freeze Frame Data shows the status of the vehicle when the DTC is detected and is useful for recreating P
the status when the malfunction occurred.
VC-25
Freeze frame data item Description

Q/CHG CONNECT DE-
Displays the connection status of the quick charge connector.
TECT
Q/CHG START/STOP
Displays the input status of the charge start/stop signal 1 from the quick charger.
SIG 1
Q/CHG START/STOP
SIG 2
QUICK CHARGE PER-
Displays the transmitting status of the charge start permission signal being sent to the quick charger.
MIT
Q/CHG RELAY + Displays the control status of the quick charge relay (+).
Q/CHG RELAY − Displays the control status of the quick charge relay (−).
PWM SIGNAL Displays the reception status of the PWM signal being sent from the Mode2 EVSE or charging station.
EVSE STATE JUDG Displays the engagement detection status of the charge connector.
WELD DIAG VOL Displays the presence or absence of voltage between the high voltage terminal of the quick charge port.
PD MODULE TEMP [°C] Displays the PDM (Power Delivery Module) internal temperature.
EV SYS W/L REQ Displays the status of EV system warning lamp signal transmission that is sent to the VCM.
F/S REQ Displays the status of fail-safe request signal transmission that is sent to the VCM.
Q/CHG PORT TEMP Displays the quick charge port temperature status.
PWM SIGNAL VOLTAGE
Displays the voltage of a PWM signal transmitted from Mode2 EVSE or charging station.
[V]
TIME Displays the number of DTC detected trips.
ELAPSED TIME Displays the time elapsed since the detection of the DTC.
DATA MONITOR MODE

NOTE:
Monitor item Unit Description

Displays the connection status of the quick charge connector.
CNCT/DISC-
Q/CHG CONNECT DETECT • CNCT: The quick charge connector is connected.
NCT
• DISCNCT: The quick charge connector is not connected.
Q/CHG START/STOP SIG 1 OFF/ON • OFF: The quick charger start switch is OFF and not under quick charge.
• ON: The quick charger start switch ON or under quick charge.
Q/CHG START/STOP SIG 2 OFF/ON • ON: Isolation check with a quick charger is NG or not completed.
• OFF: Isolation check with a quick charger completed normally.
Displays the transmission status of the charge start permission signal being sent
to the quick charger.
QUICK CHARGE PERMIT LOW/HIGH
• LOW: Allow quick charge start
• HIGH: Quick charge start is not allowed
Displays the control status of the quick charge relay (+).
Q/CHG RELAY + On/Off • On: Quick charge relay (+) is ON.
• Off: Quick charge relay (+) is OFF.
Displays the control status of the quick charge relay (−).
Q/CHG RELAY − On/Off • On: Quick charge relay (−) is ON.
• Off: Quick charge relay (−) is OFF.
Displays the reception status of the PWM signal being sent from the Mode2
COMM/NO EVSE or charging station.
PWM SIGNAL
COM • COMM: Communicating normally.
• NO COM: Not communicating
VC-26
Monitor item Unit Description
A
Displays the engagement detection status of the normal charge connector.
CNCT/ • CNCT: There is no AC input in the charge connector connected status.
INPUT/ • INPUT: There is AC input in the charge connector connected status.
EVSE STATE JUDG NONE/NO • NONE: The charge connector is not engaged or there is no PWM communi- B
CNCT OR ER- cation from the Mode2 EVSE or charging station.
ROR • NO CNCT OR ERROR: The charge connector is not engaged and malfunc-
tion of normal charge cable, or during a power outage.
Displays the presence or absence of voltage between the high voltage terminal
VC
of the quick charge port.
PRESENT/AB- • PRESENT: Detects voltage Between the high voltage terminal of quick charge
WELD DIAG VOL
SENT port. D
• ABSENT: Not detects voltage Between the high voltage terminal of quick
charge port.
PD MODULE TEMP [°C] degC Displays the PDM (Power Delivery Module) internal temperature.
E
Displays the status of EV system warning lamp signal transmission that is sent
to the VCM.
EV SYS W/L REQ On/Off
• On: Transmit the signal.
• Off: Non-transmit the signal. F
Displays the status of fail-safe request signal transmission that is sent to the
VCM.
F/S REQ On/Off
• On: Transmit the signal. G
• Off: Non-transmit the signal.
Displays the quick charge port temperature status.
Q/CHG PORT TEMP OK/NG • OK: Normal
• NG: Temperature is high
H
Displays the voltage of a PWM signal transmitted from Mode2 EVSE or charging
PWM SIGNAL VOLTAGE V
station.
I
ACTIVE TEST MODE
CAUTION:
After performing active test, always erase all DTC. J
Test item Function/Condition Judgment Check item (Remedy)

• Remove the service plug Check that the quick charge • Harness and connector K
• Power switch ON relay makes the operating • Quick charge relay (+)
Q/CHG RELAY +
• Use active test to turn ON/OFF the • PDM (Power Delivery Mod-
quick charge relay. sound.* ule)
• Remove the service plug • Harness and connector
L
Check that the quick charge
• Power switch ON • Quick charge relay (−)
Q/CHG RELAY − relay makes the operating
• Use active test to turn ON/OFF the • PDM (Power Delivery Mod-
quick charge relay. sound.* ule)
M
Check continuity between
Quick charge permit signal is forcibly connector terminals to check
QUICK CHARGE PERMIT PDM (Power Delivery Module) N
output. that the transistor included in
the PDM (Power Delivery
Module) is ON.
*: If operating noise is hard to hear, use a sound scope to check noise. O
VC-27
PDM(POWER DELIVERY MODULE)
ECU DIAGNOSIS INFORMATION
VALUES ON THE DIAGNOSIS TOOL

Specification data represents reference values.
NOTE:
• The displayed data may differ from an actual signal/value/operation, as some of them are calculated by PDM
(Power Delivery Module), based on signals transmitted from PDM (Power Delivery Module)-related sensors
to PDM (Power Delivery Module).
• Li-ion battery charge does not start when the power switch is ON. When it is required to charge with the
power switch ON, start charging before turning ON the power switch.
Monitor item Condition Values/status

Quick charging connector: Con-
CNCT
nected
Q/CHG CONNECT DETECT POWER ON
Quick charging connector: Not
DISCNCT
connected
The quick charger start switch is OFF and not under quick charge. OFF
Q/CHG START/STOP SIG 1
The quick charger start switch ON or under quick charge. ON
In the process of quick charge after the normal completion of insula-
ON
Q/CHG START/STOP SIG 2 tion resistance check.
For a few seconds after turning ON the quick charger start switch. OFF
Quick charger start switch is OFF. Not in process of quick charge. HIGH
QUICK CHARGE PERMIT A lapse of a few seconds after turning ON the quick charger start
HIGH LOW
switch.
Quick charging in progress On
Q/CHG RELAY +
Not quick charging Off
Quick charging in progress On
Q/CHG RELAY −
Not quick charging Off
Normal charging in progress COMM
PWM SIGNAL
Except above NO COM
When the charge connector is connected CNCT
Normal charging in progress INPUT
EVSE STATE JUDG
When the change connector is not connected NONE
Except above NO CNCT OR ERROR
Quick charging in progress PRESENT
WELD DIAG VOL
Except above ABSENT
(−40) – (215)°C [(−40) –
(419)°F]
PD MODULE TEMP Depending on the PDM (Power Delivery Module) temperature. Indicates depending on the
ule) temperature.
EV system warning lamp signal:
On
Transmission
EV SYS W/L REQ Power switch: ON
EV system warning lamp signal:
Off
Non-transmission
VC-28
Monitor item Condition Values/status
A
Stop charging occurs during normal/quick charging On
F/S REQ
Except above Off
When the quick charge port is abnormally hot NG B
Q/CHG PORT TEMP
Except above OK
PWM SIGNAL VOLTAGE Normal charge 4.0 – 7.0 V
VC
TERMINAL LAYOUT
JSCIA0624ZZ
H
PHYSICAL VALUES
NOTE:
Specification data are reference values. I
Terminal No.
Description
(Wire color) Value
Condition J
Input/ (Approx.)
+ – Signal name
Output
6 Quick charger communication-L Input/
— — — K
(R) (CAN) Output
7 Quick charger communication-H Input/
— — —
(W) (CAN) Output
L
9 During quick charging 13.0 – 16.0 V
Ground F/S CHG relay Input
(GR) Except above 0V
10 During charging 0V M
Ground Plug in signal Input
(BR) Except above 11.5 – 15.0 V
11
— EV system CAN-L — — —
(G) N
12 High voltage harness connector
Ground Input Power switch: ON 3.0 – 7.0 V
(P) detecting circuit power supply
15 High voltage harness connector O
Ground Output Power switch: ON 3.0 – 7.0 V
(G) detecting circuit signal
16 Power switch: ON 13.0 – 16.0 V

Ground Power ON power supply Input
(V) Power switch: OFF 0V P
18
Ground Battery power supply Input Power switch: ON 13.0 – 16.0 V
(Y)
19 During quick charging 10.8 − 13.2 V

Ground Quick charger permit signal Input
(L) Except above 0V
VC-29
Terminal No.
Description
(Wire color) Value
Condition
Input/ (Approx.)
+ – Signal name
Output
20 During quick charging OPEN

Ground Quick charger connection signal Input
(BR) Except above 6.8 – 14.8 V

Ground Quick charger start/stop signal 2 Input
(G) Except above OPEN

Ground Quick charger start/stop signal 1 Input
(Y) Except above OPEN
25 Quick charger port temperature
Ground Input During quick charging 0.5 – 4.5 V
(SB) sensor signal 2
26 Quick charger port temperature
Ground Input During quick charging 0.5 – 4.5 V
(V) sensor signal 1
27
— EV system CAN-H — — —
(L)
29 During normal charging 0 – 5.0 V

— EVSE connection signal Output
(W) Except above 5.0 V
30 Input/ During normal charging −12.6 – 12.6 V

Ground EVSE communication (PWM)
(LG) Output Except above 0V
Fail-Safe INFOID:0000000010415161
FAIL-SAFE
When there is a malfunction with the PDM (Power Delivery Module), charging is stopped or charge does not
start as a fail-safe.
FAIL-SAFE LIST
×:Applicable —: Not applicable
Items Sub type

DTC Fail-safe
(CONSULT screen terms) (CONSULT screen terms)
ERRATIC ×
ELECTRICAL MALFUNCTION ×
MISSING MESSAGE ×
U1008 QUICK CHARGER COMM
ERRATIC ×
MISSING MESSAGE ×
U100A CAN COMM ERROR
ERRATIC ×
INTERNAL ELECTRONIC ERROR ×
U100B QUICK CHARGER COMM MISSING MESSAGE ×
ERRATIC ×
U1010 CONTROL UNIT (CAN) ELECTRICAL MALFUNCTION ×
SIGNAL INVALID ×
B2801 Q/CHG ACTIVATION SIG ERROR
SIGNAL STUCK HIGH ×
SIGNAL STUCK LOW ×
B2802 Q/CHG ISOLATION SIGNAL ERROR
B2803 Q/CHG PERMIT SIGNAL ERROR SIGNAL STUCK LOW ×
B2814 QUICK CHARGE RELAY SIGNAL STUCK HIGH ×
B2820 QUICK CHARGER — —
B2830 QUICK CHARGE VOLTAGE SENSOR CMPNENT INTERNAL MLFNCTN —
VC-30
Items Sub type
DTC Fail-safe
(CONSULT screen terms) (CONSULT screen terms) A
ELECTRICAL MALFUNCTION ×
B2840 PDM (POWER DELIVERY MODULE) CMPNENT INTERNAL MLFNCTN ×
B
COMPONENT/SYS OVER TEMP ×
B2850 PD MODULE TEMP SENSOR SIGNAL STUCK LOW ×
SIGNAL STUCK LOW × VC
B2880 F/S CHG RELAY
ELECTRICAL MALFUNCTION —
D
CIRC VOLT BELOW THRESHOLD —
B2890 DC/DC CONVERTER
CMPNENT INTERNAL MLFNCTN —
COMPONENT/SYS OVER TEMP — E
PROGRAM MEMORY ERROR ×
B2900 PDM (POWER DELIVERY MODULE)
DATA MEMORY ERROR ×
MEMORY ERROR — F
B2902 PDM (POWER DELIVERY MODULE)
CMPNENT INTERNAL MLFNCTN —
SIGNAL STUCK HIGH —
B2980 QUICK CHARGE PORT TEMP G
COMPONENT/SYS OVER TEMP ×
B29A0 N/CHG PORT ENGAGEMENT ERROR
SIGNAL INVALID × H
NO SIGNAL ×
SIGNAL STUCK LOW ×
I
B29C1 EVSE UNEXPECTED OPERATION ×
SIGNAL INVALID × J
×:Applicable —: Not applicable K

Items Sub type EV system Reference
DTC Trip
(CONSULT screen terms) (CONSULT screen terms) warning lamp page
ERRATIC × 1 L
U1000 CAN COMM CIRCUIT VC-50
ELECTRICAL MALFUNCTION × 1
MISSING MESSAGE × 1
U1008 QUICK CHARGER COMM VC-51 M
ERRATIC × 1
MISSING MESSAGE × 1
U100A CAN COMM ERROR VC-54
ERRATIC × 1 N
INTERNAL ELECTRONIC ERROR × 1
U100B QUICK CHARGER COMM MISSING MESSAGE × 1 VC-51
O
ERRATIC × 1
U1010 CONTROL UNIT (CAN) ELECTRICAL MALFUNCTION × 1 VC-55
SIGNAL INVALID × 1 P
B2801 Q/CHG ACTIVATION SIG ERROR VC-56
SIGNAL STUCK HIGH × 1
SIGNAL STUCK LOW × 1
B2802 Q/CHG ISOLATION SIGNAL ERROR VC-60
B2803 Q/CHG PERMIT SIGNAL ERROR SIGNAL STUCK LOW — 1 VC-63
B2814 QUICK CHARGE RELAY SIGNAL STUCK HIGH × 1 VC-66
VC-31
Items Sub type EV system Reference
DTC Trip
(CONSULT screen terms) (CONSULT screen terms) warning lamp page
B2820 QUICK CHARGER — — 1 VC-68
B2830 QUICK CHARGE VOLTAGE SENSOR CMPNENT INTERNAL MLFNCTN × or — 1 VC-69
ELECTRICAL MALFUNCTION × 1
B2840 PDM (POWER DELIVERY MODULE) CMPNENT INTERNAL MLFNCTN × 1 VC-71
COMPONENT/SYS OVER TEMP × 1
B2850 PD MODULE TEMP SEN SIGNAL STUCK LOW × 1 VC-75
B2880 F/S CHG RELAY VC-76
ELECTRICAL MALFUNCTION — 1
CIRC VOLT BELOW THRESHOLD — 1
B2890 DC/DC CONVERTER VC-80
CMPNENT INTERNAL MLFNCTN — 1
COMPONENT/SYS OVER TEMP — 1
PROGRAM MEMORY ERROR × 1
B2900 PDM (POWER DELIVERY MODULE) VC-84
DATA MEMORY ERROR × 1
MEMORY ERROR × 1
B2902 PDM (POWER DELIVERY MODULE) VC-84
CMPNENT INTERNAL MLFNCTN × 1
B2980 QUICK CHARGE PORT TEMP VC-85
COMPONENT/SYS OVER TEMP × 1
B29A0 N/CHG PORT ENGAGEMENT ERROR VC-89
SIGNAL INVALID — 1
NO SIGNAL × 1
B29C1 EVSE UNEXPECTED OPERATION × or — 1 VC-93
SIGNAL INVALID × or — 1
DTC Sub Type Index INFOID:0000000010415163
Items
Description Remarks
(CONSULT screen terms)
ELECTRICAL MALFUNCTION Electrical malfunction —
SIGNAL STUCK LOW Signal stuck low —
SIGNAL STUCK HIGH Signal stuck high —
SIGNAL INVALID Signal invalid —
NO SIGNAL No signal —
MEMORY ERROR General memory error —
DATA MEMORY ERROR Data memory error —
PROGRAM MEMORY ERROR Program memory error —
INTERNAL ELECTRONIC ERROR Internal electronic error —
INCRRCT COMPNT INSTALLED Incorrect component installed —
OVER TEMPERATURE Over temperature —
This sub type is used by the control module
to indicate that a signal was received with-
ALIV/CNT INCRCT/NOT UPDAT Alive / Sequence counter incorrect / Not updated
out the corresponding rolling count value
being properly updates.
VC-32
Items
Description Remarks
(CONSULT screen terms) A
This sub type is used by the control module
to indicate, that a message was processed
SIG PRTCTN CLCLTN INCRCT Value of signal protection calculation incorrect
with an incorrect protection (checksum) cal- B
culation.
This sub type is used for malfunctions
MISSING MESSAGE Missing message where one (or more) expected message(s)
is not received.
VC
This sub type is used for malfunctions

ERRATIC Erratic where the serial data, is momentarily im-
plausible or discontinuous. D
PARAMETRIC Parametric malfunction —
NO OPERATION No operation —
E
UNEXPECTED OPERATION Unexpected operation —
CMPNENT INTERNAL MLFNCTN Component internal malfunction —
COMPONENT/SYS OVER TEMP Component or system over temperature — F
CIRC VOLT BELOW THRESHOLD Voltage reduction —
CIRC VOLT ABOVE THRESHOLD Overvoltage —
G
CIRC CURR ABOVE THRESHOLD Overcurrent —
VC-33
< WIRING DIAGRAM >
WIRING DIAGRAM
JRCWC0719GB
VC-34
< WIRING DIAGRAM >
VC
JRCWC0720GB
VC-35
< WIRING DIAGRAM >
JRCWC0721GB
VC-36
< WIRING DIAGRAM >
VC
JRCWC0722GB
VC-37
< WIRING DIAGRAM >
JRCWC0723GB
VC-38
< WIRING DIAGRAM >
VC
JRCWC0724GB
VC-39
< WIRING DIAGRAM >
JRCWC0725GB
VC-40
BASIC INSPECTION A
B
OVERALL SEQUENCE
VC
JSCIA0790GB
DETAILED FLOW
VC-41
1.GET INFORMATION FOR SYMPTOM
the incident/malfunction occurred) using the “Diagnostic Work Sheet”. (Refer to VC-43, "Diagnostic Work
Sheet".)
>> GO TO 2.
2.CHECK DTC IN VCM
1. Check DTC in VCM.
Are any DTCs detected?
NO >> GO TO 3.
3.CHECK DTC IN PDM (POWER DELIVERY MODULE)
1. Check DTC in PDM (Power Delivery module).
- Record DTC and freeze frame data. (Print them out with CONSULT.)
- Erase DTC.
and VC-30, "Fail-Safe".
>> GO TO 6.
and VC-30, "Fail-Safe".
>> GO TO 7.
again.
NOTE:
• Perform Component Function Check if DTC CONFIRMATION PROCEDURE is not included on Service
this check.
MATION PROCEDURE.
Is DTC detected?
YES >> GO TO 8.
VC-42
7.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE A
B
YES >> GO TO 8.
NO >> Monitor input data from related sensors or check voltage of related PDM (Power Delivery module)
VC
terminals using CONSULT. Refer to VC-28, "Reference Value".
Inspect according to Diagnosis Procedure of the system. D
YES >> GO TO 9.
NO >> Check intermittent incident. Refer to GI-47, "Intermittent Incident". E
1. Repair or replace the malfunctioning part. F
ment.
G
>> GO TO 10.
10.FINAL CHECK H
When symptom was described from the customer, refer to confirmed symptom in step 4 or 5, and check that I
YES-1 >> DTC is detected: GO TO 8. J
Diagnostic Work Sheet INFOID:0000000010415166 K
DESCRIPTION
There are many operating conditions that lead to the malfunction of “charging system” components. A good L
grasp of such conditions can make troubleshooting faster and more accurate.
KEY POINTS M
WHAT Vehicle and parts
WHEN Date, Frequencies
N
WHERE Road conditions
Operating conditions,
HOW Weather conditions,
Symptoms O
In general, each customer feels differently about symptoms. It is important to fully understand the symptoms or
conditions for a customer complaint.
Utilize the diagnostic worksheet in order to organize all the information for troubleshooting. P
NOTE:
DIAGNOSTIC WORKSHEET
VC-43
Diagnostic worksheet
License plate Date of first
Customer No. registration
name
Model
Acceptance
VIN Mileage km (mile)
Date
Question Group Information from the customer

Vehicle condition at malfunction
R/Q/N/O READY (R) Quick charge (Q) Normal charge (N) Others (O)
occurrence
“READY” not enabled Poor drivability Shock Vibration
Driving impossible Noise Poor shifting Poor braking
Poor acceleration Low electricity consumption Switch malfunction
Warning lamp ON Others
( )
Details of symptom
R
Information display
indication
Electricity consump-
km (mile)/kW
tion
Li-ion battery remain-
/
ing energy
Symptom
Charging unable Charging discontinued Slow charging
Poor timer charging Poor remote charging Immediate charging unable
Others
( )
Q, N
Details of symptom
Quick charger moni-

tor indication
A/C inoperative Poor A/C Dead 12V battery
Others
O ( )
Details of symptom
Not applicable Ordinary road Highway Mountain pass

Rough road Level road Uphill Downhill Left/right turn
R/O
Others
( )
Location/status of occurrence Start of charge During charging After the end of charging
During standby of timer charging During timer charging
Q/N/O At the end of timer charging During remote charging
Others
( )
At the system startup During READY (Vehicle stopped)
At start During acceleration During driving with a constant speed
During coasting During braking Right before stopping Right after stopping
During POWER OFF operation A/C ON During shift change
Others
Driving condition R
( )
Vehicle speed km (MPH)
Accelerator pedal
/8
opening angle
VC-44
Question Group Information from the customer
A
Not applicable
Quick charger maker Applicable
( )
Location B
Quick charger Q Model number
Serial number
VC
Setting
Others
Genuine D
EVSE N Manufacturer Other
( )
Not applicable Applicable E
Location
Wall outlet N Voltage V
Breaker A F
Other information
Not applicable Applicable
Li-ion battery remaining energy Q/N/O G
( )
Shift position/operation R P R N D ECO When operating ( )
Not applicable Applicable H
Weather condition Weather
Temperature °C (or °F)
All the time Once Sometimes ( times in the past) I
Occurrence frequency R/Q/N/O Others
( )
POWER OFF Removal of 12V battery terminal Shift lever operation J
Timing of recovery from mal- During driving READY
function Others
( )
K
VC-45
CHARGE PORT
CHARGE PORT
INSPECTION PROCEDURES
Quick Charge Port
1. Perform the following visual inspections.
• Dust and foreign matter in the quick charge port and normal charge port
• Damage in the quick charge port and normal charge port
• Malfunction in opening/closing the charge port caps and looseness when closed and locked.
• Cracks in the packing of quick charge port
JSCIA0211ZZ
• Check that the quick charge port terminals are not welded.
CAUTION:
If they are welded, inspect the quick charge gun used for
the last charge, and replace the quick charge port. For
replacement of the quick charge port, refer to VC-122,
JPCIA0367ZZ
• Check that there is no irregular wear of the quick charge port lock .
JPCIA0368ZZ
• If the port is damaged, for example if the metal plate on the inside is lost, replace the quick charge
port. For replacement of the quick charge port, refer to VC-122, "Removal and Installation".
VC-46
CHARGE PORT
- If irregular wear is found at the visual inspection, check the
charge port inner diameter and replace the quick charge A
port if the limit value is exceeded.
Repair limit : 71 mm (2.80 in) B
VC
JPCIA0372ZZ
2.
D
Normal Charge Port
1. Perform the following visual inspections.
• Dust and foreign matter in the quick charge port and normal charge port E
• Damage in the quick charge port and normal charge port
• Malfunction in opening/closing the charge port caps and looseness when closed and locked.
• Check that the normal charge port terminals are not bent.
• Check that the contact prevention cap is not missing. F
NOTE:
If it is missing, it is extremely difficult to engage the charge
connector. G
JPCIA0369ZZ
I
• Check that there is no snow or ice on the normal charge port
top side .
NOTE: J
If snow or ice reaches the charge connector lock, charging
does not start.
K
JPCIA0370ZZ
M
Handling of charge port
Cleaning of charge port
If the charge port becomes dirty, clean the port with an air blow gun. N
Handling of damaged cap
Perform the following procedure if the cap becomes damaged:
• Replace charge port cap if the charge port cap becomes damaged O
• Replace charge port if the packing of quick charge port becomes cracked.
• Replace charge port if the terminal of quick charge port or normal charge port becomes damaged.
Cleaning of the inside of rubber cap P
If air does not exit through the rubber cap hole, remove the rubber cap from the port and clean the inside so
that air exits through the rubber cap hole.
VC-47
PDM (POWER DELIVERY MODULE)
PDM (POWER DELIVERY MODULE) : Diagnosis Procedure INFOID:0000000010415168
1.CHECK FUSE
Power supply Fuse No. Capacity

12V battery power 32 10 A
Power switch ON 57 10 A
Is the fuse fusing?
NO >> GO TO 2.
2.CHECK 12V BATTERY CABLE ON PDM (POWER DELIVERY MODULE) SIDE
2. Check the installation of 12V battery negative cable and 12V
battery positive cable . [PDM (Power Delivery Module) side.]
: Vehicle front
Is the inspection result normal ?

YES >> GO TO 3.
NO >> Repair or replace 12V battery negative cable or positive
cable on PDM (Power Delivery Module) side connec-
tion.
JSMIA1254ZZ
3.CHECK 12V BATTERY NEGATIVE CABLE ON PDM (POWER DELIVERY MODULE) SIDE
Check the continuity between 12V battery negative cable on PDM (Power Delivery Module) side and ground.
+
PDM
− Continuity
(Power Delivery Module)
Connector Terminal
H41 53 Ground Existed
YES >> GO TO 4.
4.12V BATTERY POWER SUPPLY
1. Disconnect PDM (Power Delivery Module) harness connector
.
: Vehicle front
NOTE:
Loosen the PDM (Power Delivery Module) harness connector by
rotating it counterclockwise and remove it.
2. Check the voltage between PDM (Power Delivery Module) har-
JSCIA0693ZZ
VC-48
+ A
PDM
− Voltage
Connector Terminal B
12V battery volt-
F18 18 Ground
age
VC
YES >> GO TO 5.
NO >> Perform the trouble diagnosis for 12V battery power supply circuit.
D
2. Check the voltage between PDM (Power Delivery Module) harness connector and ground. E
+
PDM Voltage F
−
(Power Delivery Module) (Approx.)
Connector Terminal
F18 16 Ground 11 – 14 V
G

YES >> INSPECTION END H
NO >> GO TO 6.
6.CHECK POWER SWITCH ON POWER SUPPLY CIRCUIT
1. Turn power switch OFF. I
3. Check the continuity between PDM (Power Delivery Module) harness connector and IPDM E/R harness
connector. J
PDM
IPDM E/R
(Power Delivery Module) Continuity K
L
M
VC-49
U1000 CAN COMMUNICATION
U1000 CAN COMMUNICATION
DESCRIPTION
CAN Communication Signal Chart. Refer to LAN-41, "CAN COMMUNICATION SYSTEM : CAN Communica-
tion Signal Chart".
DTC DETECTION LOGIC
CONSULT display
DTC Detection condition
ERRATIC The PDM (Power Delivery Module) is unable to send or re-
CAN COMM CIRCUIT
U1000 ELECTRICAL MAL- ceive EV system CAN communication continually for 2 sec-
(CAN communication circuit)
FUNCTION onds or more.
POSSIBLE CAUSE
Harness and connector (EV system CAN communication line circuit is open or shorted.)
FAIL-SAFE
Charge is stopped
With CONSULT
2. Check “Self-diagnosis result” of “CHARGER/PD MODULE”.
Is DTC U1000 detected?
YES >> Proceed to VC-50, "Diagnosis Procedure".

With CONSULT
2. Erase DTC.
3. Perform DTC confirmation procedure again. Refer to VC-50, "DTC Description".
Is DTC U1000 detected again?
YES >> Perform the trouble diagnosis for CAN communication system. Refer to LAN-21, "Trouble Diagno-
sis Flow Chart".
VC-50
U1008, U100B QUICK CHARGER COMMUNICATION
A
DESCRIPTION B
Quick charger communication is a serial communication line for real time application. It is a multiplex commu-
nication line with high data communication speed and excellent error detection ability. PDM (Power Delivery
Module) and quick charger are connected with two communication lines (quick charger communication H-line VC
and quick charger communication L-line) and transmit/receive data.
DTC DETECTION LOGIC
CAUTION: D
This DTC may be detected when there is a quick charger malfunction. Therefore if this DTC is
detected, check that there are no malfunctions in the quick charger.
E
CONSULT display Malfunc-
(Trouble diagnosis contents) tion type
QUICK CHARGER COMM MISSING MES-

SAGE F
U1008 (Quick charger communica-
tion) ERRATIC The PDM (Power Delivery Module) is unable to send or
A receive quick charger communication continually for 2
MISSING MES- seconds or more.
SAGE
G
QUICK CHARGER COMM
ERRATIC
U100B (Quick charger communica-
tion) INTERNAL In a self-test of CAN control unit, when PDM (Power De- H
ELECTRONIC B livery Module) is under conditions that a write value and
ERROR read value do not match even after 100 attempts.
POSSIBLE CAUSE I
• Harness and connector (Quick charger communication line circuit is open or shorted.)
• Quick charger
• Quick charge port
• PDM (Power Delivery Module) J
FAIL-SAFE
Charge is stopped K
1.PERFORM DTC CONFIRMATION PROCEDURE L
With CONSULT
1. Perform quick charging for 5 seconds or more.
2. Turn power switch ON. M
Is DTC U1008 or U100B detected?
YES (TYPE A)>>Proceed to VC-51, "TYPE A : Diagnosis Procedure". N
YES (TYPE B)>>Proceed to VC-53, "TYPE B : Diagnosis Procedure".
TYPE A O
TYPE A : Diagnosis Procedure INFOID:0000000010415174
P
With CONSULT
2. Erase DTC.
4. Perform DTC confirmation procedure again by using a quick charger other than the one is used for the
previous DTC confirmation procedure. Refer to VC-51, "DTC Description"
VC-51
Is DTC U1008 or U100B detected again?
YES >> GO TO 2.
NO >> INSPECTION END (Quick charger malfunction)
2.CHECK QUICK CHARGE PORT CONDITION
Check for any adhering foreign substances, cracking or damage on the quick charge port. Refer to VC-46,
"Inspection".
YES >> GO TO 3.
NO >> Clean or replace the quick charge port. Refer to VC-122, "Removal and Installation".
3.CHECK QUICK CHARGE PORT
Check the quick charge port. Refer to VC-53, "Component Inspection".
YES >> GO TO 4.
NO >> Replace quick charge port. Refer to VC-122, "Removal and Installation".
4.CHECK QUICK CHARGER COMMUNICATION CIRCUIT
.
: Vehicle front
NOTE:
2. Check the continuity between quick charge port harness con-
nector and PDM (Power Delivery Module) harness connector.
JSCIA0693ZZ
PDM
Quick charge port
(Power Delivery Module) Continuity
6 7
E125 F18 Existed
7 6
YES >> GO TO 5.
5.CHECK QUICK CHARGER COMMUNICATION GROUND CIRCUIT
Check the continuity between quick charge port harness connector and ground.
+
Quick charge port − Continuity
Connector Terminal
YES >> GO TO 6.
6.CHECK INTERMITTENT INCIDENT
Check the intermittent incident. Refer to GI-47, "Intermittent Incident".
TYPE B
VC-52
TYPE B : Diagnosis Procedure INFOID:0000000011065355
A
With CONSULT
B
2. Erase DTC.
Is DTC U100B detected again? VC
YES >> Replace PDM (Power Delivery Module). Refer to VC-54, "Diagnosis Procedure"
D
1.CHECK QUICK CHARGE PORT E

1. Disconnect quick charge port harness connector.
2. Check the continuity between quick charge port terminals and quick charge port side harness connector
of same terminals.
F
JSCIA0660GB
I
YES >> GO TO 2.
J
2.CHECK QUICK CHARGE PORT TEMPERATURE SENSOR
Check the resistance between quick charge port side harness connector terminals.
K
Quick charge side harness
connector Condition Resistance (kΩ)
Terminal L
9 Temperature (-40) – (50)
5 4 − 170
10 [°C (°F)] [(−40) – (122)]
M
NO >> Replace quick charge port. Refer to VC-122, "Removal and Installation". N
VC-53
U100A CAN COMMUNICATION
U100A CAN COMMUNICATION
DESCRIPTION
CAN Communication Signal Chart. Refer to LAN-41, "CAN COMMUNICATION SYSTEM : CAN Communica-
tion Signal Chart".
DTC DETECTION LOGIC
CONSULT display
MISSING MESSAGE The PDM (Power Delivery Module) is unable to send or re-
CAN COMM ERROR
U100A ceive EV system CAN communication continually for 2 sec-
(CAN communication error) ERRATIC onds or more.
POSSIBLE CAUSE
Harness and connector (EV system CAN communication line circuit is open or shorted.)
FAIL-SAFE
Charge is stopped
With CONSULT
Is DTC U100A detected?

With CONSULT
2. Erase DTC.
Is DTC U100A detected again?
YES >> Perform the trouble diagnosis for CAN communication system. Refer to LAN-21, "Trouble Diagno-
sis Flow Chart".
VC-54
A
CONSULT display
(Trouble diagnosis contents) VC
In a self-test of CAN control unit, when PDM (Power Delivery
CONTROL UNIT (CAN) ELECTRICAL MALFUNC- Module) is under conditions that a write value and a read value
U1010
[Control unit (CAN)] TION do not match one time or more out of two attempts, and after
that, they never match even after 100 attempts. D
POSSIBLE CAUSE
PDM (Power Delivery Module) E
FAIL-SAFE
Charge is stopped
F
With CONSULT G
Is DTC U1010 detected? H
1.PERFORM DTC CONFIRMATION PROCEDURE AGAIN J
With CONSULT
1. Turn power switch ON. K
2. Erase DTC.
Is DTC U1010 detected again?
L
YES >> Replace PDM (Power Delivery Module). Refer to VC-54, "Diagnosis Procedure"
M
VC-55
B2801 QUICK CHARGE CONNECTOR
DTC DETECTION LOGIC

CAUTION:

Quick charger connector disconnection is detected
SIGNAL INVALID A while receiving the quick charge start/stop 1 signal
Q/CHG ACTIVATION SIG ERROR that is transmitted from the quick charger.
B2801 (Quick charge activation signal er- The connector connection confirmation signal is de-
ror) SIGNAL STUCK tected continuously for 3 seconds or more because
B
HIGH the signal line cut-off circuit is stuck ON during quick
charging.
POSSIBLE CAUSE
Signal invalid
• Harness and connector (Quick charge port circuit is open or shorted.)
• Quick charger
Signal stuck high
FAIL-SAFE
Charge is stopped
With CONSULT
2. Connect the quick charger connector to the quick charge port.
3. Turn ON the quick charger start switch and wait for 1 minute or more.
Is DTC B2801 detected?
YES (TYPE A)>>Proceed to VC-56, "TYPE A : Diagnosis Procedure".
TYPE A

With CONSULT
2. Erase DTC.
Is DTC B2801 detected again?
YES >> GO TO 2.
VC-56
NO >> INSPECTION END (Quick charger malfunction).
2.CHECK QUICK CHARGE PORT CONDITION A
"Inspection".
B
YES >> GO TO 3.
VC
YES >> GO TO 4.
E
4.CHECK QUICK CHARGER CONNECTION SIGNAL POWER SUPPLY (1)
Check the voltage between quick charge port harness connector terminals.
F
Quick charge port
+ − Voltage
Connector
Terminal G
E125 3 5 12V battery voltage
YES >> GO TO 8.
NO >> GO TO 5.
5.CHECK QUICK CHARGER CONNECTION SIGNAL POWER SUPPLY (2) I
Check the voltage between quick charge port harness connector and ground.
J
+
Quick charge port − Voltage
Connector Terminal K
YES >> GO TO 7. L
NO >> GO TO 6.
6.CHECK QUICK CHARGER CONNECTION SIGNAL POWER SUPPLY CIRCUIT M
.
N
: Vehicle front
NOTE:
Loosen the PDM (Power Delivery Module) harness connector by O
P
JSCIA0693ZZ
PDM
Quick charge port
E125 3 F18 20 Existed
VC-57
YES >> GO TO 9.
7.CHECK QUICK CHARGER CONNECTION SIGNAL GROUND CIRCUIT
+
Connector Terminal
YES >> GO TO 9.
8.CHECK QUICK CHARGE START/STOP 1 SIGNAL CIRCUIT
.
: Vehicle front
NOTE:
JSCIA0693ZZ
PDM
Quick charge port
YES >> GO TO 9.
TYPE B

With CONSULT
2. Erase DTC.
YES >> GO TO 2.
NO >> INSPECTION END (Quick charger malfunction)
VC-58
B
1.CHECK QUICK CHARGE PORT VC

of same terminals.
D
JSCIA0660GB
G
YES >> GO TO 2.
H
I
Terminal J
5 4 − 170
10 [°C (°F)] [(−40) – (122)]
K
NO >> Replace quick charge port. Refer to VC-122, "Removal and Installation". L
VC-59
B2802 QUICK CHARGER
B2802 QUICK CHARGER
DTC DETECTION LOGIC

CAUTION:
CONSULT display
The quick charge start/stop 2 signal that is transmitted from
SIGNAL STUCK
the quick charger at the start of quick charging is not re-
HIGH
Q/CHG ISOLATION SIGNAL ERROR ceived.
B2802
(Quick charger isolation signal error) The quick charge start/stop 2 signal that is transmitted from
SIGNAL STUCK
the quick charger at the start of quick charging is received at
LOW
an incorrect time.
POSSIBLE CAUSE
• Harness and connector (Quick charger communication line circuit is open or shorted.)
• Quick charger
FAIL-SAFE
Charge is stopped
With CONSULT
2. Connect the quick charger connector to the quick charge port.
3. Turn ON the quick charger start switch and wait for 1 minute or more.

With CONSULT
2. Erase DTC.
YES >> GO TO 2.
NO >> INSPECTION END (Quick charger malfunction).
"Inspection".
YES >> GO TO 3.
VC-60
B2802 QUICK CHARGER
3.CHECK QUICK CHARGE PORT A

Is the inspection result normal? B
YES >> GO TO 4
4.CHECK QUICK CHARGER COMMUNICATION CIRCUIT VC
.
D
: Vehicle front
NOTE:
E
nector and PDM (Power Delivery Module) harness connector. F
JSCIA0693ZZ
PDM
Quick charge port
(Power Delivery Module) Continuity G
2 21
E125 F18 Existed H
4 19
YES >> GO TO 5. I
Check the intermittent incident. Refer to GI-47, "Intermittent Incident". J
NO >> Repair or replace error-detected parts. K
L
2. Check the continuity between quick charge port terminals and quick charge port side harness connector M
of same terminals.
P
JSCIA0660GB

YES >> GO TO 2.
VC-61
B2802 QUICK CHARGER

Terminal
5 4 − 170
10 [°C (°F)] [(−40) – (122)]

VC-62
B2803 QUICK CHARGER
B2803 QUICK CHARGER
A
CONSULT display
(Trouble diagnosis contents) VC
After the charge start/stop 1 signal is received from the quick
charger, the quick charge connector lock signal is received
Q/CHG PERMIT SIGNAL ERROR SIGNAL STUCK
B2803 from the quick charger via quick charger communication even
(Quick charge permit signal error) LOW D
though the charge permit signal is not being output by the PDM
POSSIBLE CAUSE E
• Harness and connector (Charge permit signal line is shorted.)
FAIL-SAFE F
Charge is stopped
G
With CONSULT
1. Perform quick charge for 5 seconds or more. H
Is DTC B2803 detected? I
1.PERFORM DTC CONFIRMATION PROCEDURE AGAIN K

With CONSULT
2. Erase DTC. L
previous DTC confirmation procedure. Refer to VC-63, "DTC Description". M
YES >> GO TO 2.
NO >> INSPECTION END (Quick Charger malfunction). N
2.CHECK QUICK CHARGE PERMIT SIGNAL CIRCUIT (1)
With CONSULT
1. Turn power switch ON. O
2. Select “QUICK CHARGE PERMIT” in “ACTIVE TEST” mode of “CHARGER/PD MODULE” using CON-
SULT.
3. Select “QUICK CHARGE PERMIT” of “DATA MONITOR” item. P
4. Switch the quick charge permit signal circuit between ON and OFF to check that the “QUICK CHARGE
PERMIT” indication changes.
5. Switch the quick charge permit signal circuit between ON and OFF to check that the “QUICK CHARGE
PERMIT” indication changes, also change the voltage between quick charge port harness connector and
ground.
VC-63
B2803 QUICK CHARGER
Condition
Monitor item Indication
(Active test)
ON LOW
QUICK CHARGE PERMIT QUICK CHARGE PERMIT
OFF HIGH
+
Condition
Quick charge port − Voltage
(Active test)
Connector Terminal
ON 1.0 V or less
E125 4 Ground QUICK CHARGE PERMIT
OFF OPEN
YES >> Check the intermittent incident. Refer to GI-47, "Intermittent Incident".
NO >> GO TO 3.
"Inspection".
YES >> GO TO 4.
YES >> GO TO 5.
With CONSULT
2. Select “QUICK CHARGE PERMIT” in “ACTIVE TEST” mode of “CHARGER/PD MODULE” using CON-
SULT.
3. Turn ON the quick charge permit signal circuit first. After this, turn OFF the circuit.
4. Check the continuity between quick charge port harness connector and ground.
CAUTION:
To ensure correct polarity of the tester, always connect the tester to the circuit in the forward
direction.
+
Connector Terminal
NO >> GO TO 6.
VC-64
B2803 QUICK CHARGER
. A
: Vehicle front
NOTE: B
3. Check the continuity between quick charge port harness con- VC
JSCIA0693ZZ
PDM D
Quick charge port
E125 4 F18 19 Existed E
YES >> GO TO 7.
NO >> Repair or replace error-detected parts. F
Check the intermittent incident. Refer to GI-47, "Intermittent Incident" G
1.CHECK QUICK CHARGE PORT I

of same terminals. J
JSCIA0660GB
M
YES >> GO TO 2.
NO >> Replace quick charge port. Refer to VC-122, "Removal and Installation". N
Check the resistance between quick charge port side harness connector terminals. O

connector Condition Resistance (kΩ) P
Terminal
5 4 − 170
10 [°C (°F)] [(−40) – (122)]

VC-65
B2814 QUICK CHARGE RELAY
DTC DETECTION LOGIC
CONSULT display
• When the quick charge relay is ON, the terminal voltage in the
quick charge relay drive circuit is 4.69 V or more continually for 3
QUICK CHARGE RELAY SIGNAL STUCK seconds or more.
B2814
(Quick charge relay) HIGH • When the quick charge relay is ON, the high voltage circuit voltage
that is input from the quick charge sensor is 60 V or more contin-
ually for 1 second or more.
POSSIBLE CAUSE
• Harness and connector [PDM (Power Delivery Module) ground circuit is open.]
FAIL-SAFE
Charge is stopped
With CONSULT
1.CHECK 12V BATTERY NEGATIVE CABLE ON PDM (POWER DELIVERY MODULE) SIDE (1)
2. Check the installation of 12V battery negative cable on PDM
(Power Delivery Module) side .
: Vehicle front

YES >> GO TO 2.
NO >> Repair or replace 12V battery negative cable on PDM
(Power Delivery Module) side connection.
JSMIA1253ZZ
Check the continuity between 12V battery negative cable on PDM (Power Delivery Module) side and ground.
+
PDM
− Continuity
Connector Terminal
VC-66
YES >> GO TO 3. A
B
YES >> Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation". VC
VC-67
B2820 QUICK CHARGER
B2820 QUICK CHARGER
DTC DETECTION LOGIC
CONSULT display
• The quick charger malfunction signal is received from the quick charger.
• The voltage detected by the quick charger is excessively higher or lower than
the voltage detected by the Li-ion battery controller.
• The current output from the quick charger is excessively higher or lower than
QUICK CHARGER
B2820 the command current.
(Quick charger)
• Before quick charge starts, voltage is detected in quick charge port before the
charge relay in PDM (Power Delivery Module) turns ON.
• When quick charge is completed, current does not decrease for 5 seconds
even when a charge stop signal is transmitted to the quick charger.
POSSIBLE CAUSE
• Quick charger
• Li-ion battery controller (Voltage sensor system)
FAIL-SAFE
Charge is stopped
With CONSULT
1.PERFORM SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER

With CONSULT
Perform self-diagnosis for “HV BAT”.
YES >> Perform trouble diagnosis for detected DTC. Refer to the following.
• Without battery cooler: EVB-55, "DTC Index"
• With battery cooler: EVB-329, "DTC Index"
• With battery heater & cooler: EVB-617, "DTC Index"
NO >> When this DTC detected, the cause may not be in the vehicle. Therefore after erasing the self-
diagnosis result, charge using a different quick charger than the quick charger which is used when
the malfunction is detected.
VC-68
B2830 QUICK CHARGE VOLTAGE SENSOR
A
DESCRIPTION B
The quick charge voltage sensor is integrated inside the PDM (Power Delivery Module), and detects the volt-
age at the + side and − side of the high voltage circuit on the upstream side of the quick charge relay (quick
charge port side). The PDM (Power Delivery Module) monitors the status of the quick charge relay based on VC
this signal.
DTC DETECTION LOGIC
CAUTION: D
E
CONSULT display
• Before the start of quick charge, the high voltage circuit
voltage that is sent from the quick charge voltage sensor F
during charging is 60 V or more continuously for 0.3 sec-
onds or more.
• During quick charging, the high voltage circuit voltage
that is sent from the quick charge voltage sensor is less
G
QUICK CHARGE VOLT-
than 60 V continuously for 10 seconds or more.
AGE SENSOR CMPNENT INTERNAL
B2830 • Before the start of quick charging, the high voltage circuit
(Quick charge voltage sen- MLFNCTN
voltage sent from the quick charge voltage sensor is 60 H
sor)
V or more continuously for 1 second or more when the
main relay is OFF.
• After the start of quick charging, the high voltage circuit
voltage sent from the quick charge voltage sensor is 30 I
V or more continuously for 1 second or more during the
insulation check by the quick charger.
POSSIBLE CAUSE J
• Quick charger
FAIL-SAFE K
None
DTC CONFIRMATION PROCEDURE L
With CONSULT
1. Perform quick charging for 30 seconds or more. M
Is DTC B2830 detected? N
1.PERFORM DTC CONFIRMATION PROCEDURE AGAIN P
With CONSULT
2. Erase DTC.
previous DTC confirmation procedure. Refer to VC-69, "DTC Description".
VC-69
YES >> GO TO 2.
NO >> INSPECTION END (Quick Charger malfunction).
VC-70
B2840 PDM(POWER DELIVERY MODULE)
A

CAUTION:
• Never use an extension cable or similar item during charging.
• For charging with AC100 V, use an independent socket with 15 A or higher rating. For charging with VC
AC200 V, use an independent 20 A or higher socket.
NOTE:
• DTC B2840 may be detected when an extension cable is used when charging using the normal charge
cable. D
• DTC B2840 may be detected when an independent socket of 15 A or higher (AC100 V charging), or 20 A or
higher (AC200 V charging), is not used.
E
VC-71

• During normal charging, PFC output voltage inside the PDM
(Power Delivery Module) is 436.8 V or more, or less than 329 V,
continually for 0.2 seconds or more, five or more times.
• During normal charging, output voltage inside the PDM (Power
Delivery Module) is 450 V or more continuously for 1 second or
more, five or more times, or recovery from charge interrupt does
ELECTRICAL
A not occur for 60 seconds or more after output voltage of 450 V
MALFUNCTION
or more occurs.
• During normal charging, output voltage inside the PDM (Power
Delivery Module) is less than 170 V continuously for 1 second or
more, five or more times, or recovery from charge interrupt does
not occur for 60 seconds or more after output voltage of less than
170 V occurs.
• Before the start of normal or quick charging, during quick charg-
ing, or during driving, AC input voltage for the PDM (Power De-
livery Module) is 60 V or more continuously for 10 seconds or
more.
• During normal charging, AC input current to the PDM (Power
Delivery Module) is 32 A or more continuously for 0.2 seconds
or more, 20 or more times, or recovery from charge interrupt
does not occur for 60 seconds or more after input current of 32
A or higher occurs.
ing, or during driving, output current from the master power con-
verter inside the PDM (Power Delivery Module) is 5 A or higher
PDM (POWER DELIV- continuously for 10 seconds or more.
ERY MODULE) • An I2C communications malfunction occurs in the PDM (Power
B2840
(Power delivery mod- Delivery Module).
ule) • During normal charging, DC voltage output by the PDM (Power
Delivery Module) is 440 V or more, or 240 V or less, continuously
for 5 seconds or more.
CMPNENT IN-
• During normal charging, output current from the master power
TERNAL B
converter inside the PDM (Power Delivery Module) is ±20% or
MLFNCTN
more than the command current value continuously for 60 sec-
onds or more. (Models for 6.0 kW)
• During normal charging, output current from the master power
more than the command current value continuously for 30 sec-
onds or more. (Models for 6.0 kW)
ing, or during driving, output current from the slave power con-
verter inside the PDM (Power Delivery Module) is 5 A or higher
continuously for 10 seconds or more. (Models for 6.0 kW)
• During normal charging, output current from the slave power
more than the master current value continuously for 60 seconds
or more. (Models for 6.0 kW)
• During normal charging, output current from the slave power
more than the master current value continuously for 30 seconds
or more. (Models for 6.0 kW)
COMPONENT/ During normal charging, the temperature of the circuits inside the
SYS OVER C PDM (Power Delivery Module) are excessively high continuously
TEMP for 30 seconds or more.
POSSIBLE CAUSE
Electrical malfunction
• Harness and connector
Component internal malfunction
VC-72
A
Component or system over temperature
- Coolant level
• PDM (Power Delivery Module) B
FAIL-SAFE
Charge is stopped
VC
D
With CONSULT
1. Perform normal charging for 120 seconds or more.
3. Check “Self-diagnosis result” of “CHARGER/PD MODULE”. E
YES (TYPE A or B)>>Proceed to VC-73, "TYPE A AND B : Diagnosis Procedure".
YES (TYPE C)>>Proceed to VC-74, "TYPE C : Diagnosis Procedure". F
TYPE A AND B G
TYPE A AND B : Diagnosis Procedure INFOID:0000000010415199
H
DANGER:
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are I
maintenance.
WARNING: J
• The removed service plug must always be carried in a pocket of the responsible worker or placed in K
• Refer to VC-6, "High Voltage Precautions". M
CAUTION:
N
1.CHECK PDM (POWER DELIVERY MODULE) HIGH-VOLTAGE HARNESS CONNECTION
2. Remove PDM (Power Delivery Module) from the vehicle. Refer to VC-108, "Removal and Installation". O
3. Check the connection of each high-voltage harness on the PDM (Power Delivery Module) side for loose-
ness and damage.
YES >> GO TO 2.
2.CHECK PDM (POWER DELIVERY MODULE) HIGH-VOLTAGE HARNESS
1. Remove each high-voltage harness from PDM (Power Delivery Module). Refer to VC-114, "Disassembly
and Assembly".
2. Check the continuity of the following high-voltage harness.
VC-73
Li-ion battery high-voltage harness
PDM
Li-ion battery
38 37
H18 39 H17 38 Existed
40 39
Electric compressor harness
PDM
Electric compressor
H22 43 8
H23 42 H25 7 Existed
H24 41 9
Quick charge port
PDM
Quick charge port
48 11
H30 H32 Existed
49 12
Normal charge port
PDM
Normal charge port
50 3
H31 H33 Existed
51 4
TYPE C
TYPE C : Diagnosis Procedure INFOID:0000000010415200
1.CHECK HIGH VOLTAGE COOLING SYSTEM

Inspect coolant level and leakage of high voltage cooling system. Refer to HCO-11, "Inspection".
YES >> GO TO 2.
With CONSULT
2. Erase DTC.
VC-74
A
DESCRIPTION B
Two temperature sensors are integrated in the PDM (Power Delivery Module), and monitor the charging circuit
temperature and control circuit board temperature.
The PDM (Power Delivery Module) also detects sensor accuracy malfunctions by comparing the signals from VC
each sensor.
DTC DETECTION LOGIC
D
CONSULT display
PD MODULE TEMP SEN During normal charging, the signal voltage of the temperature sensor E
SIGNAL STUCK
B2850 (Power delivery module tem- inside the PDM (Power Delivery Module) is excessively low continu-
LOW
perature sensor) ously for 30 seconds or more.
POSSIBLE CAUSE F
FAIL-SAFE
None G

1.PERFORM DTC CONFIRMATION PROCEDURE H
With CONSULT
1. Perform normal charging for 30 seconds or more.
YES >> Proceed to VC-75, "Diagnosis Procedure". J
K

L
With CONSULT
2. Erase DTC.
N
VC-75
B2880 F/S CHG RELAY
B2880 F/S CHG RELAY
DTC DETECTION LOGIC

During quick charging, the voltage of the quick charge re-
SIGNAL STUCK
A lay control circuit is less than approximately 4.21 V con-
LOW
F/S CHG RELAY tinuously for 3 seconds.
B2880
(Fail-safe charge relay) During quick charging, the voltage of the quick charge re-
SIGNAL STUCK
B lay control circuit is 4.69 V or more continuously for 3 sec-
HIGH
onds.
POSSIBLE CAUSE
Signal stuck low
• Quick charge relay
• F/S CHG relay
• F/S relay
Signal stuck high
• F/S CHG relay
• F/S relay
FAIL-SAFE
Charge is stopped
With CONSULT
3. Check self-diagnosis results.
TYPE A
1.CHECK QUICK CHARGE RELAY OPERATION

With CONSULT
2. Select “Q/CHG RELAY +” in “ACTIVE TEST” mode of “CHARGER/PD MODULE” using CONSULT.
3. Switch the quick charge relay between ON and OFF to check operating noise.
NOTE:
If operating noise is hard to hear, use a sound scope to check noise.
4. Check “Q/CHG RELAY −” in same manner.
Can operating sound be heard?
YES >> GO TO 2.
NO >> GO TO 3.
VC-76
B2880 F/S CHG RELAY
2.PERFORM DTC CONFIRMATION PROCEDURE AGAIN A
With CONSULT
1. Erase DTC.
2. Turn power switch OFF. B
YES >> Replace PDM (Power delivery module). Refer to VC-108, "Removal and Installation". VC
3.CHECK F/S CHG RELAY OPERATION
With CONSULT D
1. Select “F/S CHG RLY” in “ACTIVE TEST” mode of “EV/HEV” using CONSULT.
2. Switch the F/S CHG relay between ON and OFF to check operating noise of the F/S CHG relay.
Can operating sound be heard? E
YES >> GO TO 4.
NO >> Perform the trouble diagnosis for F/S CHG relay system. Refer to EVC-373, "Diagnosis Proce-
dure". F
4.CHECK F/S CHG RELAY SIGNAL
With CONSULT G
.
H
: Vehicle front
NOTE:
I
4. Select “F/S CHG RLY” in “ACTIVE TEST” mode of “EV/HEV” J
using CONSULT.
5. Turn ON the F/S CHG relay. JSCIA0693ZZ
6. Check the voltage between PDM (Power Delivery Module) har- K

+ L
PDM
− Voltage
12V battery volt-
F18 9 Ground
age
NO >> GO TO 5
5.CHECK F/S CHG RELAY SIGNAL CIRCUIT O

3. Check the continuity between PDM (Power Delivery Module) harness connector and F/S CHG relay har- P
ness connector.
PDM
F/S CHG relay
F18 9 E64 5 Existed
VC-77
B2880 F/S CHG RELAY
YES >> GO TO 6.
6.CHECK 12V BATTERY POWER SUPPLY (1)
Check the voltage between F/S CHG relay harness connector and ground.
+
Connector Terminal
12V battery volt-
E64 3 Ground
age
YES >> Replace F/S CHG relay.
NO >> GO TO 7.
7.CHECK FUSE
Fuse No. Capacity

#34 10 A
Is the fuse fusing?
NO >> GO TO 8.
8.CHECK 12V BATTERY POWER SUPPLY (2)
2. Check the voltage between fuse terminal and ground.
+ − Voltage
YES >> GO TO 9.
NO >> Perform the trouble diagnosis for 12V battery power supply circuit.
Check the continuity between F/S CHG relay harness connector and fuse terminal.
+
F/S CHG relay − Continuity
Connector Terminal
#34 fuse termi-
E64 3 Existed
nal
TYPE B
1.CHECK F/S CHG RELAY SIGNAL CIRCUIT

VC-78
B2880 F/S CHG RELAY
. A
: Vehicle front
NOTE: B
3. Turn power switch ON. VC
4. Check the voltage between PDM (Power Delivery Module) har-
JSCIA0693ZZ
D
+
PDM Voltage
−
(Power Delivery Module) (Approx.) E
Connector Terminal
F18 9 Ground 0V
YES >> GO TO 3.
NO >> GO TO 2.
G
2.CHECK F/S CHG RELAY POWER SUPPLY
2. Remove F/S CHG relay. H
I
+
PDM Voltage
−
(Power Delivery Module) (Approx.)
J
Connector Terminal
F18 9 Ground 0V
YES >> Perform the trouble diagnosis for F/S CHG relay system. Refer to EVC-373, "Diagnosis Proce-
dure".
NO >> There may be a short circuit in the location between power and an area between F/S CHG relay L
harness connector and PDM (Power Delivery Module) harness connector. Check the harness for
short circuit.
3.CHECK INTERMITTENT INCIDENT M
N
VC-79
DTC DETECTION LOGIC

During quick or normal charging, or during driving, the 12
V DC/DC converter inside the PDM (Power Delivery Mod-
CIRC VOLT BELOW
A ule) outputs an excessively low voltage continuously for 3
THRESHOLD
seconds or more, or output, an excessively low voltage for
less than 3 seconds, 20 times.
During quick or normal charging, or during driving, an ir-
regular voltage is input into the 12 V DC/DC converter in-
ELECTRICAL MALFUNC-
DC/DC CONVERT- B side the PDM (Power Delivery Module) continuously for 3
TION
B2890 ER seconds or more, or is input continuously for less than 3
(DC/DC converter) seconds, 20 times.
CMPNENT INTERNAL An I2C communication malfunction (12 V DC/DC control
C
MLFNCTN section) occurs.
During quick or normal charging, or during driving, the
temperature of the 12 V DC/DC converter inside the PDM
COMPONENT/SYS OVER
D (Power Delivery Module) is excessively high continuously
TEMP
for 3 seconds or more, or is excessively high continuously
for less than 3 seconds, 20 times.
POSSIBLE CAUSE
Circuit voltage below threshold
• 12V battery
Electrical malfunction
Component internal malfunction
Component or system over temperature
- Cooling fan (VCM)
- Coolant level
Circuit volt above threshold
• 12V battery
FAIL-SAFE
Charge is stopped
With CONSULT
1. Set the vehicle to READY and wait 120 seconds or more.
VC-80
YES (TYPE C)>>Proceed to VC-82, "TYPE C : Diagnosis Procedure". A
YES (TYPE D)>>Proceed to VC-82, "TYPE D : Diagnosis Procedure".
B
TYPE A
VC
1.CHECK 12V BATTERY
Check the 12V battery. Refer to PG-103, "How to Handle 12V Battery".
D
YES >> GO TO 2.
NO >> Replace 12V battery. Refer to PG-112, "Removal and Installation".
E
2.CHECK 12V BATTERY CABLE ON PDM (POWER DELIVERY MODULE) SIDE (1)
2. Check the installation of 12V battery negative cable and 12V F
battery positive cable . [PDM (Power Delivery Module) side.]
: Vehicle front G
YES >> GO TO 3.
NO >> Repair or replace 12V battery negative cable or positive H
cable on PDM (Power Delivery Module) side connec-
tion.
JSMIA1254ZZ I
3.CHECK 12V BATTERY CABLE ON PDM (POWER DELIVERY MODULE) SIDE (2)
1. Disconnect 12V battery negative and positive terminal. Refer to VC-5, "Precautions for Removing Battery J
Terminal".
2. Remove 12V battery negative and positive cable on PDM (Power Delivery Module) side.
3. Check the continuity between 12V battery negative cable terminal on PDM (Power Delivery Module) side
and 12V battery negative terminal, between 12V battery positive cable terminal on PDM (Power Delivery K
Module) side and 12V battery positive terminal.
+ − L
Continuity
ule) side 12V battery side
12V battery negative ter-
H41 53
minal
Existed N
12V battery positive ter-
E203 37
minal
O
TYPE B
P
DANGER:
VC-81
maintenance.
WARNING:
• Refer to VC-6, "High Voltage Precautions".
CAUTION:
1.CHECK LI-ION BATTERY HIGH-VOLTAGE HARNESS
1. Remove PDM (Power Delivery Module) from the vehicle. Refer to VC-108, "Removal and Installation".
2. Remove Li-ion battery high-voltage harness from PDM (Power Delivery Module). Refer to VC-114, "Disas-
sembly and Assembly".
3. Check the continuity of Li-ion battery high-voltage harness.
PDM
Li-ion battery
38 37
H18 H17 Existed
39 38
TYPE C
TYPE C : Diagnosis Procedure INFOID:0000000010415210

With CONSULT
1. Erase DTC.
TYPE D
TYPE D : Diagnosis Procedure INFOID:0000000010415211
1.CHECK COOLING FAN

Check the cooling fan. Refer to EVC-367, "Component Function Check".
YES >> GO TO 2.
2.CHECK HIGH VOLTAGE COOLING SYSTEM
Inspect coolant level and leakage of high voltage cooling system. Refer to HCO-11, "Inspection".
VC-82
VC
VC-83
B2900, B2902 PDM(POWER DELIVERY MODULE)
B2900, B2902 PDM(POWER DELIVERY MODULE)
DTC DETECTION LOGIC
CONSULT display
PROGRAM MEMORY ERROR PDM (Power Delivery Module) internal ROM malfunction
B2900
DATA MEMORY ERROR PDM (Power Delivery Module) internal RAM malfunction
PDM (POWER DELIVERY • PDM (Power Delivery Module) internal EEPROM mal-
MODULE) function
MEMORY ERROR
(Power delivery module) • I2C communication malfunction (EEPROM control sec-
B2902 tion)
CMPNENT INTERNAL
I2C communication malfunction (EEPROM control section)
MLFNCTN
POSSIBLE CAUSE
FAIL-SAFE
Charge does not start
With CONSULT
Is DTC B2900 or B2902 detected?

With CONSULT
1. Erase DTC.
Is DTC B2900 or B2902 detected again?
VC-84
B2980 QUICK CHARGE PORT
A
Description B
The quick charge port contains a temperature sensor, and the quick charge port temperature signals is sent as
two lines of voltage to the PDM (Power Delivery Module).
DTC DETECTION LOGIC VC
CONSULT display
(Trouble diagnosis contents) D
• During quick charging, the signal voltage of the quick charge port
temperature sensor is 4.85 V or more continuously for 3 seconds
QUICK CHARGE PORT SIGNAL STUCK or more. E
TEMP HIGH • During quick charging, the signal voltage of the quick charge port
B2980 temperature sensor is less than 0.15 V continuously for 3 sec-
(Quick charge port temper-
ature) onds or more.
COMPONENT/SYS During quick charging, the quick charge port temperature is 90°C or F
OVER TEMP more continuously for 3 seconds or more.
POSSIBLE CAUSE G
• Harness and connector (Quick charge port circuit is open or shorted.)
• Quick charger (connector)
H
FAIL-SAFE
Signal stuck high
• None I
Component/sysem over temperature

• Charge is stopped
J
K
With CONSULT
3. Check “Self-diagnosis result” of “CHARGER/PD MODULE”. L
N
With CONSULT O
2. Erase DTC.
P
previous DTC confirmation procedure. Refer to VC-85, "DTC Description".
YES >> GO TO 2.
NO >> INSPECTION END (Quick Charger malfunction)
VC-85
"Inspection".
YES >> GO TO 3.
3.CHECK QUICK CHARGE PORT HARNESS CONNECTOR
3. Check quick charge port harness connector. (E125).
4. Check contact pressure of quick charge port harness connector (E125).
5. Check the waterproof condition of quick charge port harness connector (E125).
YES >> GO TO 4.
YES >> GO TO 5.
5.CHECK QUICK CHARGE PORT TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
.
: Vehicle front
NOTE:
2. Check the continuity between PDM (Power Delivery Module)
harness connector and quick charge port harness connector.
JSCIA0693ZZ
PDM
Quick charge port
26 9
F18 E125 Existed
25 10
YES >> GO TO 6.
6.CHECK QUICK CHARGE PORT TEMPERATURE SENSOR GROUND CIRCUIT
+
Connector Terminal
YES >> GO TO 7.
VC-86
Check the installation of 12V battery negative cable on PDM
(Power Delivery Module) side. A
: Vehicle front
Is the inspection result normal? B

YES >> GO TO 8.
NO >> Repair or replace 12V battery negative cable on PDM
(Power Delivery Module) side connection. VC
JSMIA1253ZZ
8.CHECK 12V BATTERY NEGATIVE CABLE ON PDM (POWER DELIVERY MODULE) SIDE (2) D
Check the continuity between 12V battery negative cable on PDM

(Power Delivery Module) side and ground. E
: Vehicle front
F
+
PDM
− Continuity
(Power Delivery Module) G
Connector Terminal
JSMIA1253ZZ
H
YES >> GO TO 9.
I
K
1.CHECK QUICK CHARGE PORT L

of same terminals. M
JSCIA0660GB
P
YES >> GO TO 2.
VC-87

Terminal
5 4 − 170
10 [°C (°F)] [(−40) – (122)]

VC-88
B29A0 NORMAL CHARGE PORT
A

(Trouble diagnosis contents) tion type VC
• At the start of charging or during charging, the normal
charge cable connection detection signal voltage is ap-
proximately 4.8 V or more, or 1.0 V or less, continuously
SIGNAL D
N/CHG PORT ENGAGE- A for 3 seconds or more.
STUCK HIGH
MENT ERROR • During normal charging, the normal charge cable connec-
B29A0 tion detection signal voltage is approximately 3.3 V or
(Normal charge port en-
gagement error) more continuously for 3 seconds or more.
E
During normal charging, the normal charge cable connec-
SIGNAL IN-
B tion detection signal voltage is approximately 3.7 – 4.8 V
VALID
F
POSSIBLE CAUSE
Signal stuck high
• Harness and connector (Normal charge port circuit is open or shorted.) G
• Normal charge port
• Normal charge cable
• PDM (Power Delivery Module) H
Signal invalid
• Harness and connector (Normal charge port circuit is open or shorted.)
• Normal charge port I
FAIL-SAFE
Charge is stopped
J
TYPE A
K
With CONSULT
1. Perform normal charging for 10 seconds or more. L
Is DTC B29A0 detected? M
YES >> Proceed to VC-90, "TYPE A : Diagnosis Procedure".
N
TYPE B
O
With CONSULT
1. Perform normal charging for 2 minutes or more.
3. Check “Self-diagnosis result” of “CHARGER/PD MODULE”. P
Is DTC B29A0 detected?
YES >> Proceed to VC-91, "TYPE B : Diagnosis Procedure".
TYPE A
VC-89

With CONSULT
2. Erase DTC.
4. Perform DTC confirmation procedure again by using a normal charge cable other than the one is used for
the previous DTC confirmation procedure. Refer to VC-89, "DTC Description".
Is DTC B29A0 detected again?
YES >> GO TO 2.
NO >> Replace normal charge cable.
2.CHECK NORMAL CHARGE PORT CONDITION
Check for any adhering foreign substances, cracking or damage on the normal charge port. Refer to VC-46,
"Inspection".
YES >> GO TO 3.
NO >> Clean or replace the normal charge port. Refer to VC-127, "Removal and Installation".
3.CHECK NORMAL CHARGE PORT
Check the normal charge port. Refer to VC-91, "Component Inspection".
YES >> GO TO 4.
NO >> Replace normal charge port. Refer to VC-127, "Removal and Installation".
4.CHECK EVSE CONNECTION DETECTING CIRCUIT POWER SUPPLY
2. Check the voltage between normal charge port harness connector and ground.
+
Normal charge port − Voltage
Connector Terminal
E124 2 Ground 5.0 V
YES >> GO TO 6.
NO >> GO TO 5.
5.CHECK EVSE CONNECTION DETECTING CIRCUIT
.
: Vehicle front
NOTE:
3. Check the continuity between normal charge port harness con-
JSCIA0693ZZ
PDM
Normal charge port
VC-90
YES >> GO TO 6. A
B
YES >> Replace PDM (Power Delivery Module). Refer to VC-108, "Removal and Installation". VC
TYPE B
D
1.CHECK NORMAL CHARGE CABLE RELEASE SWITCH STATUS

E
Check that there are no operation malfunctions caused by dust or a foreign substance on the normal charge
cable release switch.
F
YES >> GO TO 2.
NO >> Repair or clean.
2.PERFORM DTC CONFIRMATION PROCEDURE AGAIN G
With CONSULT
2. Erase DTC. H
4. Perform DTC confirmation procedure again by using a normal charge cable other than the one is used for
the previous DTC confirmation procedure. Refer to VC-93, "DTC Description". I
Is DTC B29A0 detected again?
NO >> Replace normal charge cable. J
1.CHECK NORMAL CHARGE PORT (1) K

1. Disconnect normal charge port harness connector.
2. Check the continuity between normal charge port terminals and normal charge port side harness connec-
tor of same terminals. L
JSCIA0694GB O
YES >> GO TO 2.
NO >> Replace normal charge port. Refer to VC-127, "Removal and Installation". P
2.CHECK NORMAL CHARGE PORT (2)
Check the resistance between normal charge port side harness connector and PDM (Power Delivery Module)
harness connector.
VC-91
Normal charge port side PDM

harness connector (Power Delivery Module) Resistance (kΩ)
Terminal Connector Terminal
2 H42 52 2.43 − 2.97
NOTE:
Since normal charge port ground (H42) is installed to the PDM (Power Delivery Module) body, resistance can
be measured between the harness connector (Terminal No.2) on the normal charge port side and PDM
(Power Delivery Module) body [excluding PDM (Power Delivery Module) cover].
VC-92
B29C1 EVSE
B29C1 EVSE
A

(Trouble diagnosis contents) tion type VC
• During normal charging, although the AC power source
is being input, there is a break of the PWM communica-
tion signal from Mode2 EVSE or charging station.
NO SIGNAL A D
• Before normal charging or during normal charging,
there is a peak value malfunction in the PWM commu-
nication signal from Mode2 EVSE or charging station.
Before the start of normal charging or during normal E
SIGNAL STUCK charging, there is no AC power source input even though
B
LOW the PDM (Power Delivery Module) permits the start of
EVSE
charging.
B29C1 (Electric vehicle supply F
equipment) Before the start of normal charging, there is AC power
UNEXPECTED
C source input despite the fact that PWM communication is
OPERATION
not received from Mode2 EVSE or charging station.
After charging is completed, AC power source continues G
SIGNAL STUCK
D to be input even though the PDM (Power Delivery Mod-
HIGH
ule) charging is stopped.
When an error is detected in a PWM communication sig- H
SIGNAL INVALID E nal from Mode2 EVSE or charging station during normal
charge.
POSSIBLE CAUSE I
No signal
J
K
Signal stuck low
• Normal charge cable L
Unexpected Operation
• Harness and connector (Normal charge port circuit is open or shorted.) M
N
Signal stuck high
• PDM (Power Delivery Module) O
Signal invalid
• Normal charge port P
FAIL-SAFE
Charge is stopped
VC-93
B29C1 EVSE
1.CONFIRMATION FOR MALFUNCTION TYPE
Check the malfunction type.
Which is the malfunction type? .
Types A, B, C or E>>GO TO 2.
Type D >> GO TO 3.
2.PERFORM DTC CONFIRMATION PROCEDURE OF TYPE A, B, C OR E
With CONSULT
1. Perform normal charging for the time listed below.
Malfunction type Time

A No signal 1 minute or more
B Signal stuck low
10 seconds or more
C Unexpected operation
E Signal invalid 30 seconds or more
Is DTC B29C1 detected?
YES (TYPE A, B and E)>>Proceed to VC-94, "TYPE A, B AND E : Diagnosis Procedure".
YES (TYPE C)>>Proceed to VC-96, "TYPE C AND D : Diagnosis Procedure".
3.PERFORM DTC CONFIRMATION PROCEDURE OF TYPE D
With CONSULT
1. Perform normal charging until charging is completed.
Is DTC B29C1 detected?
YES >> Proceed to VC-96, "TYPE C AND D : Diagnosis Procedure".
TYPE A, B AND E
TYPE A, B AND E : Diagnosis Procedure INFOID:0000000010415223
DANGER:
maintenance.
WARNING:
CAUTION:
VC-94
B29C1 EVSE
With CONSULT
2. Check "Self-diagnosis result" of "EV/HEV". B
YES >> Perform diagnosis procedure corresponding to DTC indicated. Refer to EVC-98, "DTC Index".
NO >> GO TO 2. VC
With CONSULT
1. Erase DTC. D
3. Perform DTC confirmation procedure again by using normal charge cable different from the one used for
the previous DTC confirmation procedure. Reform to VC-93, "DTC Description". E
Is DTCB29C1 detected again?
YES >> GO TO 3.
NO >> Replace normal charge cable. F
3.CHECK NORMAL CHARGE PORT CONDITION
Check for any adhering foreign substances, cracking or damage on the normal charge port. Refer to VC-46,
G
"Inspection".
YES >> GO TO 4. H
NO >> Clean or replace the normal charge port. Refer to VC-127, "Removal and Installation".
4.CHECK NORMAL CHARGE PORT
Check the normal charge port. Refer to VC-91, "Component Inspection". I
YES >> GO TO 5.
NO >> Replace normal charge port. Refer to VC-127, "Removal and Installation". J
5.CHECK EVSE COMMUNICATION
1. Disconnect PDM (Power Delivery Module) harness connector K
.
: Vehicle front
L
NOTE:
rotating it counterclockwise and remove it. M
2. Check the continuity between PDM (Power Delivery Module)
harness connector and normal charge port harness connector.
JSCIA0693ZZ N
PDM
Normal charge port
O
YES >> GO TO 6. P
6.CHECK HIGH-VOLTAGE HARNESS
1. Remove normal charge port from PDM (Power Delivery Module). Refer to VC-108, "Removal and Installa-
tion".
2. Check the high-voltage harness continuity between the normal port and PDM (Power Delivery Module).
VC-95
B29C1 EVSE
PDM
Normal charge port
3 50
H33 H31 Existed
4 51
YES >> Replace PDM (Power Delivery Module) (Fuse is fusing). Refer to VC-108, "Removal and Installa-
tion".
TYPE C AND D
TYPE C AND D : Diagnosis Procedure INFOID:0000000010415224
1.CHECK NORMAL CHARGE CABLE SPECIFICATIONS

Check whether or not the normal charge cable conforms to the SAE-J1772 standard.
Is the correct normal charge cable being used?
YES >> GO TO 2
NO >> Explain to the customer that the correct normal charge cable must be used.
With CONSULT
2. Erase DTC.
4. Perform DTC confirmation procedure again by using normal charge cable different from the one used for
the previous DTC confirmation procedure. Refer to VC-93, "DTC Description".
Is DTC B29C1 detected again?
YES >> GO TO 3.
NO >> Replace normal charge cable.
1.CHECK NORMAL CHARGE PORT (1)

1. Disconnect normal charge port harness connector.
2. Check the continuity between normal charge port terminals and normal charge port side harness connec-
tor of same terminals.
JSCIA0694GB

YES >> GO TO 2.
VC-96
B29C1 EVSE
2.CHECK NORMAL CHARGE PORT (2) A
Check the resistance between normal charge port side harness connector and PDM (Power Delivery Module)
harness connector.
B
Normal charge port side PDM
harness connector (Power Delivery Module) Resistance (kΩ)
Terminal Connector Terminal VC
2 H42 52 2.43 − 2.97
NOTE:
Since normal charge port ground (H42) is installed to the PDM (Power Delivery Module) body, resistance can D
be measured between the harness connector (Terminal No.2) on the normal charge port side and PDM
(Power Delivery Module) body [excluding PDM (Power Delivery Module) cover].
F
VC-97
DANGER:
maintenance.
WARNING:
CAUTION:
1. Remove PDM (Power Delivery Module) from the vehicle. Refer to VC-108, "Removal and Installation".
2. Use an insulation resister to check the resistance between Li-ion battery high-voltage harness connector
terminal (H17) and PDM (Power Delivery Module) body.
WARNING:
Unlike normal resistance testers, insulation resistance testers (multi tester) are used by
applying a voltage of 500 V. For this reason, improper handling of an insulation resistance tester
may cause an electric shock. In addition to this, if an insulation resistance tester is used to the 12
V circuit, its electric devices may be damaged. To avoid these hazards, carefully read the handling
manual of insulation resistance tester and perform safe operation.
CAUTION:
• Set the insulation resistance tester (multi tester) at 500 V.
• To ensure correct polarity of the tester, always connect to the circuit in the forward direction.
• Wait for 30 seconds until the resistance becomes steady.
• If the inspection result shows that there is no continuity, check that the parts are mounted cor-
rectly.
+
Li-ion battery high-voltage harness − Resistance
Connector Terminal
37 PDM (Power Delivery
H17 40 MΩ or more
38 Module) body

NO >> Replace PDM (Power Delivery Module) and high-voltage harness. Refer to VC-108, "Removal
and Installation".
VC-98
SYMPTOM DIAGNOSIS A
Symptom Table INFOID:0000000010415227
B

VC
Symptom Probable malfunction location Inspection item/reference
Charge port malfunction (bent pins, en- Inspection of charge port
Charge connector cannot be inserted.
try of foreign material Refer to VC-46, "Inspection".
D
• Charging status indicator circuit
Charging status indicator circuit.
Charging status indicator does not illuminate. • Charge indicator lamp
Refer to EVC-382, "Diagnosis Procedure".
• VCM
E
Plugin detection sound does not operate. Vehicle Sound for Pedestrians (VSP) Refer to VSP-36, "Symptom Table".
Related to EV/power train (charge control) Refer to EVC-390, "Symptom Index".
VC-99
Symptoms Check items Solution

Confirm that there has not been a power failure. Make
sure the breaker is on. If an outlet with a timer device in-
There is no power coming from the outlet.
stalled is used, power will only be available at the time
set by the timer.
The outlet plug is not connected correctly. Confirm the outlet plug is connected correctly.
The charge connector is not connected correctly. Confirm the charge connector is connected correctly.
Before charging, place power switch in the OFF posi-
Power switch is in the ON position.
tion.
Disconnect a connector of normal charge connector or
quick charge connector.
Both the normal charge connector and the quick
NOTE:
charge connector are connected.
Normal charge and quick charge cannot perform at the
same time.
Timer charge has been set. Push immediate charging switch.
No action.
NOTE:
The Li-ion battery is already fully charged. Charging can not be performed if the Li-ion battery is al-
ready fully charged. Charging automatically stops if the
Immediate charge Li-ion battery is fully charged.
cannot be performed.
Charging does not start because the charge amount Confirm the charge percentage set in the timer charge.
has been set to 80% and the Li-ion battery is already Change the charging percentage the desired charge
charged to more than 80%. setting.
Confirm the Li-ion battery temperature in combination
meter.
The temperature of the Li-ion battery is too hot or too
NOTE:
cold to charge.
If the meter indicates the Li-ion battery is too hot (red
zone) or too cold (blue zone), charging is not performed.
The 12V battery is discharged. Charge the 12V battery.
• Check the PDM (Power Delivery Module) self-diagno-
sis results.
Vehicle, charge cable, or quick charger malfunction.
• Check by changing the combination of vehicle and
charge cable.
When connected to the socket where the phenomenon
When a NISSAN genuine Mode2 EVSE is used, the occurs, check the conditions of indicator lamp illumina-
grounding work on the socket side does not conform tion on the control box. If the "READY" lamp is blinking,
to NISSAN recommended work. have a specialist check the conditions of grounding
work on the socket side.
The shift position is in a range other than “P” range. Change the shift position to “P” range.
VC-100
A
set by the timer. B
VC
tion.
quick charge connector. D
NOTE:
same time.
E
No action
NOTE:
The Li-ion battery is already fully charged. Charging cannot be performed if the Li-ion battery is al-
ready fully charged. Charging automatically stops if the F
Li-ion battery is fully charged.
meter. G
NOTE:
cold to charge.
The 12V battery is discharged. Charge the 12V battery. H
sis results.
• Check by changing the combination of vehicle and I
charge cable.
Timer charge cannot
be performed. The charge cable is not connected. Connect the charge cable.
Charging does not start because the timer charge Confirm when the timer charge time is set to start charg- J
start time and end time are set and the current time ing. Change the timer charge setting to the desired
is before the set start time. charge time.
Charging does not start because only the timer Confirm when the timer charge time is set to start K
charge start time is set and the current time is after charging. Change the timer charge setting to the de-
the set start time. sired charge time.
Charging does not start because only the timer Confirm when the timer charge time is set to start charg- L
charge end time is set and the current time is after ing. Change the timer charge setting to the desired
the set end time. charge time.
has been set to 80% and the Li-ion battery is already Change the charging percentage the desired charge M
Confirm that the date and time shown on the timer
charge screen are the same as the clock on the naviga- N
tion display.
The time on the clock is wrong. NOTE:
If the 12V battery terminal is disconnected, the time set-
ting must be updated. There must be a GPS signal to O
adjust the timer setting clock.
The immediate charging switch has been pressed. Check immediate charging switch.
Timer charge has not been set. Set the timer charge schedule. P
VC-101
set by the timer.
tion.
NOTE:
same time.
has been set to 80% and the Li-ion battery is already Change the charging percentage the desired charge
No action
NOTE:
Remote charge can- meter.
not be performed. NOTE:
cold to charge.
sis results.
charge cable.
The charge cable is not connected. Connect the charge cable.
Confirm that there is a cellular signal in your location.
Remote charge can not be started unless the web en-
Communication with the vehicle cannot be estab- abled smart phone can connect to the intent.
lished.
Confirm that there is a cellular signal at the vehicle loca-
tion.
NOTE:
The vehicle is left standing for long time. If the power switch is in the OFF position for more than
2 weeks, the remote charge is not performed.
VC-102
A
set by the timer. B
Check that the charge cable has not been disconnect-
The charge cable has been disconnected.
ed.
Release the release switch. VC
NOTE:
The release switch has been pressed.
If the charge connector button is pressed for a long pe-
riod of time, charging will be stopped.
D
Normal charge stops perform normal charge (immediate charge).
in the middle of charg- NOTE:
ing. Timer charge end time has been reached. When timer charge is set and the charge end time is
reached, charging will be stopped, even if the Li-ion bat- E
tery is not fully charged.
meter.
NOTE:
F
cold to charge.
• Check the PDM (Power Delivery Module) self-diagno- G
sis results.
Vehicle or charge cable malfunction.
charge cable.
H
• Inspect the socket which is used and the charge ca-
ble plug.
• Check by changing the combination of socket and
charge cable. I
There is insufficient contact with the charge cable NOTE:
The normal charging
plug due to socket wear or another issue. Insufficient contact limits the charging current or causes
time is too long.
(charging current is limited.) charging to stop. The charging current history can be
checked from the “CHARGE CURRENT LIMITATION J
HISTORY” in the work support items for “CHARGER/
PD MODULE” on CONSULT.
Refer to VC-25, "CONSULT Function".
K
VC-103
Check that the charge connector is connected correctly
The charge connector is not connected correctly.
and that it is locked.
The self-diagnostic function of the quick charger de-
VC-60
tects a isolation error.
tion.
NOTE:
same time.
No action
NOTE:
Quick charge cannot
be performed.
meter.
NOTE:
cold to charge.
sis results.
Vehicle or quick charger malfunction
quick charger.
The power switch of the quick charger is off. Check the power switch of the quick charger.
NOTE:
same time.
meter.
NOTE:
cold to charge.
sis results.
Vehicle or quick charger malfunction
quick charger.
Quick charge stops in
the middle of charging Perform quick charge again (as needed).
NOTE:
Charging will stop depending on the timer function set-
Charging is stopped by the quick charge timer. ting of the quick charger.
Perform quick charge again (as needed).
NOTE:
Charging will stop depending on the timer of the vehicle.
Perform quick charge again (as needed).
NOTE:
Charging stops at 90% capacity. When charging has been started when the Li-ion battery
remaining energy is less than half, charging will stop
when the energy reaches 90%.
Check whether the power supply for the quick charger
The power supply for the quick charger is OFF.
is off.
VC-104
B
REMOVAL
VC
JPCIA0297GB
VC-105
PDM (Power Delivery Module) Quick charge port Normal charge port
Cable bracket 12 V negative battery cable Water hose
Clamp Gasket Charge port harness bracket
12V positive battery cable Li-ion battery high-voltage harness
bracket (center)
High-voltage warning label Breather
bracket (rear)
Normal charge port harness bracket Bus bar cover
bracket (front)
Arrow view Arrow view To electric water pump
: Always replace after disassembly
, , , Indicate connections which bear the same mark.
VC-106
DISASSEMBLY
A
VC
JPCIA0298GB
P
Quick charge port Normal charge port Clamp
Li-ion battery high-voltage harness Electric compressor harness
: Indicate connections which bear the same mark.
VC-107
DANGER:
maintenance.
WARNING:
CAUTION:
REMOVAL
WARNING:
Disconnect high voltage. Refer to GI-27, "How to Disconnect High Voltage".
2. Check voltage in high voltage circuit. (Check that condenser are discharged.) Refer to GI-31, "Check Volt-
age in High Voltage Circuit".
3. Disengage the Li-ion battery high-voltage harness clamp .
: Vehicle front
WARNING:
Be sure to put on insulating protective gear before

beginning work on the high voltage system.
JSCIA1264ZZ
4. Remove the clip and then remove the acoustic insulating plate .
JSCIA1265ZZ
: Vehicle front
WARNING:
VC-108
Be sure to put on insulating protective gear before beginning work on the high voltage sys- A
tem.
5. Disengage the Li-ion battery high-voltage harness clamp .

VC
JSCIA1266ZZ F
: Vehicle front
WARNING: G
Be sure to put on insulating protective gear before beginning work on the high voltage sys-
tem. H
I
6. Remove breather box and the bracket bolt . And then remove normal charge port harness bracket .
JSCIA1267ZZ
M
: Vehicle front
WARNING:
N
tem.
O
7. Drain the coolant. Refer to HCO-11, "Draining". P

8. Remove the reservoir tank. Refer to HCO-14, "Exploded View".
9. Remove the cowl top extension. Refer to EXT-25, "Removal and Installation".
10. Remove the right front wheel.
11. Remove the front right fender protector. Refer to EXT-26, "Removal and Installation".
12. Disconnect the electric compressor high-voltage harness connector and low-voltage harness connector.
Refer to HA-34, "Removal and Installation".
VC-109
13. Remove the electric compressor mounting bolts and move the
electric compressor in the direction of the arrow ( ). Refer to
HA-34, "Exploded View".
WARNING:

NOTE: JPCIA0357ZZ
Use rope or other means to fasten the electric compressor in a

location where it does not interfere with work.
14. Disconnect water hose and water hose .
: Electric water pump

: Inverter
WARNING:

JPCIA0302ZZ
15. Remove the PDM (Power Delivery Module) harness connector , then remove the harness bracket .
JSCIA1133ZZ
WARNING:
tem.
NOTE:
Loosen the PDM (Power Delivery Module) harness connector by rotating it counterclockwise and remove
it.
VC-110
16. Remove the bracket , and disconnect the 12 V battery nega-
tive cable and 12 V battery positive cable on the PDM A
(Power Delivery Module) side.
VC
JSCIA1143ZZ
D
17. Remove the normal charge port and quick charge port. Refer to VC-127, "Removal and Installation" (nor-
mal charge port) and VC-122, "Removal and Installation" (quick charge port).
18. Remove the quick charge port harness clamp and normal charge port harness clamp from the E
bracket.
JSCIA1134ZZ
J
WARNING:
tem. K
L
19. Remove the bus bar cover and remove the bus bar fastening
bolt between the PDM (Power Delivery Module) and inverter.
M
: Vehicle front
WARNING:
N
O
JPCIA0305ZZ
CAUTION:
Must be opening of PDM (Power Delivery Module) with a tape or equivalent to seal out foreign P
materials.
VC-111
20. Remove the PDM (Power Delivery Module) mounting bolts .
JPCIA0348ZZ
PDM (Power Delivery Module) right side PDM (Power Delivery Module) left side
Vehicle front
WARNING:
tem.
21. Insert guide pins [SST: KV99112300 (J-51050)] (C) and (D) into the PDM (Power Delivery Module) mount-
ing bolt holes shown in the figure.
JPCIA0356ZZ
PDM (Power Delivery Module) right side PDM (Power Delivery Module) left side
C Guide pin (106 mm) D Guide pin (96 mm)
Vehicle front
WARNING:
tem.
NOTE:
Install and remove the guide pins by hand.
VC-112
22. Install the engine slinger (service part) onto the PDM (Power Delivery Module).
NOTE: A
• Parts number
- Engine slinger (LH) : 10006 MA00B
- Engine slinger (RH) : 10006 AG01A B
- Engine slinger mounting bolt (RH) : 01125 N8031
- Engine slinger mounting bolt (LH) : 01125 N8061
VC
G
JPCIA0307ZZ
NOTE:
• Fasten the left engine slinger with a bolt at 1 location.
H
Vehicle front
• Tighten the engine slinger mounting bolts to the following torque.

I
Tightening torque value : 25 N·m (2.6 kg-m)

23. Install the slinger and shackle [SST: KV99112200 (J-51049)] J
onto the left and right engine slingers, then install the engine
crane.
NOTE:
K
Because of the engine hood rod, install the engine slinger from
the vehicle left side.
JSCIA1135ZZ M
24. Separate the PDM (Power Delivery Module) from the inverter.
• Because the bus bar gasket is difficult to remove, gently rock the PDM (Power Delivery Module) while
N
raising the engine crane.
• When lifting with the engine crane, the PDM (Power Delivery Module) tilts. Therefore hold the bus bar
side (vehicle left side) while raising the engine crane.
• When the PDM (Power Delivery Module) has been raised to at or above the height of the bus bar, move O
the engine crane, avoiding the bus bar, and pull to remove the locating pin.
CAUTION:
• Be careful that the engine crane does not contact the hood.
P
• When removing, be careful that the PDM (Power Delivery Module) does not contact the wind-
shield glass.
• When moving, be careful that the PDM (Power Delivery Module) does not contact the high-volt-
age bus bar.
VC-113
25. Prepare the work bench, and lower the PDM (Power Delivery
Module) onto blocks of wood or similar material.
JPCIA0334ZZ
CAUTION:
• Never place it in the opening area (shaded area )
located at the back of PDM (Power Delivery Module).
Place it on other area such as a place of wood.
• To prevent the intrusion of foreign matter such as dust
and dirt into PDM (Power Delivery Module), cover the
opening area (shaded area ) located at the back of
PDM (Power Delivery Module) with a tape.
: Back of PDM (Power Delivery Module)

: Front of PDM (Power Delivery Module)
JPCIA0469ZZ
26. Cover the high-voltage bus bar with shop paper .
: Vehicle front
CAUTION:
Be sure to protect the high-voltage bus bar with clean shop
paper so that dust, dirt, and other substances do not enter
the driver motor. If the high-voltage bus bar is touched or if
the high-voltage bus bar is dirty, clean it using ethanol.
JPCIA0333ZZ
INSTALLATION
Note the following items and install in the reverse order of removal.
WARNING:
Be sure to put on insulating protective gear before beginning work on the high voltage system.
CAUTION:
• Be sure to perform correct air bleeding after adding coolant. Refer to HCO-12, "Refilling".
• After all parts are installed, be sure to check equipotential. Refer to VC-119, "Inspection".
DISASSEMBLY
CAUTION:
• Always prepare a protective cover [servive parts number: 291X2 3NF0A] before checking/replacing
the following parts that the cover of PDM (Power Delivery Module) is required to be opened.
- PDM (Power Delivery Module)
- Quick charge port
VC-114
- Normal charge port
- Electric compressor harness A
- Li-ion battery high-voltage harness
1. In order to prevent dust or other substances on the PDM (Power Delivery Module) cover from entering into
the PDM (Power Delivery Module), wipe away any dirt from the PDM (Power Delivery Module) cover B
using dry shop cloth or similar material.
2. Remove the PDM (Power Delivery Module) cover mounting
bolts in the order from16 to 3 as shown in the figure.
VC
: Vehicle front
JPCIA0309ZZ
3. Use a flathead screwdriver, pawl, or similar tool to pry open a F

part of the PDM (Power Delivery Module) cover and cut away
the liquid gasket.
CAUTION: G
Wrap the flathead screwdriver with tape or shop cloth when
working to avoid scratching the mounting surface.
H
I
JPCIA0310ZZ
NOTE:
If the gasket is difficult to separate, use a remover (A) to create J
clearance while cutting away the liquid gasket.
M
JPCIA0311ZZ
4. Wear anti-static gloves and remove the PDM (Power Delivery

Module) cover by lifting first the rear then the front as shown in N
the figure.
CAUTION:
Anti-static gloves must be worn for all subsequent steps.
O
JPCIA0312ZZ
CAUTION:
VC-115
When lifting up the PDM (Power Delivery Module) cover, be
careful not to contact the circuit board .
JPCIA0313ZZ
5. Install a protective cover [service parts number : 291X2

3NF0A].
CAUTION:
• In order to prevent entry of dust or dirt into the circuit
board section, install the protective cover immediately
after removing the PDM (Power Delivery Module) cover.
JPCIA0314ZZ
6. Remove the mounting bolt and screw from each high-voltage terminal, then remove the high-voltage ter-
minals from the PDM (Power Delivery Module).
• Removing the quick charge port
JPCIA0352ZZ
VC-116
• Removing the Li-ion battery high-voltage harness
A
VC
E
JPCIA0353ZZ
• Removing the normal charge port

F
J
JPCIA0354ZZ
• Removing the electric compressor harness

K
O
JPCIA0355ZZ
ASSEMBLY
1. Install each of the high-voltage harnesses. P
2. Use an acrylic scraper [SST: KV10120900 (J-51053)] and remove the old liquid gasket from the mounting
surface.
WARNING:
Do not use a metal scraper as it may produce metal particles.
CAUTION:
• Work with the protective cover installed.
• Do not use an air blow.
VC-117
• Do not use part cleaner.
• Do not use gasket remover.
• Be careful that the removed liquid gasket does not enter into the circuit board.
3. Moisten shop paper with ethanol, and degrease the liquid gasket application surface.
CAUTION:
• Do not use part cleaner.
• Do not use gasket remover.
4. Apply liquid gasket (Three Bond 1217H or an equivalent) to
the position shown in the figure, checking that there are no gaps.
: PDM (Power Delivery Module) cover side

: PDM (Power Delivery Module) side
: Vehicle front
: Start and end point of liquid gasket application
C : φ3.4 - 5.1 mm (0.134 - 0.201 in )
D : 1.3 mm ( 0.051 in )
E : 10 - 15 mm ( 0.39 - 0.59 in )
F : 23.5 mm ( 0.925 in )
G : 38 - 43 mm ( 1.50 - 1.69 in )
JPCIA0315ZZ
5. Remove the protective cover.

CAUTION:
Remove the protective cover slowly in order to prevent any dust or other substances on the pro-
tective cover from entering the inside.
6. Lower the PDM (Power Delivery Module) cover vertically to install it.
CAUTION:
When lowering the PDM (Power Delivery Module) cover, be careful not to contact the circuit board
section.
7. Tighten the mounting bolts in the order from 1 to 16 as shown in
the figure.
: Vehicle front
NOTE:
In the figure, 9 and 16 indicate the second tightening of 1 and 2.
JPCIA0309ZZ
8. Follow the procedure below and install the air leak tester attachment [SST: KV99112400 (J-51051)].
NOTE:
The airtightness test is a check performed after PDM (Power Delivery Module) installation. However
because it is difficult to install the attachment when the PDM is installed in the vehicle, install only the
attachment before installing the PDM (Power Delivery Module) into the vehicle.
• Disconnect the breather.
VC-118
• Adjust the length (A) of the attachment part to match the pre-
scribed value. A
Standard : 20 mm ( 0.79 in )
CAUTION: B
Be sure to check because this is the reference for screw-
ing in the attachment.
VC
JPCIA0316ZZ
D
• Insert the attachment (A) at the location where the breather is
disconnected.
NOTE: E
Check that it is inserted securely all the way.
• Rotate the wing screw 5 times in the tightening direction
(clockwise).
NOTE: F
Although the screw can be rotated more than 5 in the tighten-
ing direction, it is not necessary to further tighten it when the
airtightness test is performed. G
JPCIA0317ZZ
H

I
Air Leak Inspection
CAUTION:
• Install the attachment before installing the PDM (Power Delivery Module).
J
• To prevent leakage of air, check that each harness is securely installed.
1. Install the air leak tester [SST: KV99111400 (J-50378)] onto the
attachment.
K
WARNING:
In order to prevent electric shock, be sure to wear

insulated protective gear. L
M
CAUTION:
The gauge is a precision instrument. Be careful not to drop
N
JSCIA1136ZZ
2. Follow the procedure below and perform the pressure inspection.

WARNING:
VC-119
a. Open the cock on the pressure inspection gauge.

CAUTION:
Do not operate the pump before opening the stopcock on
the pressure inspection gauge. Doing so may damage the
gauge. If the pump is operated before the stopcock is
opened, first disconnect the air pump hose to release the
pressure.
JSCIA0638ZZ
b. Operate the air pump slowly and apply the specified inspection pressure inside the PDM (Power Delivery
Module). If the gauge pressure does not rise, or if the gauge reading fluctuates, check for the location of
air leakage.
Prescribed inspection pressure : 20.0 kPa (0.204 kg/cm2)

CAUTION:
• Operate the air pump carefully when applying pressure. If pressure is applied suddenly to the
c. Close the cock and wait for 30 minutes.
d. Check that the pressure inspection gauge reading remains at or above the limit value.
Repair limit : 19.8 kPa (0.202 kg/cm2)

NOTE:
3. If it is confirmed that airtightness is maintained, remove the pressure inspection gauge and remove the
attachment from the PDM (Power Delivery Module).
4. Install the breather.
Electric Equipotential Test
• Check the resistance between the PDM (Power Delivery Module) (aluminum part) and the body (ground
bolt).
• Check the resistance between the PDM (Power Delivery Module) (aluminum part) and other high-voltage
part (housing or conducting part).
WARNING:
Standard : Less than 0.1Ω

substance.
VC-120
QUICK CHARGE PORT
QUICK CHARGE PORT
A
REMOVAL B
VC
JSCIA1118GB
J
Quick charge port Charge port bracket Normal charge port
Bracket Bracket
K
To PDM (Power Delivery Module)

L
, : Indicates that the part is connected at points with same symbol in actual vehicle.
DISASSEMBLY
M
JPCIA0319ZZ
VC-121
QUICK CHARGE PORT
Quick charge port Clip Spring (large)

Port cap Damper Pin
Lever Spring (small)
DANGER:
maintenance.
WARNING:
CAUTION:
REMOVAL
WARNING:
1. Check voltage in high voltage circuit. (Check that condenser are discharged.) Refer to GI-31, "Check Volt-
2. Remove the charge port upper cover and the charge port cover. Refer to DLK-189, "CHARGE PORT
COVER : Removal and Installation" (TYPE 1), DLK-424, "CHARGE PORT COVER : Removal and Instal-
lation" (TYPE 2) or DLK-642, "CHARGE PORT COVER : Removal and Installation" (TYPE 3).
3. Remove the quick charge port harness connector clamp from the bracket, then disconnect the quick
charge port harness connector .
JSCIA1119ZZ
WARNING:
tem.
VC-122
QUICK CHARGE PORT
4. Remove the mounting nuts and then remove the bracket of quick charge port harness. B
VC
F
JSCIA1120ZZ
WARNING:
G
tem.
H
5. Remove quick charge port mounting nuts . I

WARNING:
Be sure to put on insulating protective gear before J

JSCIA1121ZZ L
6. Pull out the quick charge port toward the rear of the vehicle.
WARNING: M
tem.
N
7. Remove and disassemble the PDM (Power Delivery Module) when replacing quick charge port. Refer to O
VC-108, "Removal and Installation".
INSTALLATION
To install, be careful to the following items and follow procedure in the reverse order of removal. P
WARNING:
CAUTION:
VC-123
QUICK CHARGE PORT
Be sure to reinstall high-voltage harness clips in their original positions. If a clip is damaged, replace it
with a new clip before installing.
DISASSEMBLY
Cover Side
1. Use a suitable tool (A) to remove the clip that is attached to
the pin.
JSCIA0213ZZ
2. Pull out pin of port cap.

CAUTION:
When pin is pulled out, the spring will also jump out. Take
care not to lose it.
JSCIA0214ZZ
3. Remove damper from port cap.
JSCIA0215ZZ
Lever Side
the pin.
JSCIA0216ZZ
VC-124
QUICK CHARGE PORT
2. Press while removing pin to ensure that spring does not
jump out, then remove lever. A
VC
JSCIA0217ZZ
D
ASSEMBLY
CAUTION: E
• Never reuse the clips.
• Pay attention to direction that cover side damper is facing.
• Pay attention to direction that spring is facing.
F
: Spring (small)
: Spring (large)
G
JSCIA0381ZZ
I
VC-125
NORMAL CHARGE PORT
NORMAL CHARGE PORT
REMOVAL
JSCIA1118GB
Quick charge port Charge port bracket Normal charge port

Bracket Bracket
To PDM (Power Delivery Module)
, : Indicates that the part is connected at points with same symbol in actual vehicle.
DISASSEMBLY
VC-126
NORMAL CHARGE PORT
VC
JPCIA0323ZZ F
Normal charge port Clip Lever

Spring (small) Pin Spring (large) G
Port cap Damper
H
DANGER: I
J
maintenance.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- K
the tool box during the procedure to prevent the plug from being connected by mistake. L
parts. To keep others from touching the high voltage parts, these parts must be covered with an insu- M
CAUTION: N
REMOVAL O
WARNING:
1. Check voltage in high voltage circuit. (Check that condenser are discharged.) Refer to GI-31, "Check Volt- P
2. Remove the charge port upper cover and the charge port cover. Refer to DLK-189, "CHARGE PORT
COVER : Removal and Installation" (TYPE 1), DLK-424, "CHARGE PORT COVER : Removal and Instal-
lation" (TYPE 2) or DLK-642, "CHARGE PORT COVER : Removal and Installation" (TYPE 3).
VC-127
NORMAL CHARGE PORT
3. Remove the normal charge port harness connector clamp from the bracket, then disconnect the nor-
mal charge port harness connector .
JSCIA1122ZZ
WARNING:
tem.
4. Remove the mounting nuts and then remove the bracket of normal charge port harness.
JSCIA1123ZZ
WARNING:
tem.
VC-128
NORMAL CHARGE PORT
5. Remove normal charge port mounting nuts .
WARNING: A

beginning work on the high voltage system. B
VC
JSCIA1124ZZ
D
6. Pull out the normal charge port toward the rear of the vehicle.
WARNING:
E
tem.
F
7. Remove and disassemble the PDM (Power Delivery Module) when replacing normal charge port . Refer
to VC-108, "Removal and Installation". G
INSTALLATION
H
WARNING:
I
CAUTION: J
Be sure to reinstall high-voltage harness clips in their original positions. If a clip is damaged, replace it
Disassembly and Assembly INFOID:0000000010415238 K
DISASSEMBLY
Cover Side L

the pin.
M
JSCIA0219ZZ
VC-129
NORMAL CHARGE PORT
2. Pull out pin of port cap.
CAUTION:
When pin is pulled out, the spring will also jump out. Take
care not to lose it.
JSCIA0220ZZ
3. Remove damper from port cap.
JSCIA0221ZZ
Lever Side
the pin.
JSCIA0222ZZ
2. Press while removing pin to ensure that spring does not

jump out, then remove lever.
JSCIA0223ZZ
ASSEMBLY
CAUTION:
• Never reuse the clips.
• Pay attention to direction that cover side damper is facing.
VC-130
NORMAL CHARGE PORT
A
: Spring (large)
: Spring (small)
B
VC
JSCIA0382ZZ
VC-131
REMOVAL
1. Remove switch panel from instrument lower panel assembly . Refer to IP-13, "Exploded View".
2. Remove immediate charging switch from switch panel as fol-
lows.
a. Disengage the pawls while pressing the behind of switch ( )
JSCIA1125ZZ
INSTALLATION
VC-132
A
REMOVAL B
1. Remove charging status indicator.
1. Apply protective tape (A) on the part to protect it from dam-
age. VC
JSCIA1126ZZ
F
2. Insert remover tool (A) between charging status indicator
and instrument panel assembly to disengage the pawl and
metal clips as shown in the figure. G
3. Pull toward the arrow direction ( ).
4. Disconnect harness connector.
H
: Pawl
: Metal clip
I
CAUTION:
Apply shop cloth or take similar steps at location of tool ful- JSCIA1127ZZ
crum, and take care that no scratches or dents are made.

J
INSTALLATION
Position clips, and then press each into the instrument panel to fasten clips in place.
K
VC-133
NORMAL CHARGE PORT
: Spring (large)
: Spring (small)
JSCIA0382ZZ
VC-134
A
REMOVAL B
1. Remove switch panel from instrument lower panel assembly . Refer to IP-13, "Exploded View".
2. Remove immediate charging switch from switch panel as fol-
lows. VC
a. Disengage the pawls while pressing the behind of switch ( )
D
JSCIA1125ZZ
F
INSTALLATION
G
VC-135
REMOVAL
1. Remove charging status indicator.
1. Apply protective tape (A) on the part to protect it from dam-
age.
JSCIA1126ZZ
2. Insert remover tool (A) between charging status indicator

and instrument panel assembly to disengage the pawl and
metal clips as shown in the figure.
3. Pull toward the arrow direction ( ).
4. Disconnect harness connector.
: Pawl
: Metal clip
CAUTION:
Apply shop cloth or take similar steps at location of tool ful- JSCIA1127ZZ
crum, and take care that no scratches or dents are made.

INSTALLATION
Position clips, and then press each into the instrument panel to fasten clips in place.
VC-136
ACCELERATOR CONTROL SYSTEM

SECTION ACC B
ACC
E
CONTENTS
PRECAUTION ............................................... 2 Precautions for Removing Battery Terminal ............. 3 F
PRECAUTIONS ................................................... 2 REMOVAL AND INSTALLATION ................ 5

Point to Be Checked Before Starting Maintenance ACCELERATOR CONTROL SYSTEM .............. 5
Work .......................................................................... 2 Exploded View .......................................................... 5
Precaution for Supplemental Restraint System Removal and Installation .......................................... 5
Inspection ................................................................. 6 H
SIONER" ................................................................... 2
ACC-1
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
NOTE:
ACC-2
PRECAUTIONS
< PRECAUTION >
“SEAT BELT” of this Service Manual. A
WARNING:
Always observe the following items for preventing accidental activation. B
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal ACC
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser- D
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS E
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the F
injury.
• When using air or electric power tools or hammers, always switch the power switch OFF, disconnect G
H
NOTE: I
then a DTC detection error or ECU data corruption may occur. J
start after a lapse of 60 minutes from power switch OFF. K
SEF289H
WORK PROCEDURE L
NOTE:
If EVSE is connected, the air conditioning system may be automatically activated by the timer A/C func- M
tion.
3. Check that the charge status indicator lamp does not blink and wait for 5 minutes or more. N
NOTE:
detected.
O
CAUTION:
battery terminals are disconnected, start over from Step 1. P
NOTE:
the power switch.
ACC-3
PRECAUTIONS
< PRECAUTION >
NOTE:
NOTE:
ACC-4
B
LHD
ACC
JSCIA1058GB
H
Accelerator pedal assembly Accelerator pedal stopper
Locating pin
I
RHD
J
JSCIA1059GB
O
Accelerator pedal assembly Accelerator pedal stopper

Locating pin P
REMOVAL
1. Disconnect accelerator pedal position sensor harness connector.
ACC-5
2. Loosen mounting bolts, and remove accelerator pedal assembly.
CAUTION:
• Never disassemble accelerator pedal assembly. Never remove accelerator pedal position sensor
from accelerator pedal assembly.
• Avoid impact from dropping etc. during handling.
• Be careful to keep accelerator pedal assembly away from water.
INSTALLATION
• Insert locating pin into vehicle side to position accelerator pedal
assembly. Tighten mounting bolts to accelerator pedal assembly.
CAUTION:
When harness connector of accelerator pedal position sensor
is disconnected, perform “ACCELERATOR PEDAL RELEASED
POSITION LEARNING”. Refer to EVC-122, "Work Procedure".
JSCIA1069ZZ

• Check accelerator pedal moves smoothly within the whole operation range when it is fully depressed and
released.
• Check accelerator pedal securely returns to the fully released position.
• For the electrical inspection of accelerator pedal position sensor. Refer to EVC-217, "Component Inspection
(Accelerator Pedal Position Sensor)".
ACC-6
TRANSMISSION & DRIVELINE
TRANSAXLE & TRANSMISSION

SECTION TM B
TM
E
CONTENTS
REDUCTION GEAR: RN1F61B PARKING CABLE ............................................. 20 F
Exploded View .........................................................20
PRECAUTION ............................................... 3 Removal and Installation .........................................20
Adjustment ...............................................................22 G
PRECAUTIONS ................................................... 3
Precaution for Technicians Using Medical Electric...... 3 UNIT REMOVAL AND INSTALLATION ...... 23
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- REDUCTION GEAR .......................................... 23 H
SIONER" ................................................................... 3 Exploded View .........................................................23
Precaution Necessary for Steering Wheel Rota- Removal and Installation .........................................24
tion after 12V Battery Disconnect .............................. 4 Inspection and Adjustment ......................................27 I
Precaution for Procedure without Cowl Top Cover...... 4
High Voltage Precautions .......................................... 4 SERVICE DATA AND SPECIFICATIONS
Precautions for Removing Battery Terminal ............. 7 (SDS) ............................................................ 28 J
PREPARATION ............................................ 8 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 28
PREPARATION ................................................... 8 General Specifications .............................................28 K
Commercial Service Tools ........................................ 8 Earth Brush ..............................................................28
SHIFT SELECTOR
SYSTEM DESCRIPTION .............................. 9
L
STRUCTURE AND OPERATION ........................ 9 PRECAUTION .............................................. 29
Sectional View ........................................................... 9 PRECAUTIONS ................................................. 29
Power Transfer Diagram ......................................... 10 Precaution for Technicians Using Medical Electric....29 M
Operating Principle .................................................. 10 Precaution for Supplemental Restraint System
PERIODIC MAINTENANCE ......................... 12
SIONER" .................................................................29 N
REDUCTION GEAR OIL ....................................12 Precaution Necessary for Steering Wheel Rota-
Inspection ................................................................ 12 tion after 12V Battery Disconnect ............................30
Draining and Refilling .............................................. 12 High Voltage Precautions ........................................30
O
Precautions for Removing Battery Terminal ............33
REMOVAL AND INSTALLATION ............... 13
SYSTEM DESCRIPTION ............................. 34
EARTH BRUSH ..................................................13 P
Exploded View ........................................................ 13 COMPONENT PARTS ...................................... 34
Removal and Installation ......................................... 13 SHIFT LOCK SYSTEM ..............................................34
Inspection ................................................................ 15 SHIFT LOCK SYSTEM : Component Parts Loca-
BREATHER HOSE .............................................16 tion ...........................................................................34
Exploded View ........................................................ 16 SHIFT LOCK SYSTEM : Shift Lock Solenoid ..........36
Removal and Installation ......................................... 16 SHIFT LOCK SYSTEM : Stop Lamp Switch ............36
TM-1
SHIFT LOCK SYSTEM : M/C Relay ....................... 36 WIRING DIAGRAM .................................... 42
STRUCTURE AND OPERATION ...................... 37 SHIFT LOCK SYSTEM ...................................... 42
Wiring Diagram ....................................................... 42
SHIFT LOCK SYSTEM ............................................. 37
SHIFT LOCK SYSTEM : System Description ......... 37 BASIC INSPECTION .................................. 47
SYSTEM ............................................................. 39 SHIFT POSITION ............................................... 47
SHIFT LOCK SYSTEM ............................................. 39 Inspection ................................................................ 47
SHIFT LOCK SYSTEM : Circuit Diagram ............... 39
DTC/CIRCUIT DIAGNOSIS ........................ 48
METER) ..................................................................... 39
SHIFT LOCK SYSTEM ...................................... 48
Component Function Check ................................... 48
METER) : Shift Position Indicator ........................... 39
Component Inspection (Shift Lock Solenoid) .......... 50
WARNING/INDICATOR/CHIME LIST ....................... 40
WARNING/INDICATOR/CHIME LIST : Warning/ REMOVAL AND INSTALLATION .............. 52
Indicator (On Information Display) .......................... 40
SHIFT SELECTOR ............................................ 52
ECU DIAGNOSIS INFORMATION .............. 41 Exploded View ........................................................ 52
Removal and Installation ......................................... 52
VCM ................................................................... 41 Disassembly and Assembly .................................... 53
List of ECU Reference ............................................ 41 Inspection ................................................................ 55
TM-2
PRECAUTIONS
< PRECAUTION > [REDUCTION GEAR: RN1F61B]
PRECAUTION A
PRECAUTIONS
B
WARNING: C
TM
WARNING:
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an E
F
G
WARNING:
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), H
the implantable cardioverter defibrillator (ICD), when using the service, etc. I
device. The possible effects on the devices must be checked with the device manufacturer before J
TCU use.
WARNING: K
rior/exterior antenna. L
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant- M
facturer before Intelligent Key use. N
O
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and P
WARNING:
TM-3
PRECAUTIONS
connectors.
WARNING:
injury.
INFOID:0000000010784668
OPERATION PROCEDURE
NOTE:
NOTE:
tion.
windshield.
PIIB3706J
DANGER:
TM-4
PRECAUTIONS
maintenance.
B
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in C
• Never allow workers other than the responsible person to touch the vehicle containing high voltage TM
CAUTION:
• Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace E
high voltage harness connector, immediately dry the high voltage connector completely with an air F
blow gun.
G
nected to charge port before starting maintenance work. H
NOTE:
I
J
REGULATIONS ON WORKERS WITH MEDICAL ELECTRONICS K
WARNING:
maker or other medical device is close to these parts, the medical device may be affected by the mag- L
Hybrid vehicles and electric vehicles contain parts with high voltage and intense magnetic force. Never carry M
media may lose their magnetic recording. N
O
TM-5
PRECAUTIONS
workers.
JSAIA1600GB
TM-6
PRECAUTIONS
A
NOTE: B
• Always disconnect the battery terminal within 60 minutes after C
start after a lapse of 60 minutes from power switch OFF. TM
SEF289H
WORK PROCEDURE
E
NOTE:
tion. F
NOTE: G
detected.
4. Remove 12V battery terminal within 60 minutes after turning the power switch OFF → ON → OFF. H
CAUTION:
battery terminals are disconnected, start over from Step 1. I
NOTE:
Once the power switch is turned ON → OFF, the 12V battery automatic charge control does not start for J
the power switch. K
NOTE:
L
NOTE:
M
TM-7
PREPARATION
< PREPARATION > [REDUCTION GEAR: RN1F61B]
PREPARATION
PREPARATION

ponents
Insulated gloves • Use protective gloves made of insulating
material.
• The protective gloves must be capable of
JMCIA0149ZZ

components
tight]
JPCIA0066ZZ

ponents
material.
JPCIA0011ZZ

components
JPCIA0167ZZ

Insulated helmet
ponents
JPCIA0013ZZ
Insulation resistance tester Measuring insulation resistance, voltage,

(Multi tester) and resistance
JPCIA0014ZZ
TM-8
< SYSTEM DESCRIPTION > [REDUCTION GEAR: RN1F61B]
Sectional View INFOID:0000000010410441
B
TM
N
JSDIA3977ZZ
Input gear Brush cover Earth brush

O
O-ring Final gear Main shaft
TM-9
Power Transfer Diagram INFOID:0000000010410442
JSDIA6163ZZ
From traction motor To drive shaft

: Vehicle front
: Power flow
Operating Principle INFOID:0000000010926668
PARKING MECHANISM
• The parking mechanism consists of a manual lever, manual shaft, manual plate, detent spring, parking rod,
parking pawl, and parking gear.
• The manual lever is connected to the shift selector via parking cable.
TM-10
• When the shift selector is set in “P” position, the manual lever, manual shaft, and manual plate turn through
the parking cable, allowing the parking rod to slide. The sliding parking rod pushes up the parking pawl, A
which engages with the parking gear locking the parking mechanism.
TM
JSDIA6164GB
TM-11
REDUCTION GEAR OIL
< PERIODIC MAINTENANCE > [REDUCTION GEAR: RN1F61B]
REDUCTION GEAR OIL
OIL LEAKAGE
Check reduction gear surrounding area (oil seal, drain plug, and filler plug etc.) for oil leakage.
OIL LEVEL
• Remove filler plug and gasket. Then check that oil is filled up
from mounting hole for the filler plug.
CAUTION:
Turn the power switch OFF while checking oil level.
• Set a gasket on filler plug and install it on reduction gear and
tighten to the specified torque. Refer to TM-23, "Exploded View".
CAUTION:
• Never reuse gasket.
• If foreign matter, such as gear abrasion powder, is on the
magnet of the filler plug, wipe it free of adherents before
installation. JSDIA3975ZZ
Draining and Refilling INFOID:0000000010410444
DRAINING
1. Turn the power switch OFF.
2. Remove filler plug.
3. Remove drain plug and drain gear oil.
4. Set a gasket on drain plug and install it to reduction gear and
tighten to the specified torque. Refer to TM-23, "Exploded View".
CAUTION:
• If foreign matter, such as gear abrasion powder, is on the
magnet of the drain plug, wipe it free of adherents before
installation.
JSDIA3976ZZ
REFILLING
1. Remove filler plug . Fill with new gear oil until oil level reaches
the specified level near filler plug mounting hole.
Oil grade and oil capacity : Refer to MA-11, "Fluids

and Lubricants".
2. After refilling oil, check oil level. Set a gasket on filler plug, then
install it to reduction gear. Refer to TM-23, "Exploded View".
CAUTION:
• If foreign matter, such as gear abrasion powder, is on the JSDIA3975ZZ
magnet of the filler plug, wipe it free of adherents before
installation.
TM-12
EARTH BRUSH
< REMOVAL AND INSTALLATION > [REDUCTION GEAR: RN1F61B]

EARTH BRUSH
B
TM
JSDIA6098GB J
Reduction gear Earth brush O-ring

Brush cover K
: Vehicle front

L

M
REMOVAL N
2. Disconnect breather hose from brush cover , then remove
the brush cover bolts and remove brush cover. O
JSDIA2106ZZ
TM-13
EARTH BRUSH
3. Remove O-ring . Remove brush fixing bolts , then remove
earth brush.
CAUTION:
• Carefully remove earth brush, because the spring in the
earth brush pushes out the brush.
• Never touch brush area.
JSDIA3956ZZ
INSTALLATION
CAUTION:
• Degrease shaft surface (brush contact surface) , and verify
that there is no dust or other substance on it, then install the
earth brush.
• Degrease brush surface, and verify that there is no dust or
other substance on it, then install the earth brush.
• Never reuse O-ring.
• Never apply oil to O-ring. Verify that there is no oil on it, then
install O-ring.
• Never touch brush area.
JSDIA3957ZZ
• When assembling earth brush, do not touch brush area , press earth brush onto shaft and fasten with
brush fixing bolt.
JSDIA3958ZZ
CAUTION:
Never touch brush area .
JSDIA2925ZZ
When Replacing With New Part

NOTE:
A new earth brush includes a stopper for preventing brush pop-out. Install with stopper attached.
TM-14
EARTH BRUSH
When installing a new earth brush, pull out stopper after installa-
tion, allowing brush to contact shaft. A
CAUTION:
Before installation, degrease the stopper surface (shaft side)
and check that the surface is free of foreign matter.
B
JSDIA2931ZZ
TM
INSPECTION OF REDUCTION GEAR MAIN SHAFT E

Check that there is no substance such as oil and dust on main shaft
surface , and that no corrosion has occurred.
CAUTION:
• When substances such as oil and dust are adherent to the F
shaft surface (brush contact surface), remove them and
degrease the shaft surface to install brush.
• When there is corrosion on shaft surface, remove corrosion G
to install brush.
H
JSDIA3957ZZ
INSPECTION FOR BRUSH WEAR

Remove earth brush and measure amount of protrusion (A). If it is at I
or below limit value, replace earth brush.
Brush wear limit : TM-28, "Earth Brush" J

CAUTION:
When reusing with original parts, never allow oil to contact
brush area. Refer to TM-13, "Removal and Installation". K
JSDIA2926ZZ L
TM-15
BREATHER HOSE
BREATHER HOSE
JSDIA6099ZZ
Traction motor inverter Harness bracket Reduction gear

Harness bracket Clip Breather hose
Breather
: Vehicle front
DANGER:
maintenance.
WARNING:
• Refer to TM-4, "High Voltage Precautions".
CAUTION:
TM-16
BREATHER HOSE
instructed in the Service Manual. A malfunction may occur if this is not observed. A
REMOVAL
WARNING:
Follow the instructions below before starting the procedure. B
1. Remove front under cover. Refer to EXT-27, "FRONT UNDER COVER : Removal and Installation". C
2. Remove clip of normal charge port from harness bracket.
: Vehicle front TM
WARNING:
Be sure to put on insulating protective gear before E

F
JSDIA4052ZZ
3. Remove the clip and then remove the acoustic insulating plate . G
J
JSCIA1265ZZ
: Vehicle front
K
WARNING:
Be sure to put on insulating protective gear before beginning work on the high voltage sys- L
tem.
4. Remove harness bracket mounting bolt .

N
: Vehicle front
WARNING:
O
P
JSDIA4054ZZ
TM-17
BREATHER HOSE
5. Remove clip of normal charge port from harness bracket.
: Vehicle front
WARNING:

JSDIA6643ZZ
6. Remove breather from harness bracket .
JSDIA4055ZZ
7. Remove clip of breather hose from harness bracket and pull

out breather hose from brush cover tube of reduction gear.
JSDIA4056ZZ
INSTALLATION
WARNING:
CAUTION:
• Never reuse resin clip (hose clip).
• Be careful not to be crushed or blocked by folding or bending the hose when installing the breather
hose.
• Ensure the breather is securely installed to the bracket.
• Ensure the clips are securely installed to the brackets.
• Install breather hose so that the paint mark is facing left-
ward.
: Vehicle left
JSDIA3970ZZ
TM-18
BREATHER HOSE
• As shown in figure, fit breather hose onto brush cover tube A

part all the way to its base (A).
JSDIA2129ZZ
TM
TM-19
PARKING CABLE
PARKING CABLE
JSDIA6108GB
Shift selector assembly Parking cable Reduction gear

Manual lever Bracket Lock plate
Bracket Grommet
: Vehicle front
REMOVAL
1. Remove instrument lower panel assembly and instrument stay cover. Refer to IP-16, "Removal and Instal-
lation".
TM-20
PARKING CABLE
2. Remove the tip of parking cable from shift selector assembly.
A
: Vehicle front
JSDIA6111ZZ
TM
3. Lift up the pawl and remove socket from shift selector
assembly.
E
: Vehicle front
CAUTION:
Never damage the pawl.
F
G
JSDIA6116ZZ
4. Disengage the pawls ( ) of the grommet and push grommet

downward. H
JSDIA6117ZZ
K
5. Remove parking cable mounting nut ( ) and remove parking
cable from manual lever .
L
: Vehicle front
N
JSDIA6118ZZ
6. Remove lock plate . O

7. Remove floor under cover. Refer to EXT-29, "FLOOR UNDER
COVER : Removal and Installation".
P
JSDIA1812ZZ
TM-21
PARKING CABLE
8. Remove parking cable from bracket .
: Vehicle front
9. Remove parking cable from the vehicle.
JSDIA6119ZZ
INSTALLATION
Note the following and install in the reverse order of removal.
• When installing control cable to shift selector assembly, check that
parking cable is fully pressed in with the rib surface facing rear-
ward.
: Vehicle front
JSDIA6120ZZ
• Check that the pulling on the socket does not disconnect it.
: Vehicle front
: Pawl
• Perform adjustment of parking cable after installation. Refer to TM-

22, "Adjustment".
JSDIA6116ZZ
Adjustment INFOID:0000000010778215
ADJUSTMENT OF PARKING CABLE

1. Shift the selector lever to “P” position.
2. Loosen parking cable mounting nut ( ) and set manual lever
to “P” position.
: Parking cable
: Vehicle front
3. Rotate the wheels at least a quarter turn and be certain the park
position mechanism is fully engaged.
4. Tighten parking cable mounting nut to the specified torque.
CAUTION:
In tightening, fix the manual lever. JSDIA6118ZZ
TM-22
REDUCTION GEAR
< UNIT REMOVAL AND INSTALLATION > [REDUCTION GEAR: RN1F61B]

REDUCTION GEAR
B
TM
JSDIA6520GB K
High voltage warning label 3-phase bus bar cover Gasket

Seal Traction motor Motor mounting RH bracket L
Motor mounting RH O-ring Water inlet
Water outlet Drain plug Copper washer
M
Gasket Drain plug Motor mounting LH
Motor mounting LH bracket Clip Breather hose
Breather box Filler plug Reduction gear N
O-ring Motor mounting rear bracket Motor mounting rear
Bracket*
O
A. Shaft spline B. Inside of input shaft (inside of spline)
: N·m (kg-m, ft-lb) P

*: Without air conditioning system
TM-23
REDUCTION GEAR
DANGER:
maintenance.
WARNING:
• Refer to TM-4, "High Voltage Precautions".
CAUTION:
REMOVAL
WARNING:
2. Remove drain bolt of traction motor to drain coolant.
WARNING:
age system.
3. Drain reduction gear oil. Refer to TM-12, "Draining and Refill-

ing".
JSCIA0684ZZ
4. Remove electric power train and reduction gear from vehicle
together as suspension member assembly. Refer to FSU-22, "Removal and Installation".
6. Remove traction motor inverter. Refer to TMS-106, "Removal and Installation".
7. Remove joint bolt ( ) of motor mounting rear bracket and motor
mounting rear.
WARNING:
age system.
JSDIA3959ZZ
TM-24
REDUCTION GEAR
8. Remove joint bolt ( ) of motor mounting LH bracket and motor
mounting LH. A
WARNING:
ing protective gear before beginning work on the high volt- B
age system.
JSDIA3960ZZ
TM
9. Remove joint bolt ( ) of motor mounting RH bracket and motor
mounting RH.
WARNING: E
age system.
F
10. Hook the sling belt to each motor mounting bracket and prepare G
to disconnect the traction motor and reduction gear from the JSDIA3961ZZ
front suspension member assembly.

11. Hoist the traction motor and reduction gear and disconnect them from the front suspension member H
assembly.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning I
J
CAUTION:
When hoisting the traction motor and reduction gear, insert a long bolt into the motor mounting
bracket to prevent the sling belt from slipping out. At that time, be sure to install a nut. K
12. Remove support bearing bracket of drive shaft (right side). Refer to FAX-22, "Removal and Installation".
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning L
13. Remove motor mounting LH bracket .

WARNING: N
age system.
O
P
: Bolt
JSDIA6149ZZ
TM-25
REDUCTION GEAR
14. Remove motor mounting rear bracket .
WARNING:
age system.
: Bolt
JSDIA3964ZZ
15. Remove motor mounting RH bracket .

WARNING:
age system.
: Bolt
JSCIA0685ZZ
16. Remove joint bolts ( ) traction motor and reduction gear.

WARNING:
age system.
17. Separate traction motor from reduction gear.

WARNING:
age system.
JSDIA6369ZZ
INSTALLATION
WARNING:
CAUTION:
When assembling the reduction gear and traction motor, clean the mating surface and be sure that no
dust, dirt, or foreign material is between the surfaces.
TM-26
REDUCTION GEAR
• Before installing reduction gear and traction motor, apply grease to full periphery of shaft spline , and also
inject grease [minimum 10 g (0.4 oz), maximum less than 20 g (0.7 oz)] into reduction gear input shaft A
(inside spline) . Take care to prevent damage to O-ring when installing.
TM
JSDIA2307ZZ F
CAUTION:
• Before applying grease, clean old grease and wear particles, that are adhered to the grease apply-
ing parts.
• When installing O-ring, clean the O-ring installation groove completely, and then install. G
• When all parts are installed, be sure to check equipotential of traction motor, PDM (Power Delivery Module),
and traction motor inverter.
- Traction motor: Refer to TM-27, "Inspection and Adjustment". H
- PDM (Power Delivery Module): Refer to VC-119, "Inspection".
- Traction motor inverter: Refer to TMS-110, "Inspection and Adjustment".
Inspection and Adjustment INFOID:0000000010410452 I

After installing traction motor, measure resistance below. J
• Between traction motor (aluminum part) and body (ground bolt).
• Between traction motor (aluminum part) and other high voltage system.
WARNING: K
L
Standard : Less than 0.1 Ω M

substance. N

O
traction motor is replaced. Refer to TMS-42, "Work Procedure".
TM-27
< SERVICE DATA AND SPECIFICATIONS (SDS) [REDUCTION GEAR: RN1F61B]

General Specifications INFOID:0000000010410453
Reduction gear model RN1F61B

Gear ratio 9.301
Input gear 17
Number of teeth Main gear (IN / OUT) 42 / 17
Final gear 64
Oil capacity Refer to MA-11, "Fluids and Lubricants".
Earth Brush INFOID:0000000010410454
Unit: mm (in)
Item Limit
Brush wear amount 4.0 (0.157)
TM-28
PRECAUTIONS
< PRECAUTION > [SHIFT SELECTOR]
PRECAUTION A
PRECAUTIONS
B
WARNING: C
TM
WARNING:
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an E
F
G
WARNING:
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), H
the implantable cardioverter defibrillator (ICD), when using the service, etc. I
device. The possible effects on the devices must be checked with the device manufacturer before J
TCU use.
WARNING: K
rior/exterior antenna. L
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant- M
facturer before Intelligent Key use. N
O
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and P
WARNING:
TM-29
PRECAUTIONS
connectors.
WARNING:
injury.
INFOID:0000000010922318
OPERATION PROCEDURE
NOTE:
NOTE:
tion.
DANGER:
maintenance.
WARNING:
CAUTION:
TM-30
PRECAUTIONS
it with a new clip before installing. A
blow gun.
B
POINT TO BE CHECKED BEFORE STARTING MAINTENANCE WORK C
NOTE:
If the timer air conditioner or timer charge is set when the EVSE is connected, the high voltage system starts TM
E
HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS F
WARNING: G
nets. Such persons must not perform work on the vehicle. H
metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage I
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT” J
TM-31
PRECAUTIONS
workers.
JSAIA1600GB
TM-32
PRECAUTIONS
A
NOTE: B
• Always disconnect the battery terminal within 60 minutes after C
start after a lapse of 60 minutes from power switch OFF. TM
SEF289H
WORK PROCEDURE
E
NOTE:
tion. F
NOTE: G
detected.
4. Remove 12V battery terminal within 60 minutes after turning the power switch OFF → ON → OFF. H
CAUTION:
battery terminals are disconnected, start over from Step 1. I
NOTE:
Once the power switch is turned ON → OFF, the 12V battery automatic charge control does not start for J
the power switch. K
NOTE:
L
NOTE:
M
TM-33
COMPONENT PARTS
< SYSTEM DESCRIPTION > [SHIFT SELECTOR]
SYSTEM DESCRIPTION
COMPONENT PARTS
SHIFT LOCK SYSTEM
SHIFT LOCK SYSTEM : Component Parts Location INFOID:0000000010926692
LHD MODELS
JSDIA6343ZZ
Brake pedal Shift selector Motor room, LH
TM-34
COMPONENT PARTS
No. Component Function A

• It controls ON/OFF of the M/C relay.
• It controls GND of shift lock solenoid circuit.
VCM
Refer to EVC-15, "Component Parts Location" for detailed installation loca-
B
tion.
It transmits quick charger connecting signal and EVSE connecting signal to
VCM via CAN communication.
PDM C
Refer to VC-11, "Component Parts Location" for detailed installation loca-
tion.
Stop lamp switch TM-36, "SHIFT LOCK SYSTEM : Stop Lamp Switch"
TM
Shift lock solenoid TM-36, "SHIFT LOCK SYSTEM : Shift Lock Solenoid"
M/C relay TM-36, "SHIFT LOCK SYSTEM : M/C Relay"

E
RHD MODELS
JSDIA6629ZZ
Shift selector Brake pedal Motor room, LH
TM-35
COMPONENT PARTS

• It controls ON/OFF of the M/C relay.
• It controls GND of shift lock solenoid circuit.
VCM
Refer to EVC-15, "Component Parts Location" for detailed installation loca-
tion.
It transmits quick charger connecting signal and EVSE connecting signal to
VCM via CAN communication.
PDM
Refer to VC-11, "Component Parts Location" for detailed installation loca-
tion.
Shift lock solenoid TM-36, "SHIFT LOCK SYSTEM : Shift Lock Solenoid"
Stop lamp switch TM-36, "SHIFT LOCK SYSTEM : Stop Lamp Switch"
M/C relay TM-36, "SHIFT LOCK SYSTEM : M/C Relay"
SHIFT LOCK SYSTEM : Shift Lock Solenoid INFOID:0000000010926694
When the shift lock solenoid is ON, it moves the lock lever of shift
selector. For shift lock operation, refer to TM-37, "SHIFT LOCK SYS-
TEM : System Description".
The shift lock solenoid is controlled by VCM.
JSDIA6368ZZ
SHIFT LOCK SYSTEM : Stop Lamp Switch INFOID:0000000010926693
The stop lamp switch is installed to the brake pedal bracket. The
switch detects the state of the brake pedal and transmits an ON/OFF
signal to VCM.
The contact of the stop lamp switch is usually open. When the brake
pedal is depressed, it closes and the stop lamp switch signal is
transmitted to VCM as a voltage signal.
JSFIA1143ZZ
SHIFT LOCK SYSTEM : M/C Relay INFOID:0000000010926695
• The M/C relay is controlled by the VCM.

• When the M/C relay turns ON, 12 V battery power is supplied to the shift lock solenoid circuit.
TM-36
A
SHIFT LOCK SYSTEM
SHIFT LOCK SYSTEM : System Description INFOID:0000000010779461
B
• The shift lock system prevents the select lever from being moved from “P” position to other positions due to
a driver's improper operation and prevents the occurrence of an abrupt start.
• Shift lock can be released when the following conditions are satisfied. C
- Power switch is ON.
- Brake pedal is depressed. (Stop lamp switch is ON)
- Quick charge connector is not connected.
- Normal charge connector is not connected. TM
SHIFT LOCK OPERATION AT P POSITION

When brake pedal is not depressed (no selector operation allowed) E
When the brake pedal is not depressed with the ignition switch ON,
the shift lock solenoid is OFF (not energized) and the solenoid rod
is extended with spring. F
The connecting lock lever is located at the position shown in the
figure when the solenoid rod is extended. It prevents the movement
of the detent rod . The selector lever cannot be shifted from the “P”
G
position for this reason.
H
JSDIA6121ZZ
When brake pedal is depressed (selector lever operation allowed)

The shift lock solenoid is turned ON (energized) when the brake I
pedal is depressed with the ignition switch ON. The solenoid rod
is compressed with the electromagnetic force. The connecting lock
lever rotates when the solenoid rod is compressed. Therefore, the J
detent rod can be moved. The selector lever can be shifted to
other positions for this reason.
K
JSDIA6122ZZ
L
FORCIBLE RELEASE OF SHIFT LOCK

• When battery voltage decreases or an electrical/mechanical mal-
M
function occurs in the shift lock system, the selector lever cannot
be operated in “P” position. When shift lock release button and
shift lock release rod are pressed in this state, lock lever is
forcibly rotated, and then it becomes possible to release shift lock. N
JSDIA6123ZZ
P
• To release the shift lock forcibly and shift the selector lever from “P” position to other positions, follow the
steps below.
1. Turn ignition switch OFF.
2. Apply parking brake.
TM-37
3. Remove shift lock cover .
CAUTION:
• Never damage shift lock cover.
• Never damage finisher.
JSDIA6140ZZ
4. Insert key or suitable tool to finisher opening.

5. Press and hold the selector lever knob button and move the
selector lever from “P” position to other positions while press the
shift lock release button.
JSDIA6141ZZ
TM-38
SYSTEM
SYSTEM
A
SHIFT LOCK SYSTEM
SHIFT LOCK SYSTEM : Circuit Diagram INFOID:0000000011098838
B
TM
O
JSDIA6627GB
INFORMATION DISPLAY (COMBINATION METER) P
INFORMATION DISPLAY (COMBINATION METER) : Shift Position Indicator

INFOID:0000000010990681
PURPOSE
The shift position indicator displays the shift position of the vehicle.
TM-39
SYSTEM
SYSTEM DIAGRAM
JSDIA6379GB
SIGNAL PATH
• The VCM judges the shift position by the shift position signals and park position switch signal.
• The VCM transmits the shift position signal to the combination meter via CAN communication. The combina-
tion meter shows the shift position indicator on the information display, according to the signal.
LIGHTING CONDITION
Power switch: ON
BLINKING CONDITION
• When shift lever is shifted to “R” position while driving forward at 11 km/h (7 MPH) or more.
• When shift lever is shifted to “D” position or “B” position while driving backward at 11 km/h (7 MPH) or more.
SHUTOFF CONDITION
When any of the conditions listed below is satisfied.
• Power switch: Other than ON
• Shift warning message is displayed. Refer to EVC-60, "INFORMATION DISPLAY (COMBINATION METER)
: Shift Warning Message".
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)
INFOID:0000000010990683
Item Reference
Refer to TM-39, "INFORMATION DISPLAY (COMBINATION METER) : Shift Position
Shift position indicator
Indicator".
TM-40
VCM
< ECU DIAGNOSIS INFORMATION > [SHIFT SELECTOR]

VCM
List of ECU Reference INFOID:0000000011199156
B
ECU Reference
C
EVC-81, "Reference Value"
EVC-93, "Fail-Safe"
VCM
EVC-95, "DTC Inspection Priority Chart" TM
EVC-98, "DTC Index"
TM-41
SHIFT LOCK SYSTEM
< WIRING DIAGRAM > [SHIFT SELECTOR]
WIRING DIAGRAM
SHIFT LOCK SYSTEM
JRDWC3171GB
TM-42
SHIFT LOCK SYSTEM
TM
JRDWC3172GB
TM-43
SHIFT LOCK SYSTEM
JRDWC3173GB
TM-44
SHIFT LOCK SYSTEM
TM
JRDWC3174GB
TM-45
SHIFT LOCK SYSTEM
JRDWC3175GB
TM-46
SHIFT POSITION
< BASIC INSPECTION > [SHIFT SELECTOR]
BASIC INSPECTION A
SHIFT POSITION
B
1. Disconnect normal charge connector and quick charge connector.

2. Power switch is ON. C
3. Press the shift selector button with the brake pedal depressed, and confirm that the selector lever can be
moved to positions other than “P”. Also confirm that movement is not allowed from the “P” position to other
position without depressing the brake pedal. TM
4. Move the selector lever and check for “excessive effort”, “sticking”, “noise” or “rattle”.
5. Make sure that the selector lever is moved to all the shift posi-
tions in the manner shown. E
: Press selector button to operate selector lever while depressing

the brake pedal.
F
: Press selector button to operate selector lever.
: Selector lever can be operated without pressing selector button.
6. When the shift selector button is pressed without applying for- G

ward/backward force to the selector lever at “P” or “N” positions,
there should be no “sticking” on the shift selector button opera- JSDIA6193ZZ
tion. H
7. The relationship between selector lever, engine starting ability, driving force, and shift position indicator
lighting should satisfy the conditions of the following table.
I
Selector lever EV system starting Shift position indicator (on combina-
Driving force for reverse Driving force for forward
position property tion meter) lighting
P Get started — — P indicator shall be illuminated J
R — Generated — R indicator shall be illuminated
N Get started — — N indicator shall be illuminated
D/B — — Generated D or B indicator shall be illuminated K
8. Confirm that the back-up lamps illuminate only when lever is placed in the “R” position.
9. Check that the reduction gear is locked when the selector lever is in the “P” position.
L
TM-47
SHIFT LOCK SYSTEM
< DTC/CIRCUIT DIAGNOSIS > [SHIFT SELECTOR]
SHIFT LOCK SYSTEM
1.CHECK SHIFT LOCK OPERATION (PART 1)

2. Fulfill all of the following conditions.
Power switch : ON
Brake pedal : Depressed
Normal charge connector : Disconnected
Quick charge connector : Disconnected
3. Attempt to shift the selector lever to any other than position.
Can the selector lever be shifted to any other position?
YES >> GO TO 2.
NO >> Go to TM-49, "Diagnosis Procedure".
Power switch : ON
Brake pedal : Released
YES >> Go to TM-49, "Diagnosis Procedure".
NO >> GO TO 3.
Power switch : ON
Normal charge connector : Connected
NO >> GO TO 4.
Power switch : ON
Quick charge connector : Connected
TM-48
SHIFT LOCK SYSTEM
NO >> GO TO 5.
5.CHECK SHIFT LOCK OPERATION (PART 5) A

B
Power switch : OFF
C
Can the selector lever be shifted to any other position? TM
E
1.CHECK DTC (VCM)

F
With CONSULT
Check “Self Diagnostic Result” in “EV/HEV”.
G
NO >> GO TO 2.
2.CHECK POWER SOURCE (PART 1) H
2. Power switch ON.
3. Check the voltage between the shift selector harness connector terminal and ground. I
+
Shift selector – Voltage J
Connector Terminal
12V battery
M57 13 Ground K
voltage
YES >> GO TO 3. L
NO >> GO TO 6.
3.CHECK GROUND CIRCUIT
Check the continuity between the shift selector harness connector terminal and ground. M
Shift selector
— Condition Continuity N
Connector Terminal
M57 15 Ground Depress the brake pedal Existed
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK HARNESS BETWEEN SHIFT SELECTOR AND VCM P
2. Check the continuity between the shift selector harness connector terminal and VCM harness connector
terminal.
TM-49
SHIFT LOCK SYSTEM
Shift selector VCM

Continuity
3. Also check short circuit in harness.
YES >> GO TO 9.
5.CHECK SHIFT LOCK SOLENOID
Check shift lock solenoid. Refer to TM-50, "Component Inspection (Shift Lock Solenoid)".
6.CHECK FUSE
2. Remove 10A fuse (No. 88, located in fuse holder-2).
YES >> GO TO 7.
7.CHECK HARNESS BETWEEN M/C RELAY AND SHIFT SELECTOR
1. Install 10A fuse (No. 88, located in fuse holder-2).
3. Check the continuity between the M/C relay harness connector terminal and shift selector harness con-
nector terminal.
M/C relay Shift selector

Continuity
E65 5 M57 13 Existed
4. Also check short circuit in harness.
YES >> GO TO 8.
8.CHECK M/C RELAY CIRCUIT
Check M/C relay circuit. Refer to EVC-371, "Diagnosis Procedure".
9.CHECK STOP LAMP SWITCH CIRCUIT
Check stop lamp switch circuit. Refer to EVC-212, "Diagnosis Procedure".
Component Inspection (Shift Lock Solenoid) INFOID:0000000010922987
1.CHECK SHIFT LOCK SOLENOID

Apply voltage to terminals of shift selector connector and check that shift lock solenoid is activated.
CAUTION:
• Connect the fuse between the terminals when applying the voltage.
TM-50
SHIFT LOCK SYSTEM
• Never cause shorting between terminals.
A
+ (fuse) −
Shift selector Condition Status
B
Terminal
Apply battery voltage be-
13 15 Shift lock solenoid operates
tween terminals 13 and 15.
C
NO >> Replace shift selector. Refer to TM-52, "Removal and Installation". TM
TM-51
SHIFT SELECTOR
< REMOVAL AND INSTALLATION > [SHIFT SELECTOR]

SHIFT SELECTOR
JSDIA6107GB
Selector knob Lock pin Knob cover

Shift selector assembly
REMOVAL
CAUTION:
Always apply the parking brake before performing removal and installation.
1. Shift the selector lever to “R” position.
2. Remove instrument lower panel assembly. Refer to IP-16, "Removal and Installation".
3. Disconnect the tip of parking cable from shift selector assem-
bly.
: Vehicle front
JSDIA6111ZZ
TM-52
SHIFT SELECTOR
4. Lift up the pawl and remove socket from shift selector
assembly. A
: Vehicle front
CAUTION: B
Never damage the pawl.
JSDIA6116ZZ
TM
5. Remove shift selector mounting nuts ( ).
6. Remove shift selector from the vehicle.
E
G
JSDIA6350ZZ
INSTALLATION
Note the following and install in the reverse order of removal. H
• When installing control cable to shift selector assembly, check that
parking cable is fully pressed in with the rib surface facing rear-
ward. I
: Vehicle front
J
K
JSDIA6120ZZ
• Check that the pulling on the socket does not disconnect it. L
: Vehicle front
: Pawl M
JSDIA6116ZZ O
CAUTION: P
When removing selector knob, selector knob and knob cover may be scratched or the inside of knob
cover may be damaged. For reasons, never perform this procedure except when replacing selector
knob.
DISASSEMBLY
1. Shift the selector lever to “R” position.
TM-53
SHIFT SELECTOR
2. Insert the flat-bladed screwdriver (A) into the clearance between
selector knob and knob cover , and remove knob cover
from selector knob in manner of twisting the knob cover.
JSDIA6352ZZ
3. Pull out lock pin from selector knob.
JSDIA6459ZZ
4. Remove selector knob and knob cover from shift selector

assembly.
JSDIA6460ZZ
ASSEMBLY
1. Install the lock pin to the selector knob .
CAUTION:
Never reuse selector knob.
2. Install the knob cover to the selector knob.
CAUTION:
Never reuse knob cover.
JSDIA6461ZZ
TM-54
SHIFT SELECTOR
3. Install the selector knob to the selector lever until it clicks.
CAUTION: A
• When installing the selector knob to the selector lever,
never press the selector knob button.
• Never strike the selector knob to press it into place.
B
4. After installing selector knob, pull the selector knob to check that
it does not become disconnected.
C
JSDIA6462ZZ
TM
INSPECTION AFTER INSTALLATION E

Check the shift position. Refer to TM-47, "Inspection".
TM-55
SECTION FAX FRONT AXLE

B
FAX
E
CONTENTS
PRECAUTION ............................................... 2 FRONT DRIVE SHAFT ...................................... 9 F
Inspection ................................................................. 9
PRECAUTIONS ................................................... 2
Precaution for Technicians Using Medical Electric...... 2 REMOVAL AND INSTALLATION ............... 10 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- FRONT WHEEL HUB AND KNUCKLE ............ 10
SIONER" ................................................................... 2 Exploded View .........................................................10
Removal and Installation .........................................10 H
Precautions for Drive Shaft ....................................... 4 Inspection ................................................................13
PREPARATION ............................................ 5 FRONT DRIVE SHAFT BOOT .......................... 14 I

Exploded View .........................................................14
PREPARATION ................................................... 5 Removal and Installation .........................................15
Special Service Tools ................................................ 5 Inspection ................................................................20
Commercial Service Tools ........................................ 6 J
Lubricant or/and Sealant ........................................... 6 FRONT DRIVE SHAFT ..................................... 21
Exploded View .........................................................21
SYMPTOM DIAGNOSIS ............................... 7 Removal and Installation .........................................22 K
Disassembly and Assembly .....................................27
NOISE, VIBRATION AND HARSHNESS Inspection ................................................................32
(NVH) TROUBLESHOOTING ............................. 7
SERVICE DATA AND SPECIFICATIONS L
NVH Troubleshooting Chart ...................................... 7
(SDS) ............................................................ 33
PERIODIC MAINTENANCE .......................... 8
SERVICE DATA AND SPECIFICATIONS M
FRONT WHEEL HUB AND KNUCKLE .............. 8 (SDS) ................................................................. 33
Inspection .................................................................. 8 Wheel Bearing .........................................................33
Drive Shaft ...............................................................33 N
FAX-1
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
WARNING:
FAX-2
PRECAUTIONS
< PRECAUTION >
B
connectors.
WARNING: C
FAX
injury.
• When removing the 12V battery terminal, turn OFF the power F
NOTE:
ECU may be active for several minutes after the power switch is G
turning OFF the power switch. Even when the power switch is H
• Disconnect 12V battery terminal according to the following steps. I
SEF289H
WORK PROCEDURE
1. Check that EVSE is not connected. J
NOTE:
tion.
K
NOTE:
L
detected.
CAUTION: M
• After turning the power switch OFF, if “Remote A/C” is activated by user operation, stop the air N
NOTE:
approximately 1 hour. O
the power switch.
NOTE: P
NOTE:
FAX-3
PRECAUTIONS
< PRECAUTION >
Precautions for Drive Shaft INFOID:0000000010414169
Observe the following precautions when disassembling and assembling drive shaft.
• Perform work in a location which is as dust-free as possible.
• Clean the parts, before disassembling and assembling.
• Prevent the entry of foreign objects during disassembly of the service location.
• Reassemble disassembled parts carefully in the correct order. If work is interrupted, a clean cover must be
placed over parts.
• Use paper waste. Fabric shop cloths must not be used because of the danger of lint adhering to parts.
• Clean disassembled parts (except for rubber parts) with kerosene which shall be removed by blowing with
air or wiping with paper waste.
FAX-4
PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
B
Tool number
Description C
Tool name
KV40104000 Removing and Installing wheel hub lock nut.
Hub lock nut wrench
a: 85 mm (3.35 in) FAX
b: 65 mm (2.56 in)
E
ZZA0802D
KV40107300 Installing boot band

Boot band crimping tool F
ZZA1229D
H
KV40107500 Removing drive shaft
Drive shaft attachment
J
ZZA1230D
KV38107900 Installing drive shaft

Protector
K
a: 32 mm (1.26 in) dia.
PDIA1183J
FAX-5
PREPARATION
< PREPARATION >

Drive shaft puller Removing drive shaft joint sub assembly
JPDIG0152ZZ
Sliding hammer Removing drive shaft
ZZA0023D
Ball joint remover Removing hub bolt
NT146
Lubricant or/and Sealant INFOID:0000000010981833
Name Description
• Joint sub-assembly inside
Fill NISSAN Genuine grease or equivalent
• Housing inside
Apply paste [service parts (440037S000)] • Joint sub-assembly
FAX-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
SYMPTOM DIAGNOSIS A
NVH Troubleshooting Chart INFOID:0000000010414172
B
Use chart below to find the cause of the symptom. If necessary, repair or replace these parts.
Refer to DRIVE SHAFT in this chart

Refer to FRONT AXLE in this chart
C
NVH in FAX and FSU sections

FAX-10, "Exploded View"
FAX-32, "Inspection"
FAX-8, "Inspection"
NVH in WT section
NVH in WT section
NVH in BR section
NVH in ST section
FAX
—
Reference
FRONT AXLE AND FRONT SUSPENSION

G
Improper installation, looseness

H
Wheel bearing damage

Joint sliding resistance
Possible cause and SUSPECTED PARTS

Excessive joint angle
Parts interference
I
ROAD WHEEL
DRIVE SHAFT
FRONT AXLE
STEERING
Imbalance
BRAKE
J
TIRE
DRIVE Noise × × × × × × × × ×
SHAFT K
Shake × × × × × × × × ×
Noise × × × × × × × × ×
Shake × × × × × × × × × L
Symptom
FRONT Vibration × × × × × × ×
AXLE Shimmy × × × × × × ×
Judder × × × × × × M
Poor quality ride or handling × × × × ×
×: Applicable
N
FAX-7
FRONT WHEEL HUB AND KNUCKLE
COMPONENT PART
Check that the mounting conditions (looseness, backlash) of each component and component conditions
(wear, damage) are normal.
WHEEL HUB ASSEMBLY (BEARING-INTEGRATED TYPE)
Make sure following items, and replace the part if necessary.
• Move wheel hub and bearing assembly in the axial direction by hand. Check there is no looseness of wheel
bearing.
Axial end play : Refer to FAX-33, "Wheel Bearing".

• Rotate wheel hub and bearing assembly and make sure there is no unusual noise or other irregular condi-
tions. If there is any of irregular conditions, replace wheel hub and bearing assembly.
FAX-8
FRONT DRIVE SHAFT
FRONT DRIVE SHAFT
A
Check the following items, and replace the part if necessary. B

• Check drive shaft mounting point and joint for looseness and other damage.
CAUTION:
Replace entire drive shaft assembly when noise or vibration occurs from drive shaft.
• Check boot for cracks and other damage. C
FAX
FAX-9
JSDIA6375GB
Steering knuckle Splash guard Hub bolt

Wheel hub assembly (Bearing-inte- Disc rotor Wheel hub lock nut
grated type)
Adjusting cap Cotter pin

REMOVAL
1. Remove tires. Refer to WT-65, "Removal and Installation".
2. Remove front wheel sensor from steering knuckle. Refer to BRC-185, "FRONT WHEEL SENSOR :
3. Remove lock plate from strut assembly.
• LHD: Refer to BR-447, "FRONT : Exploded View".
• RHD: Refer to BR-927, "FRONT : Exploded View".
JSDIA3795ZZ
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
• LHD: Refer to BR-473, "BRAKE CALIPER ASSEMBLY : Removal and Installation".
• RHD: Refer to BR-954, "BRAKE CALIPER ASSEMBLY : Removal and Installation".
CAUTION:
Never depress brake pedal while brake caliper is removed.
5. Remove disc rotor.
FAX-10
CAUTION:
• Put matching marks on the wheel hub assembly and A
the disc rotor before removing the disc rotor.
• Never drop disc rotor.
B
JPDIG0066ZZ FAX
6. Remove cotter pin, adjusting cap, and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
E
JSDIA2708ZZ
H
7. Separate steering knuckle from transverse link.
8. Separate steering outer socket from steering knuckle. Refer to ST-43, "Removal and Installation".
9. Remove strut assembly from steering knuckle. I
CAUTION:
• Never place drive shaft joint at an extreme angle.
• Be careful not to overextend slide joint.
• Never allow drive shaft to hang down without support for J
joint sub-assembly, shaft and the other parts.
WEIA0179E
L
10. Patch hub lock nut with a piece of wood. Hammer the wood to
disengage wheel hub and bearing assembly from drive shaft.
NOTE: M
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure. N
O
JPDIG0070ZZ
11. Remove wheel hub lock nut. P

12. Hang drive shaft in a place where it will not interfere with work.
13. Remove wheel hub and bearing assembly.
14. Remove splash guard.
15. Remove steering knuckle from transverse link. Refer to FSU-18, "Removal and Installation".
FAX-11
16. Remove hub bolts from wheel hub and bearing assembly,
using the ball joint remover (A) (commercial service tool).
CAUTION:
• Remove hub bolt only when necessary.
• Never hammer the hub bolt to avoid impact to the wheel
hub and bearing assembly.
• Pull out the hub bolt in a direction perpendicular to the
wheel hub and bearing assembly.
JPDIF0299ZZ
17. Perform inspection after removal. Refer to FAX-13, "Inspection".

INSTALLATION
Note the following, and install in the reverse order of the removal.
Hub Bolts
• Place a washer as shown in the figure to install the hub bolts
by using the tightening force of the nut .
CAUTION:
• Check that there is no clearance between wheel hub and
bearing assembly, and hub bolt.
• Never reuse hub bolt.
JPDIF0300ZZ
Drive shaft
• Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matching surface.
• Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface of joint sub-assembly of drive shaft.
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste : 1.0 – 3.0 g (0.04 – 0.10 oz)
JSDIA2844ZZ
• Tighten the wheel hub lock nut to the specified torque. Refer to FAX-10, "Exploded View".
CAUTION:
• Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
• Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
• Never reuse wheel hub lock nut.
FAX-12
• When installing a cotter pin and adjusting cap , securely bend
the basal portion to prevent rattles. A
CAUTION:
Never reuse cotter pin.
B
JPDIF0295ZZ
FAX
Disc rotor
CAUTION:
• Align the matching marks made during removal when reus- E
ing the disc rotor.
F
JPDIG0066ZZ H
• Perform inspection after installation. Refer to FAX-13, "Inspection".

I
INSPECTION AFTER REMOVAL J

Check the following items, and replace the part if necessary.
• Check components for deformation, cracks, and other damage.
• Check boots of transverse link and steering outer socket ball joint for breakage, axial end play, and swing
torque. K
- Transverse link: FSU-19, "Inspection".
- Steering outer socket: ST-45, "Inspection".
INSPECTION AFTER INSTALLATION L
1. Check wheel sensor harness for proper connection. Refer to BRC-185, "FRONT WHEEL SENSOR :
Exploded View".
M
2. Check the wheel alignment. Refer to FSU-11, "Inspection".
3. Adjust neutral position of steering angle sensor. Refer to BRC-67, "Work Procedure".
N
FAX-13
FRONT DRIVE SHAFT BOOT
LEFT SIDE
JSDIA3041ZZ
Circular clip Dust shield Housing assembly

Snap ring Spider assembly Boot band
Boot Shaft Circular clip
Joint sub-assembly
: Wheel side

: Fill NISSAN Genuine grease or equivalent.
RIGHT SIDE
JSDIA6664GB
Joint sub-assembly Circular clip Boot band

Boot Shaft Stopper ring
Spider assembly Snap ring Housing
FAX-14
Dust shield Support bearing Retainer
Support bearing bracket
A
: Wheel side
: N·m (kg-m, ft-lb) B

1: Fill NISSAN Genuine grease or equivalent. C
2: Apply paste [service parts (440037S000)].

FAX
REMOVAL
Wheel Side E
Removal and Installation". F
• RHD: Refer to BR-927, "FRONT : Exploded View". G
I
JSDIA3795ZZ
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work. J
CAUTION: K
5. Remove cotter pin, adjusting cap and then loosen wheel hub
L
PDIA1180J
6. Separate steering outer socket from steering knuckle. Refer to ST-43, "Removal and Installation". O
FAX-15
7. Remove strut assembly from steering knuckle.
CAUTION:
• Never allow drive shaft to hang down without support for
WEIA0179E
8. Patch wheel hub lock nut with a piece of wood (A). Hammer (B)
the wood to disengage wheel hub and bearing assembly from
drive shaft.
NOTE:
cedure.
JSDIA3971ZZ
9. Remove wheel hub lock nut.

10. Remove drive shaft from wheel hub and bearing assembly.
CAUTION:
• Never allow drive shaft to hang down without support for joint sub-assembly, shaft and the other
parts.
11. Remove boot bands, and then separate boot from joint sub-assembly.
12. Screw drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft.
CAUTION:
• Align sliding hammer and drive shaft and remove them by
pulling directory.
• If joint sub-assembly cannot be pulled out, try after
removing drive shaft from vehicle. Refer to FAX-22,
JPDIF0258ZZ
13. Remove circular clip from shaft.
JPDIF0007ZZ
14. Remove boot from shaft.

Reduction Gear Side
FAX-16
Remove boot after removing drive shaft.
• Remove: Refer to FAX-22, "Removal and Installation". A
• Disassembly: Refer to FAX-27, "Disassembly and Assembly".
INSTALLATION
B
Wheel Side
1. Clean the old grease on joint sub-assembly with paper waste.
C
2. Fill serration slot joint sub-assembly with NISSAN genuine
grease or equivalent until the serration slot and ball groove
become full to the brim.
CAUTION: FAX
After applying grease, use a shop cloth to wipe off old
grease that has oozed out.
E
F
JPDIF0008ZZ
3. Install boot and boot bands to shaft.

CAUTION: G
• Never reuse boot and boot band.
• Wrap serration on shaft with tape to protect the boot
from damage. H
JPDIF0009ZZ
J
4. Remove the tape wrapped around the serration on shaft.
5. Position the circular clip on groove at the shaft edge. K

CAUTION:
Never reuse circular clip.
L
JPDIF0007ZZ
N
NOTE:
Drive joint inserter is recommended when installing circular clip O
.
JPDIF0010ZZ
FAX-17
6. Align both center axles of the shaft edge and joint sub-assembly. Then assemble shaft with joint sub-
assembly holding circular clip.
7. Install joint sub-assembly to shaft using plastic hammer.

CAUTION:
• Check circular clip is properly positioned on groove of the
joint sub-assembly.
• Confirm that joint sub-assembly is correctly engaged
while rotating drive shaft.
JPDIF0011ZZ
8. Fill into the boot inside with the specified amount of grease from large diameter side of boot.
Grease amount : Refer to FAX-33, "Drive Shaft".
9. Install the boot securely into grooves (indicated by “*” marks)

shown in the figure.
CAUTION:
If grease adheres to the boot mounting surface (indicated
by “*” mark) on the shaft or joint subassembly. boot may be
removed. Remove all grease from the boot mounting sur-
face.
10. To prevent the deformation of the boot, adjust the boot installa-
tion length (L) to the specified value shown below by inserting
the suitable tool into the inside of the boot from the large diame-
ter side of the boot and discharging the inside air. JPDIG0136ZZ
L : Refer to FAX-33, "Drive Shaft".

CAUTION:
• If the boot mounting length exceeds the standard, it may cause breakage in the boot.
• Be careful not to touch the inside of the boot with a tip of tool.
11. Secure the large and small ends of the boot with boot bands
using the boot band crimping tool (A) (SST: KV40107300).
CAUTION:
• Never reuse boot band.
JPDIF0012ZZ
• Clamp orientation to be locked (A) at reverse drive side.
JSDIA4267ZZ
FAX-18
NOTE: A
Secure boot band so that dimension (M) meets the specification as shown in the figure.
M : 1.0 – 4.0 mm (0.039 – 0.157 in)

B
FAX
DSF0047D
12. Check that displacement does not occur when boot is rotated with the joint sub-assembly and shaft fixed. E
CAUTION:
• Reinstall them using boot bands when boot installation positions become incorrect.
• Never reuse boot band. F
13. Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
G
14. Clean the matching surface of drive shaft and wheel hub and
bearing assembly. And then apply paste [service parts
(440037S000)] to surface of joint sub-assembly of drive shaft.
CAUTION: H
Apply paste to cover entire flat surface of joint sub-assem-
bly of drive shaft.
I
Amount paste : 1.0 – 3.0 g (0.04 – 0.10 oz)
J
JSDIA2844ZZ
15. Insert drive shaft to wheel hub and bearing assembly, and then temporarily tighten wheel hub lock nut.
CAUTION: K
16. Install strut assembly from steering knuckle. Refer to FSU-18, "Exploded View". L
17. Install steering outer socket to steering knuckle. Refer to ST-40, "Exploded View".
18. Tighten the wheel hub lock nut to the specified torque. Refer to FAX-10, "Exploded View".
CAUTION: M
• Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
N
19. When installing a cotter pin and adjusting cap , securely
bend the basal portion to prevent rattles.
CAUTION: O
JPDIF0295ZZ
20. Install lock plate to strut assembly.
FAX-19
21. Install wheel sensor to steering knuckle. Refer to BRC-185, "FRONT WHEEL SENSOR : Removal and
Installation".
22. Install tires to vehicle.Refer to WT-65, "Removal and Installation".
23. Perform inspection after installation. Refer to FAX-20, "Inspection".
Reduction Gear Side
• Installation: Refer to FAX-22, "Removal and Installation".
• Assembly: Refer to FAX-27, "Disassembly and Assembly".

1. Check wheel sensor harness for proper connection. Refer to BRC-185, "FRONT WHEEL SENSOR :
Exploded View".
FAX-20
FRONT DRIVE SHAFT
FRONT DRIVE SHAFT
A
LEFT SIDE B
FAX
JSDIA3041ZZ
H
Circular clip Dust shield Housing assembly
Snap ring Spider assembly Boot band
Boot Shaft Circular clip I
Joint sub-assembly
: Wheel side
J
: Fill NISSAN Genuine grease or equivalent.
K
RIGHT SIDE
JSDIA6664GB
Joint sub-assembly Circular clip Boot band

Boot Shaft Stopper ring
Spider assembly Snap ring Housing
FAX-21
FRONT DRIVE SHAFT
Dust shield Support bearing Retainer
Support bearing bracket
: Wheel side

1: Fill NISSAN Genuine grease or equivalent.
2: Apply paste [service parts (440037S000)].
REMOVAL
Left Side
1. Drain reduction gear oil.
JSDIA3795ZZ
CAUTION:
PDIA1180J
FAX-22
FRONT DRIVE SHAFT
CAUTION: A
B
WEIA0179E
FAX
drive shaft.
E
NOTE:
cedure. F
G
JSDIA3971ZZ

H
CAUTION:
• Be careful not to overextend slide joint. I
parts.
J
12. Remove drive shaft from reduction gear assembly.
• Use the drive shaft attachment (A) (SST: KV40107500) and a
sliding hammer (B) (commercial service tool) while inserting
tip of the drive shaft attachment between housing and reduc- K
tion gear assembly.
CAUTION:
• Never place drive shaft joint at an extreme angle when L
removing drive shaft. Also be careful not to overextend
slide joint.
• Confirm that the circular clip is attached to the drive
M
shaft.
JPDIF0004ZZ
13. Perform inspection after removal. Refer to FAX-32, "Inspection".
Right Side N
1. Drain reduction gear oil.
3. Remove front wheel sensor from steering knuckle. Refer to BRC-185, "FRONT WHEEL SENSOR : O
FAX-23
FRONT DRIVE SHAFT
JSDIA3795ZZ
CAUTION:
PDIA1180J
CAUTION:
WEIA0179E
drive shaft.
NOTE:
cedure.
JSDIA3971ZZ

CAUTION:
FAX-24
FRONT DRIVE SHAFT
parts. A
12. Remove retainer mounting bolts and retainer.

13. Remove drive shaft from reduction gear assembly. B
• Use the drive shaft attachment (SST: KV40107500) and a sliding hammer while inserting tip of the drive
shaft attachment between housing and reduction gear assembly.
CAUTION:
Never place drive shaft joint at an extreme angle when removing drive shaft. Also be careful not C
to overextend slide joint.
14. If necessary, remove the support bearing bracket mounting bolts and the support bearing bracket.
15. Perform inspection after removal. Refer to FAX-32, "Inspection". FAX
INSTALLATION
Left Side E
Reduction Gear Side
• Place the protector (A) (SST: KV38107900) onto reduction gear F
assembly to prevent damage to the oil seal while inserting drive
shaft. Slide drive shaft sliding joint and tap with a hammer to install
securely. G
CAUTION:
Check that circular clip is completely engaged.
H
JPDIF0023ZZ
I

J
Wheel Hub Side
CAUTION:
K
L
ing assembly. And then apply paste [service parts (440037S000)]
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly M
of drive shaft.
Amount paste : 1.0 – 3.0 g (0.04 – 0.10 oz) N
JSDIA2844ZZ
O
CAUTION:
• Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel P
hub lock nut.
FAX-25
FRONT DRIVE SHAFT
• When installing a cotter pin and adjusting cap , securely bend
the basal portion to prevent rattles.
CAUTION:
JPDIF0295ZZ

Right Side
Reduction Gear Side
• Install support bearing bracket in following procedure.
- Temporarily tighten support bearing bracket mounting bolts in
the numerical order as shown in the figure, then tighten them to
specified torque.
JSDIA3834ZZ
- Set retainer so that notch becomes upper side. Temporarily

tighten mounting bolts in the numerical order as shown in the fig-
ure, then tighten them to specified torque.
CAUTION:
Never reuse retainer.
JSDIA3836ZZ
• Place the protector (A) (SST: KV38107900) onto reduction gear

assembly to prevent damage to the oil seal while inserting drive
shaft. Slide drive shaft sliding joint and tap with a hammer to install
securely.
JSDIA6354ZZ

Wheel Hub Side
FAX-26
FRONT DRIVE SHAFT
CAUTION:
Never apply lubricating oil to these matching surface. A
ing assembly. And then apply paste [service parts (440037S000)] B
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
C
of drive shaft.
Amount paste : 1.0 – 3.0 g (0.04 – 0.10 oz)

FAX
JSDIA2844ZZ
E
CAUTION:
• Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel F
hub lock nut.
• When installing a cotter pin and adjusting cap , securely bend G
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin. H
JPDIF0295ZZ
J

K
DISASSEMBLY L
Transaxle Assembly Side
1. Fix shaft with a vise.
CAUTION: M
Protect shaft using aluminum or copper plates when fixing with a vise.
2. Remove boot bands, and then remove boot from housing.
3. Remove stopper ring. N
4. Put matching marks on housing and shaft, and then pull out housing from shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces. O
FAX-27
FRONT DRIVE SHAFT
5. Put matching marks on the spider assembly and shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never
scratch the surfaces.
JPDIF0006ZZ
6. Remove snap ring , and then remove spider assembly from

shaft.
JPDIF0014ZZ

8. Clean old grease on housing with paper waste.
Support Bearing
1. Remove dust shield from housing.
JPDIF0121ZZ
2. Remove snap ring .
JPDIF0106ZZ
FAX-28
FRONT DRIVE SHAFT
3. Press out support bearing from housing.
A
YAX004
FAX
4. Remove dust shield.
Wheel Side
1. Fix shaft with a vise. E
CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2. Remove boot bands, and then remove boot from joint sub-assembly. F
3. Screw drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem- G
bly from shaft.
CAUTION:
• If joint sub-assembly cannot be removed after five or
H
more unsuccessful attempts, replace shaft and joint sub
assembly as a set.
• Align sliding hammer and drive shaft and remove them by
pulling directory. I
JPDIG0151ZZ
4. Remove circular clip from shaft. J

6. Clean old grease on joint sub-assembly with paper towels while rotating ball cage.
K
ASSEMBLY
Transaxle Assembly Side
1. Wrap serration on shaft with tape to protect boot from dam- L
age. Install new boot and boot bands to shaft.
CAUTION:
Never reuse boot and boot band. M
2. Remove the tape wrapped around the serration on shaft.
JPDIF0009ZZ O
FAX-29
FRONT DRIVE SHAFT
3. To install the spider assembly , align it with the matching
marks on the shaft put during the removal, and direct the
serration mounting surface to the shaft.
JPDIF0017ZZ
4. Secure spider assembly onto shaft with snap ring .

CAUTION:
Never reuse snap ring.
JPDIF0014ZZ
5. Apply the appropriate amount of grease to spider assembly and sliding surface.
6. Assemble the housing onto spider assembly, and apply the balance of the specified amount grease.
Grease amount : Refer to FAX-33, "Drive Shaft".

7. Align matching marks put during the removal of housing.
8. Install stopper ring.
CAUTION:
Never reuse stopper ring.
9. Install boot securely into grooves (indicated by “*” marks) shown
in the figure.
CAUTION:
If grease adheres to the boot mounting surface (indicated
by “*” mark) on shaft or housing, boot may be removed.
Remove all grease from the surface.
JPDIF0230ZZ
10. To prevent from deformation of the boot, adjust the boot installation length to the value shown below (L) by
inserting the suitable tool into the inside of boot from the large diameter side of boot and discharging
inside air.
L : Refer to FAX-33, "Drive Shaft".

CAUTION:
• If the boot installation length exceeds the standard, it may cause breakage in boot.
• Be careful not to touch the inside of the boot with the tip of tool.
11. Install new boot bands securely.
CAUTION:
Never reuse boot band.
FAX-30
FRONT DRIVE SHAFT
a. Put boot band in the groove on drive shaft boot. Then fit pawls
( ) into holes to temporary installation. A
NOTE:
For the large diameter side, fit projection and guide slit at
first.
B
SDIA3557E
FAX
b. Pinch projection on the band with suitable pliers to tighten band.
c. Insert tip of band below end of the pawl.
E
G
SDIA3558E
12. Secure housing and shaft, and then make sure that they are in the correct position when rotating boot.
H
Install them with new boot band when the mounting positions become incorrect.
Support Bearing
1. Install dust shield on housing. I
CAUTION:
Never reuse dust shield.
2. Press support bearing onto housing to using the suitable tool J
(A).
3. Install snap ring.
CAUTION: K
Never reuse snap ring.
JPDIF0056ZZ M
4. Install dust shields.
CAUTION:
Never reuse dust shields. N
JPDIF0127ZZ
Wheel Side
For further details, refer to the installation procedure of “FAX-15, "Removal and Installation"” for the drive shaft
boot.
FAX-31
FRONT DRIVE SHAFT
INSPECTION AFTER REMOVAL

• Move joint up/down, left/right, and in the axial directions. Check for motion that is not smooth and for signifi-
cant looseness.
• Check boot for cracks, damage, and leakage of grease.
• Check the support bearing bracket for cracks, deformation and other damage.
INSPECTION AFTER DISASSEMBLY
Shaft
Check shaft for runout, cracks, or other damage.
Joint Sub-Assembly
Check the following:
• Joint sub-assembly for rough rotation and excessive axial looseness.
• The inside of the joint sub-assembly for entry of foreign material.
• Joint sub-assembly for compression scars, cracks, and fractures inside of joint sub-assembly.
Replace joint sub-assembly if there are any non-standard conditions of components.
Housing assembly
Replace housing assembly if there is scratching or wear of housing assembly roller contact surface.
Support Bearing (Right Side)
Check bearing rolls freely and is free from noise, cracks, pitting or wear. Replace support bearing if there are
any non-standard conditions.
Support Bearing Bracket (Right Side)
Check for support bearing bracket, cracks, or damage. Replace support bearing bracket if there are any non-
standard conditions.
FAX-32
Wheel Bearing INFOID:0000000010414188
B
Item Standard
C
Axial end play 0.05 mm (0.002 in) or less
Drive Shaft INFOID:0000000010414189

FAX
Standard
Item
Wheel side Reduction gear side E
Grease quantity 110 – 120 g (3.53 – 4.23 oz) 175 – 195 g (6.17 – 6.88 oz)
* 131.0 mm (5.16 in) 176.9 mm (6.96 in)
Boots installed length
F
*: For measuring position, refer to FAX-27, "Disassembly and Assembly".
FAX-33
SECTION RAX REAR AXLE

B
RAX
E
CONTENTS
PRECAUTION ............................................... 2 REAR WHEEL HUB ........................................... 6 F
Inspection ................................................................. 6
PRECAUTIONS ................................................... 2
Precaution for Technicians Using Medical Electric...... 2 REMOVAL AND INSTALLATION ................ 7 G
REAR WHEEL HUB ........................................... 7
PREPARATION ............................................ 4 Exploded View .......................................................... 7
Removal and Installation .......................................... 7 H
PREPARATION ................................................... 4 Inspection ................................................................. 8
Commercial Service Tools ........................................ 4
SERVICE DATA AND SPECIFICATIONS I
SYMPTOM DIAGNOSIS ............................... 5 (SDS) ............................................................ 10
NOISE, VIBRATION AND HARSHNESS SERVICE DATA AND SPECIFICATIONS
(NVH) TROUBLESHOOTING ............................. 5 (SDS) ................................................................. 10 J
NVH Troubleshooting Chart ...................................... 5 Wheel Bearing .........................................................10
PERIODIC MAINTENANCE .......................... 6 K
RAX-1
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
NOTE:
SEF289H
RAX-2
PRECAUTIONS
< PRECAUTION >
WORK PROCEDURE
1. Check that EVSE is not connected. A
NOTE:
tion. B
NOTE: C
detected.
4. Remove 12V battery terminal within 60 minutes after turning the power switch OFF → ON → OFF. RAX
CAUTION:
• After turning the power switch OFF, if “Remote A/C” is activated by user operation, stop the air E
NOTE:
Once the power switch is turned ON → OFF, the 12V battery automatic charge control does not start for F
the power switch. G
NOTE:
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC. H
NOTE:
I
RAX-3
PREPARATION
< PREPARATION >
PREPARATION
PREPARATION

Ball joint remover Removing hub bolt
NT146
RAX-4
SYMPTOM DIAGNOSIS A
B
NVH in RAX and RSU sections

C
RAX-7, "Exploded View"
RAX-6, "Inspection"
NVH in WT section
NVH in WT section
NVH in BR section
RAX
—
Reference
REAR AXLE AND REAR SUSPENSION

F

G
Wheel bearing damage

H
Parts interference
ROAD WHEEL
I
BRAKE
TIRE
Noise × × × × × × × J
Shake × × × × × × ×
Vibration × × × × ×
Symptom REAR AXLE K
Shimmy × × × × × ×
Judder × × × × ×
Poor quality ride or handling × × × × × L
×: Applicable
RAX-5
REAR WHEEL HUB
REAR WHEEL HUB
COMPONENT PART
Check the mounting conditions (looseness, back lash) of each component and component conditions (wear,
damage) are normal.
WHEEL HUB ASSEMBLY (BEARING-INTEGRATED TYPE)
Check the following items, and replace the part it necessary.
• Move wheel hub assembly in the axial direction by hand. Check there is no looseness of wheel bearing.
Axial end play : Refer to RAX-10, "Wheel Bearing".

• Rotate wheel hub and bearing assembly and make sure there is no unusual noise or other irregular condi-
tions. If there is any of irregular conditions, replace wheel hub and bearing assembly.
RAX-6
REAR WHEEL HUB
REAR WHEEL HUB
B
RAX
JSDIA6430GB
H
Rear suspension beam Dust shield Parking brake shoe assembly
Wheel hub assembly Hub bolt Disc rotor
(Bearing-integrated type) I
Plug
: N·m (kg-m, ft-lb) J


K
REMOVAL
1. Remove tires. Refer to WT-65, "Removal and Installation". L
2. Remove wheel sensor. Refer to BRC-186, "REAR WHEEL SENSOR : Removal and Installation".
3. Remove caliper assembly, and put on the leaf spring.
• LHD: Refer to BR-482, "BRAKE CALIPER ASSEMBLY : M
• RHD: Refer to BR-963, "BRAKE CALIPER ASSEMBLY :
CAUTION: N
JSDIA6670ZZ
P
4. Remove disc rotor. If disc rotor cannot be removed, remove as follows.
CAUTION:
• Parking brake completely in the released position.
RAX-7
REAR WHEEL HUB
• Put matching marks on the wheel hub assembly and
the disc rotor before removing the disc rotor.
a. Fix the disc rotor with wheel nuts and remove the adjusting hole
plug.
JSDIA2721ZZ
b. Using suitable tool, rotate adjuster in the direction to retract

and loosen brake shoe.
c. Remove disc rotor.
5. Remove wheel hub assembly.
CAUTION:
Never remove parking brake shoe assembly. Protect it from
falling.
JPDIG0204ZZ
6. Remove parking brake shoe and parking brake cable from back plate. Refer to PB-14, "Removal and
Installation", PB-10, "Removal and Installation".
7. Remove hub bolts from wheel hub assembly, using the ball
joint remover (A) (commercial service tool).
CAUTION:
• Remove hub bolt only when necessary.
• Never hammer the hub bolt to avoid impact to the wheel
bearing.
• Pull out the hub bolt in a direction perpendicular to the
wheel hub assembly.
8. Perform inspection after removal. Refer to RAX-8, "Inspection".
JPDIF0299ZZ
INSTALLATION
• Place a washer as shown in the figure to install the hub bolts
by using the tightening force of the nut .
CAUTION:
• Check that there is no clearance between wheel hub assem-
bly and hub bolt.
• Never reuse hub bolt.
• Fit the pin of rear brake assembly to hole of rear suspension beam
when install rear brake assembly.
• Align the matching marks that have been made during removal
when reusing the disc rotor.
• Perform inspection after installation. Refer to RAX-8, "Inspection". JPDIF0300ZZ

Check the wheel hub assembly for wear, cracks, and damage. Replace if necessary.
1. Check wheel sensor harness for proper connection. BRC-186, "REAR WHEEL SENSOR : Exploded
View".
RAX-8
REAR WHEEL HUB
2. Adjust parking brake operation (stroke). Refer to PB-7, "Inspection and Adjustment".
3. Check wheel alignment. Refer to RSU-7, "Inspection". A
RAX
RAX-9
Wheel Bearing INFOID:0000000010414199
Item Standard
Axial end play 0.05 mm (0.002 in) or less
RAX-10
SUSPENSION
SECTION
FRONT SUSPENSION
FSU B
FSU
CONTENTS
PRECAUTION ............................................... 2 Adjustment ...............................................................12 F
PRECAUTIONS ................................................... 2 REMOVAL AND INSTALLATION ............... 13

Precaution for Supplemental Restraint System FRONT COIL SPRING AND STRUT ................ 13
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Exploded View .........................................................13
SIONER" ................................................................... 2 Removal and Installation .........................................13
Disassembly and Assembly .....................................14 H
tion after 12V Battery Disconnect .............................. 3 Inspection ................................................................17
Precaution for Procedure without Cowl Top Cover...... 3 Disposal ...................................................................17
High Voltage Precautions .......................................... 3 I
TRANSVERSE LINK ......................................... 18
Precautions for Removing Battery Terminal ............. 6 Exploded View .........................................................18
Precautions for Suspension ...................................... 6 Removal and Installation .........................................18
Inspection ................................................................19 J
PREPARATION ............................................ 7
PREPARATION ................................................... 7 FRONT STABILIZER ........................................ 20
Exploded View .........................................................20 K
Special Service Tools ................................................ 7
Commercial Service Tools ........................................ 7
Sealant or/and Lubricant ........................................... 8 Inspection ................................................................21
FRONT SUSPENSION MEMBER ..................... 22 L

SYMPTOM DIAGNOSIS ............................... 9
Exploded View .........................................................22
NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................22
(NVH) TROUBLESHOOTING ............................. 9 Inspection and Adjustment ......................................26 M
PERIODIC MAINTENANCE ......................... 10 (SDS) ............................................................ 28
N
FRONT SUSPENSION ASSEMBLY ..................10 SERVICE DATA AND SPECIFICATIONS
Inspection ................................................................ 10 (SDS) ................................................................. 28
Wheel Alignment .....................................................28 O
WHEEL ALIGNMENT .........................................11 Ball Joint ..................................................................28
Inspection ................................................................ 11 Wheelarch Height ....................................................28
P
FSU-1
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
WARNING:
FSU-2
PRECAUTIONS
< PRECAUTION >
B
connectors.
WARNING: C
D
injury.
the 12V battery, and wait at least 3 minutes before performing any service. FSU
INFOID:0000000011008081
F
procedure below before starting the repair operation. G
OPERATION PROCEDURE
1. Connect both 12V battery cables. H
NOTE:
2. Turn the power switch to ACC position. I
disconnected and the steering wheel can be turned. J
turn the power switch from ACC position to ON position, then to LOCK position. (The steering wheel will K
NOTE:
L
tion.
M
windshield. N
PIIB3706J
DANGER:
FSU-3
PRECAUTIONS
< PRECAUTION >
maintenance.
WARNING:
CAUTION:
WARNING:
FSU-4
PRECAUTIONS
< PRECAUTION >
workers. A
FSU
JSAIA1600GB P
FSU-5
PRECAUTIONS
< PRECAUTION >
NOTE:
SEF289H
WORK PROCEDURE
NOTE:
tion.
NOTE:
detected.
CAUTION:
NOTE:
the power switch.
NOTE:
NOTE:
Precautions for Suspension INFOID:0000000010414206
• When installing rubber bushings, the final tightening must be carried out under unladen conditions with tires
on ground. Spilled oil might shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
- Unladen conditions mean that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and
mats are in designated positions.
• After servicing suspension parts, be sure to check wheel alignment.
• Self-lock nuts are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-oiled,
tighten as they are.
• The tightening surface must be kept free from oil/grease.
• When jacking up the vehicle with a floor jack, never hang the jack on the torque rod.
FSU-6
PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
B
Tool number
Description C
Tool name
KV991040S1 Measuring wheel alignment
KV99104020 Adapter A
KV99104030 Adapter B D
KV99104040 Adapter C
KV99104050 Adapter D
KV99104060 Plate FSU
KV99104070 Guide bolt
KV99104080 Spring ZZA1167D
KV99104090 Center plate F

ST35652000 Disassembling and assembling strut
Strut attachment
G
H
ZZA0807D
Commercial Service Tools INFOID:0000000010414208 I
Tool name Description J

Spring compressor Removing and installing coil spring
L
S-NT717

M
ponents
Insulated gloves • Use protective gloves made of insulating
material. N
• The protective gloves must be capable
of resisting the voltage of 600 or more.
JMCIA0149ZZ

components
Leather gloves • Protect insulated gloves P
[Use leather gloves that can fasten the
wrist tight]
JPCIA0066ZZ
FSU-7
PREPARATION
< PREPARATION >

ponents
material.
JPCIA0011ZZ

components
JPCIA0167ZZ

Insulated helmet
ponents
JPCIA0013ZZ
Name Description
Anti-corrosion oil Piston rod of strut
FSU-8
SYMPTOM DIAGNOSIS A
B
FSU-13, FSU-18, FSU-20, FSU-22
FSU-13, FSU-18, FSU-20, FSU-22

C
NVH in FAX and FSU sections
NVH in FAX section

NVH in WT section
NVH in WT section
NVH in BR section
NVH in ST section
D
FSU-17
FSU-17
FSU-21
FSU-11
—
—
Reference
FSU
Shock absorber deformation, damage or deflection

G
FRONT AXLE AND FRONT SUSPENSION

Bushing or mounting deterioration H
Incorrect wheel alignment

I
Suspension looseness
Stabilizer bar fatigue

Parts interference
ROAD WHEEL
DRIVE SHAFT
Spring fatigue
STEERING
BRAKE
TIRE
K
Noise × × × × × × × × × × × ×
Shake × × × × × × × × × × ×
L
Vibration × × × × × × × × ×
Symptom FRONT SUSPENSION Shimmy × × × × × × × × × ×
Judder × × × × × × × × M
Poor quality ride or
× × × × × × × × × ×
handling
×: Applicable N
FSU-9
FRONT SUSPENSION ASSEMBLY
FRONT SUSPENSION ASSEMBLY
COMPONENT PART
Check the mounting conditions (looseness, backlash) of each component and component conditions (wear,
damage) are normal.
Ball Joint Axial End Play
1. Set front wheels in a straight-ahead position.
2. Move axle side of transverse link in the axial direction by hand.
Check there is no end play.
Axial end play : Refer to FSU-28, "Ball Joint".

CAUTION:
• Never depress brake pedal when measuring.
• Never perform with tires on level ground.
• Be careful not to damage ball joint boot. Never damage
the installation position by applying excessive force.
JSEIA0444ZZ
STRUT ASSEMBLY
Check for oil leakage, damage, and replace if necessary.
FSU-10
WHEEL ALIGNMENT
WHEEL ALIGNMENT
A
DESCRIPTION B
CAUTION:
• The adjustment mechanisms of camber, caster, and kingpin inclination angles are not included.
• If camber, caster, or kingpin inclination angle is outside the standard, check front suspension parts C
for wear and damage. Replace suspect parts if a malfunction is detected.
• Kingpin inclination angle is reference value, no inspection is required.
Measure wheel alignment under unladen conditions.
NOTE: D
“Unladen conditions” means that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools and
PRELIMINARY CHECK FSU
• Tires for improper air pressure and wear. Refer to WT-71, "Tire Air Pressure".
• Road wheels for runout. F
• Wheel bearing axial end play. Refer to FAX-8, "Inspection".
• Transverse link ball joint axial end play. Refer to FSU-10, "Inspection".
• Strut operation.
G
• Each mounting part of axle and suspension for looseness and deformation.
• Each of suspension member, strut and transverse link for cracks, deformation and other damage.
• Vehicle height (posture).
H
CAMBER, CASTER, AND KINGPIN INCLINATION ANGLES
Before inspection, mount front wheels onto turning radius gauge. Mount rear wheels onto a stand at the same
height so that vehicle remains horizontal.
I
Using a CCK Gauge
Install the CCK gauge attachment (SST: KV991040S1) with the following procedure on wheel, then measure
wheel alignment.
J
1. Remove three wheel to nuts, and install the guide bolts to hub
bolt.
2. Screw the adapter into the plate until it contacts the plate tightly.
K
3. Screw the center plate into the plate.
4. Insert the plate assembly on the guide bolt. Put the spring in,
and then evenly screw the three guide bolt nuts. When fastening L
the guide nuts, do not completely compress the spring.
M
SEIA0240E
5. Place the dent of alignment gauge onto the projection of the

center plate and tightly contact them to measure. N
Camber, caster, kingpin : Refer to FSU-28, "Wheel

inclination angles Alignment". O
CAUTION:
• If camber, caster, or kingpin inclination angle exceeds the
standard value, check front suspension parts for wear and P
damage. Replace suspect parts if a malfunction is
detected.
• Kingpin inclination angle is reference value, no inspection SEIA0241E
is required.
TOE-IN
Measure toe-in by the following procedure.
FSU-11
WHEEL ALIGNMENT
WARNING:
• Always perform the following procedure on a flat surface.
• Check that no person is in front of vehicle before pushing it.
1. Bounce front of vehicle up and down to stabilize the vehicle height (posture).
2. Push vehicle straight ahead about 5 m (16 ft).
3. Put matching mark on base line of the tread (rear side) of
both tires at the same height of hub center. These are measur-
ing points.
JPEIA0014ZZ
4. Measure distance (A) (rear side).
: Vehicle front
5. Push vehicle slowly ahead to rotate wheels 180 degrees (1/2

turn).
NOTE:
If the wheels rotates more than 180 degrees (1/2 turn), start this
procedure again from the beginning. Do not push the vehicle
backward.
6. Measure distance (B) (front side). JPEIA0015ZZ
Total toe-in = A – B
Total toe-in : Refer to FSU-28, "Wheel Alignment".
• If toe-in exceeds the standard value, adjust toe-in by varying the length of between steering outer socket
and inner socket. Refer toFSU-12, "Adjustment" FSU-12, "Adjustment".
Adjustment INFOID:0000000010414212
TOE-IN
• Loosen the steering outer socket, and then adjust the length using steering inner socket.
Toe-in : Refer to FSU-28, "Wheel Alignment".

CAUTION:
• Always evenly adjust both toe-in alternately and adjust the difference between the left and right to
the standard.
• Always fix the steering inner socket when tightening the steering outer socket.
• After toe-in adjustment, adjust neutral position of steering angle sensor. Refer to BRC-67, "Work Procedure".
FSU-12
FRONT COIL SPRING AND STRUT
B
FSU
JSEIA0946GB
H
Piston rod lock nut Mounting insulator Mounting bearing
Bumper rubber Dust cover Coil spring
Lower rubber seat Strut Steering knuckle
I

: Always replace after every disassembly. J
: Anti-corrosion oil
Removal and Installation INFOID:0000000010414214 K
REMOVAL
1. Remove tires. Refer to WT-65, "Removal and Installation". L
2. Remove lock plate and brake hose from strut assembly.
• RHD: Refer to BR-927, "FRONT : Exploded View". M
3. Remove wheel sensor. Refer to BRC-185, "FRONT WHEEL SENSOR : Removal and Installation".
4. Remove stabilizer connecting rod from strut assembly. Refer to FSU-20, "Removal and Installation".
N
5. Remove strut mounting bolts, nuts and strut from steering
knuckle.
6. Remove mounting bolt of mounting insulator, and then remove
strut assembly. O
JSEIA0685ZZ
INSTALLATION
FSU-13
• Install strut assembly in the direction shown in the figure of mout-
ing insulator.
: Vehicle front
: Vehicle outside
NOTE:
This figure shows right mounting insulator and the symmetric fig-
ure shows left.
• Never reuse strut mounting nut.
• Perform final tightening of fixing parts at the vehicle installation JSEIA0950ZZ
position (rubber bushing), under unladen conditions with tires on
level ground.
• Perform inspection after installation. Refer to FSU-17, "Inspection".
• After replacing the strut, always follow the disposal procedure to discard the strut. Refer to FSU-17, "Dis-
posal".
DISASSEMBLY
CAUTION:
Never damage strut assembly piston rod when removing components from strut assembly.
1. Install strut attachment (A) (SST: ST35652000) to strut assem-
bly and secure it in a vise.
CAUTION:
When installing the strut attachment to strut assembly,
wrap a shop cloth around strut to protect from damage.
JPEIA0006ZZ
2. Using a spring compressor (A) (commercial service tool), com-

press coil spring between spring upper seat and lower seat
(strut assembly) until coil spring with a spring compressor is
free.
CAUTION:
Be sure a spring compressor is securely attached to coil
spring. Compress coil spring.
JPEIA0007ZZ
3. Check coil spring with a spring compressor between spring

upper seat and lower seat (strut assembly) is free. And then
remove piston rod lock nut while securing the piston rod tip so
that piston rod does not turn.
4. Remove mounting insulator, mounting bearing, dust cover, and
bumper rubber from strut.
5. After removing coil spring with a spring compressor, then gradu-
ally release a spring compressor.
CAUTION:
Loosen while making sure coil spring attachment position
does not move. JSEIA0584ZZ
6. Remove lower rubber seat.

7. Perform inspection after disassembly. Refer to FSU-17, "Inspection".
FSU-14
ASSEMBLY
CAUTION: A
Never damage strut assembly piston rod when installing components from strut assembly.
1. Install strut attachment (SST: ST35652000) to strut and secure it in a vise.
CAUTION: B
When installing the strut attachment to strut assembly, wrap a shop cloth around strut to protect
from damage.
2. Install lower rubber seat. C
3. Compress coil spring using a spring compressor (commercial service tool), and install it onto strut assem-
bly.
CAUTION:
D
• Be sure a compressor is securely attached to coil spring. Compress coil spring.
• Set the coil spring so that its paint marks is aligned
with the position of 1.75 turns from the bottom end of the
coil spring. FSU
: Upper side
F
G
JSEIA0893ZZ
• Align the lower end of coil spring with lower rubber H

seat as shown in the figure.
Dimension (A) : 5 mm (0.20 in) or less I
4. Apply soapy water to bound bumper.

CAUTION:
J
Never use machine oil.
5. Insert bumper rubber into piston rod.
JSEIA0658ZZ
K
6. Install dust cover securely to strut cap .

7. Install mounting bearing. L
CAUTION:
Never apply oils, such as grease, when installing the
mounting bearing. M
JSEIA0951ZZ
O
8. Check the direction of the mounting insulator faced forward of
the vehicle and install it in the direction shown in the figure of the
mouting insulator to the strut.
P
: Vehicle front
: Vehicle outside
NOTE:
This figure shows right mounting insulator and the symmetric
figure shows left.
JSEIA0950ZZ
FSU-15
CAUTION:
Align the upper end of coil spring with upper rubber seat
as shown in the figure.
Dimension (A) : 5 mm (0.20 in) or less
JSEIA0992ZZ
9. Secure piston rod tip so that piston rod does not turn, then
tighten piston rod lock nut with specified torque.
CAUTION:
• Never reuse piston rod lock nut.
JSEIA0584ZZ
• After tightening, apply anti-corrosion oil to the end of

piston rod. Never let oil scatter outside the top surface
of mouting insulator.
JSEIA0952ZZ
10. Gradually release a spring compressor (A) (commercial service

tool), and remove from coil spring.
CAUTION:
Loosen while making sure coil spring attachment position
does not move.
JPEIA0007ZZ
FSU-16
11. Remove the strut attachment (A) (SST: ST35652000) from strut
assembly. A
JPEIA0006ZZ
D
INSPECTION AFTER DISASSEMBLY FSU

Check the following items, and replace the parts if necessary.
Strut
• Strut for deformation, cracks or damage F
• Piston rod for damage, uneven wear or distortion
• Oil leakage
Strut Mounting Insulator, bumper rubber and dust cover G
Check strut mounting insulator, bumper rubber and dust cover for cracks, wear or damage.
Coil Spring
Check coil spring for cracks, wear or damage. H
1. Check wheel sensor harness for proper connector. Refer to BRC-185, "FRONT WHEEL SENSOR :
I
Exploded View".
2. Check wheel alignment. Refer to FSU-11, "Inspection".
3. Adjust neutral position of steering angle sensor. Refer to BRC-67, "Work Procedure". J
Disposal INFOID:0000000010414217
1. Set strut assembly horizontally to the ground with the piston rod fully extracted. K
2. Drill 2 – 3 mm (0.08 – 0.12 in) dia. hole at the position ( ) from
top as shown in the figure to release gas gradually.
CAUTION: L
• Wear eye protection (safety glass).
• Wear gloves.
• Be careful with metal chips or oil blown out by the com-
M
pressed gas.
NOTE:
• Drill vertically in this direction ( ).
• Directly to the outer tube avoiding brackets. N
• The gas is clear, colorless, odorless, and harmless. JPEIA0160ZZ
A : 20 – 30 mm (0.79 – 1.18 in) O

3. Position the drilled hole downward and drain oil by moving the piston rod several times.
CAUTION:
Dispose of drained oil according to the law and local regulations. P
FSU-17
TRANSVERSE LINK
TRANSVERSE LINK
JSEIA0947GB
Front suspension member Transverse link

REMOVAL
2. Remove steering outer socket from steering knuckle so as not to
damage ball joint boot using suitable ball joint remover (com-
mercial service tool).
CAUTION:
Temporarily tighten the nut to prevent damage to threads
and to prevent the ball joint remover from sudden drop
turning.
3. Remove front suspension member. Refer to FSU-22, "Removal
and Installation"
NOTE:
Remove it with each component parts (front suspension mem- SGIA0184J
ber, reduction gear, traction motor, traction motor inverter, PDM
(power delivery module), steering gear assembly, stabilizer bar, transverse link).
4. Remove steering outer socket mounting nut temporarily tightened and separate steering outer socket
from steering knuckle. Refer to FAX-10, "Removal and Installation".
CAUTION:
Remove the nut while supporting steering knuckle.
5. Remove steering knuckle from transverse link. Refer to FAX-10, "Removal and Installation".
CAUTION:
Operate in two people because steering knuckle is heavy.
6. Remove stabilizer. Refer to FSU-20, "Removal and Installation".
7. Remove transverse link from suspension member.
NOTE:
To remove transverse link mounting nut, move stabilizer bar.
INSTALLATION
FSU-18
TRANSVERSE LINK
• Never reuse transverse link mounting nut. A
• Perform final tightening of fixing parts at the vehicle installation position (rubber bushing), under unladen
conditions with tires on level ground.
B
INSPECTION AFTER REMOVAL C

Check the following items, and replace the parts if necessary.
Transverse Link
• Transverse link and bushing for deformation, cracks or damage. D
• Ball joint boot for cracks or other damage, and also for grease leakage.
Swing Torque
FSU
1. Manually move ball stud to confirm it moves smoothly with no binding.
2. Move ball stud at least ten times by hand to check for smooth movement.
3. Hook a spring balance (A) at cutout on ball stud . Confirm F
spring balance measurement value is within specifications when
ball stud begins moving.
G
Swing torque : Refer to FSU-28, "Ball Joint".
Measurement on : Refer to FSU-28, "Ball Joint"
spring balance H
• If swing torque exceeds standard range, replace transverse link
assembly.
JPEIA0138ZZ
I
Axial End Play
1. Move ball stud at least ten times by hand to check for smooth movement.
2. Move tip of ball stud in axial direction to check for looseness. J
Axial end play : Refer to FSU-28, "Ball Joint".

K
• If axial end play exceeds the standard value, replace transverse link assembly.
1. Check wheel alignment. Refer to FSU-11, "Inspection". L
FSU-19
FRONT STABILIZER
FRONT STABILIZER
JSEIA0948GB
Stabilizer bar Stabilizer clamp Stabilizer bushing

Stabilizer connecting rod Strut assembly Front suspension member
REMOVAL
2. Remove stabilizer connecting rod .
3. Remove front suspension member. Refer to FSU-22, "Removal
and Installation".
NOTE:
Remove it with each component parts (front suspension mem-
ber, reduction gear, traction motor, traction motor inverter, PDM
(power delivery module), steering gear assembly, stabilizer bar,
transverse link).
JSEIA0597ZZ
4. Remove mounting bolts ( ) of stabilizer clamp, and then

remove stabilizer clamp and stabilizer bushing from front sus-
pension member.
5. Remove stabilizer bar.
6. Perform inspection after removal. Refer to FSU-21, "Inspection".
WEIA0182E
INSTALLATION
FSU-20
FRONT STABILIZER
• Install stabilizer clamp and stabilizer bush with notch and slit
faced forward of the vehicle ( ). A
JPEIA0058ZZ
D
• To install stabilizer clamp mounting bolt, follow the tightening
method and the numerical order shown below:
FSU
Manual tightening :1
Temporary tightening :2→ 3
Final tightening (Specified torque) :4→ 5 F
: Vehicle front
G
JPEIA0245GB
• To install stabilizer connecting rod , tighten the mounting nut with H

the hexagonal part on the stabilizer connecting rod side fixed.
• Perform final tightening of fixing parts at the vehicle installation
position (rubber bushing), under unladen conditions with tires on I
level ground.
J
JPEIA0252ZZ
K
L
Check stabilizer bar, stabilizer connecting rod, stabilizer bushing and stabilizer clamp for deformation, cracks
or damage. Replace it if necessary.
M
2. Adjust neutral position of steering angle sensor. Refer to BRC-67, "Work Procedure". N
FSU-21
FRONT SUSPENSION MEMBER
JSEIA0949GB
Front suspension member Rebound stopper rubber Insulator

Member stay Rebound stopper
DANGER:
maintenance.
WARNING:
• Refer to GI-29, "High Voltage Precautions".
CAUTION:
REMOVAL
WARNING:
Disconnect the high voltage. Refer to GI-27, "How to Disconnect High Voltage".
1. Check voltage in high voltage circuit. (Check that condenser are discharged.)
a. Lift up the vehicle and remove the Li-ion battery under covers. Refer to EVB-492, "Removal and Installa-
tion" (without battery cooler), EVB-788, "Removal and Installation" (with battery heater and amp : cooler).
FSU-22
b. Disconnect high voltage harness connector and PTC heater harness connector from front side of Li-ion
battery. Refer to EVB-213, "Exploded View" (Type 1), EVB-492, "Exploded View" (Type 2). A
c. Measure voltage between high voltage harness connector terminals and PTC heater harness connector
terminals.
B
JPCIA0296ZZ
DANGER: FSU
F
G
CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher. H
2. Drain coolant. Refer to HCO-11, "Draining".

3. Remove front under cover. Refer to EXT-27, "FRONT UNDER COVER : Exploded View". I
5. Remove fender protector (right side). Refer to EXT-26, "Removal and Installation".
6. Remove mouting bolt, ground cable and bracket of traction J
motor from vehicle.
WARNING:
K
To prevent electric shock hazards, be sure to wear
protective gear.
L
JSEIA0616ZZ
M
7. Disconnect the high voltage harness connector from electric compressor. Refer to HA-34, "Removal and
Installation" . N
WARNING:
• To prevent electric shock hazards, be sure to wear protective gear.

O
FSU-23
• Follow the procedure below and disconnect the high voltage harness connector.
JPCIA0035ZZ
8. Disconnect the low voltage harness connector from electric compressor. Refer to HA-34, "Removal and
Installation" .
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
9. Remove electric compressor mounting bolt. Hang electric compressor not to interfere with work. Refer to
HA-34, "Exploded View" (with heat pump system), HA-101, "Exploded View" (without heat pump system).
WARNING:
CAUTION:
Never apply excessive stress to high-pressure flexible hose and low-pressure flexible hose.
10. Disconnect 12V battery negative cable and remove bracket

, and disconnect 12V battery positive cable of PDM (power
delivery module).
: Vehicle front
11. Remove quick charge port. Refer to VC-122, "Removal and

Installation".
12. Remove normal charge port. Refer to VC-127, "Removal and
Installation".
13. Remove parking cable of reduction gear. Refer to TM-20, JPCIA0304ZZ
14. Disconnect low voltage harness connectors and remove har-

ness clip . And then remove low voltage harness from vehicle.
JSEIA1035ZZ
FSU-24
15. Remove water hose (upper side) from PDM (power delivery
module). A
WARNING:
To prevent electric shock hazards, be sure to wear B

protective gear.
C
CAUTION:
• Take care that coolant does not contact the high voltage JSEIA1036ZZ
harness connectors. D
• If coolant contacts a high voltage harness connector, immediately use an air blow and fully
remove the liquid.
FSU
16. Remove water hose (lower side) from traction motor.
WARNING:
F
To prevent electric shock hazards, be sure to wear
protective gear.
G
CAUTION:
• Take care that coolant does not contact the high voltage H
harness connectors. JSEIA0614ZZ
• If coolant contacts a high voltage harness connector,
immediately use an air blow and fully remove the liquid. I
17. Remove drive shaft. Refer to FAX-22, "Removal and Installation".

18. Separate stabilizer connecting rod from strut assembly. Refer to FSU-20, "Removal and Installation". J
19. Separate steering shaft from steering gear assembly. Refer to ST-38, "Removal and Installation".
20. Set suitable jack under front suspension member.
CAUTION: K
• Never damage the front suspension member with a jack.
• Check the stable condition when using a jack.
21. Remove member stay and rebound stopper. L
22. Remove suspension member mounting bolts, insulator, and
rebound stopper rubber.
23. Gradually lower the jack to remove front suspension member M
from vehicle body.
CAUTION:
Operate while checking that jack supporting status is sta- JPEIA0285ZZ
N
ble.
NOTE:
Remove it with each component parts (front suspension member, reduction gear, traction motor, traction
motor inverter, PDM (power delivery module), steering gear assembly, stabilizer bar, transverse link). O
24. Remove the following parts from front suspension member.
• Reduction gear: Refer to TM-24, "Removal and Installation".
• Traction motor: Refer to TMS-112, "Removal and Installation". P
• Traction motor inverter: Refer to TMS-106, "Removal and Installation".
• PDM (power delivery module): Refer to VC-108, "Removal and Installation".
• Steering gear assembly : Refer to ST-43, "Removal and Installation".
• Stabilizer bar: Refer to FSU-20, "Removal and Installation".
• Transverse link: Refer to FSU-18, "Removal and Installation".
25. Perform inspection after removal. Refer to FSU-26, "Inspection and Adjustment".
INSTALLATION
FSU-25
WARNING:
CAUTION:
Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace it
• Follow the procedure below and connect the high voltage harness connector.
JPCIA0036ZZ
• To install rebound stopper , insert it with the protrusion aligned

with the hole of member stay .
JSEIA0991ZZ
• To install member stay and mounting bolts of front suspension

member, temporarily tighten the bolts before tightening to the
specified torque, referring to the tightening method and the numer-
ical order shown below:
Temporary tightening :1→2→3→4→5→6→7→8

Final tightening
:1→2→3→4→5→6→7→8
(Specified torque)
: Vehicle front
JSEIA0953ZZ
• Perform final tightening of fixing parts at the vehicle installation
position (rubber bushing), under unladen conditions with tires on level ground.
• Perform inspection and adjustment after installation. Refer to FSU-19, "Inspection".
Inspection and Adjustment INFOID:0000000010414226

Check front suspension member for cracks, wear or damage. Replace it if necessary.
1. When all parts are installed, be sure to check equipotential of traction motor, electric compressor, and
traction motor inverter.
• Traction motor: Refer to TMS-115, "Inspection and Adjustment".
• Electric compressor: Refer to HA-38, "Inspection".
• Traction motor inverter: Refer to TMS-110, "Inspection and Adjustment".
FSU-26
3. Adjust neutral position of steering angle sensor. Refer to BRC-67, "Work Procedure". A
FSU
FSU-27
Wheel Alignment INFOID:0000000010414227
Item Standard
Minimum –1° 05′ (–1.08°)
Camber Nominal –0° 20′ (–0.33°)

Degree minute (Decimal degree) Maximum 0° 25′ (0.42°)
Left and right difference*1 –0° 45′ (–0.75°) - 0° 45′ (0.75°)

Minimum 3° 45′ (3.75°)
Caster Nominal 4° 30′ (4.50°)

Degree minute (Decimal degree) Maximum 5° 15′ (5.25°)
Left and right difference*1 –0° 45′ (–0.75°) - 0° 45′ (0.75°)

Minimum 11° 10′ (11.17°)
Kingpin inclination
Nominal 11° 55′ (11.92°)
Degree minute (Decimal degree)
Maximum 12° 40′ (12.66°)
Minimum Out 1 mm (Out 0.04 in)
Total toe-in
Nominal In 1 mm (In 0.04 in)
Distance
Maximum In 3 mm (In 0.12 in)
Toe-in
Minimum Out 0° 05’ (Out 0.08°)
Total toe angle
Nominal In 0° 07’ (In 0.12°)
Maximum In 0° 19’ (In 0.31°)
Measure value under unladen*2 conditions.

*1: A difference when assuming the left side a standard.
*2: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.
Ball Joint INFOID:0000000010414228
Item Standard
Swing torque 0.5 – 4.9 N·m (0.06 – 0.49 kg-m, 5 – 43 in-lb)
Measurement on spring balance 15.4 – 150.8 N (1.6 – 15.3 kg, 3.5 – 33.8 lb)
Axial end play 0 mm (0 in)
Wheelarch Height INFOID:0000000010414229
Item Standard
Front (Hf) 697 mm (27.44 in)
FSU-28
Item Standard
A
Rear (Hr) 708 mm (27.87 in)
JSEIA0559ZZ
FSU
Measure value under unladen* conditions.
*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.
FSU-29
SUSPENSION
SECTION RSU
REAR SUSPENSION
B
RSU
CONTENTS
PRECAUTION ............................................... 2 Removal and Installation .......................................... 9 F
Inspection ................................................................. 9
PRECAUTIONS ................................................... 2 Disposal .................................................................... 9
Precaution Necessary for Steering Wheel Rota- LEAF SPRING ................................................... 11
tion after 12V Battery Disconnect .............................. 2 Exploded View .........................................................11
Precautions for Removing Battery Terminal ............. 3 Removal and Installation .........................................11
Inspection ................................................................12 H
Precautions for Suspension ...................................... 3
SYMPTOM DIAGNOSIS ............................... 5 REAR STABILIZER .......................................... 13

Exploded View (Except for Hong Kong) ..................13 I
NOISE, VIBRATION AND HARSHNESS Removal and Installation (Except for Hong Kong)....13
(NVH) TROUBLESHOOTING ............................. 5 Inspection (Except for Hong Kong) ..........................13
REAR SUSPENSION BEAM ............................ 14 J
PERIODIC MAINTENANCE .......................... 6 Exploded View .........................................................14
REAR SUSPENSION ASSEMBLY ..................... 6 Inspection ................................................................15 K
Inspection .................................................................. 6
WHEEL ALIGNMENT .......................................... 7 (SDS) ............................................................ 16
Inspection .................................................................. 7 L
REMOVAL AND INSTALLATION ................ 9 (SDS) ................................................................. 16
Wheel Alignment .....................................................16 M
REAR SHOCK ABSORBER ............................... 9
Exploded View .......................................................... 9 Wheelarch Height ....................................................16
RSU-1
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
WARNING:
TCU use.
WARNING:
INFOID:0000000011237859
OPERATION PROCEDURE
NOTE:
RSU-2
PRECAUTIONS
< PRECAUTION >
disconnected and the steering wheel can be turned. A
turn the power switch from ACC position to ON position, then to LOCK position. (The steering wheel will B
NOTE: C
tion.
Precautions for Removing Battery Terminal INFOID:0000000010414233 D
switch and wait at least 5 minutes. RSU
NOTE:
then a DTC detection error or ECU data corruption may occur. F
OFF, the 12V battery automatic charge control may automatically G
SEF289H
WORK PROCEDURE H
NOTE:
If EVSE is connected, the air conditioning system may be automatically activated by the timer A/C func- I
tion.
3. Check that the charge status indicator lamp does not blink and wait for 5 minutes or more. J
NOTE:
detected. K
CAUTION:
• After all doors (including back door) are closed, if a door (including back door) is opened before L
NOTE: M
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON N
the power switch.
NOTE:
then DTC may be detected. O
NOTE:
The removal of 12V battery may cause a DTC detection error. P
Precautions for Suspension INFOID:0000000010414234
• When installing rubber bushings, the final tightening must be carried out under unladen conditions with tires
on ground. Spilled oil might shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
- Unladen conditions mean that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and
• After servicing suspension parts, be sure to check wheel alignment.
RSU-3
PRECAUTIONS
< PRECAUTION >
• Self-lock nuts are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-oiled,
tighten as they are.
• The tightening surface must be kept free from oil/grease.
• When jacking up the vehicle with a floor jack, never hang the jack on the torque rod.
RSU-4
SYMPTOM DIAGNOSIS A
B
RSU-9, RSU-11, RSU-13, RSU-14
RSU-9, RSU-11, RSU-13, RSU-14
NVH in RAX and RSU sections

C
NVH in WT section
NVH in WT section
NVH in BR section
D
RSU-12
RSU-9
RSU-7
—
—
Reference
RSU
Shock absorber deformation, damage or deflection

G
REAR AXLE AND REAR SUSPENSION

Bushing or mounting deterioration
Improper installation, looseness H
Incorrect wheel alignment

Suspension looseness
I
Parts interference
ROAD WHEEL
Spring fatigue J
BRAKE
TIRE
K
Noise × × × × × × × × × ×
Shake × × × × × × × × ×
Vibration × × × × × × × L
Symptom REAR SUSPENSION
Shimmy × × × × × × × × ×
Judder × × × × × × ×
M
Poor quality ride or handling × × × × × × × × ×
×: Applicable
N
RSU-5
REAR SUSPENSION ASSEMBLY
REAR SUSPENSION ASSEMBLY
COMPONENT PART
Check the mounting conditions (looseness, backlash) of each component and component conditions (wear,
damage) are normal.
SHOCK ABSORBER ASSEMBLY
Check for oil leakage, damage, and replace if necessary.
RSU-6
WHEEL ALIGNMENT
WHEEL ALIGNMENT
A
DESCRIPTION B
CAUTION:
• The adjustment mechanisms of camber and toe-in are not included.
• If camber and toe-in is outside the standard, check front suspension parts for wear and damage. C
Replace suspect parts if a malfunction is detected.
Measure wheel alignment under unladen conditions.
NOTE:
“Unladen conditions” means that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools and D
PRELIMINARY CHECK
RSU
• Tires for improper air pressure and wear. Refer to WT-71, "Tire Air Pressure".
• Road wheels for runout.
• Wheel bearing axial end play. Refer to RAX-8, "Inspection". F
• Shock absorber operation
• Each mounting point of axle and suspension for looseness and deformation
• Each of rear suspension beam and shock absorber for cracks, deformation, and other damage
G
• Vehicle height (posture)
CAMBER
• Measure camber of both right and left wheels with a suitable align- H
ment gauge.
• If camber is outside specified range, replace rear suspension
beam. Refer to RSU-14, "Removal and Installation".
I
Camber : Refer to RSU-16, "Wheel Alignment".
SRA096A K
TOE-IN
Measure toe-in by the following procedure.
L
WARNING:
• Always perform the following procedure on a flat surface.
• Check that no person is in front of vehicle before pushing it.
1. Bounce the front of vehicle up and down to stabilize the vehicle height (posture). M
2. Push vehicle straight ahead about 5 m (16 ft).
3. Put matching mark on base line of the tread (rear side) of
both tires at the same height of hub center. These are measur- N
ing points.
JPEIA0014ZZ
RSU-7
WHEEL ALIGNMENT
4. Measure distance (A) (rear side).
: Vehicle front
5. Push vehicle slowly ahead to rotate wheels 180 degrees (1/2

turn).
NOTE:
If the wheels rotates more than 180 degrees (1/2 turn), start this
procedure again from the beginning. Do not push the vehicle
backward.
6. Measure distance (B) (front side). JPEIA0015ZZ
Total toe-in = A − B
Total toe-in : Refer to RSU-16, "Wheel Alignment".
• If toe-in is outside specified range, replace rear suspension beam. Refer to RSU-14, "Removal and
Installation".
RSU-8
REAR SHOCK ABSORBER
REAR SHOCK ABSORBER
B
RSU
JSEIA0954GB
H
Shock absorber Rear suspension beam

I
REMOVAL J
2. Remove shock absorber mounting bolt and nut (lower side).
K
3. Remove shock absorber mounting nut (upper side).
4. Remove shock absorber from the vehicle.
INSTALLATION L
• Perform final tightening of bolts and nuts at the shock absorber side (rubber bushing), under unladen condi-
tions with tires on level ground. M
INSPECTION AFTER REMOVAL N
Shock Absorber
O
• Shock absorber for deformation, cracks, and other damage.
• Piston rod for damage, uneven wear, and distortion.
• Welded and sealed areas for oil leakage.
P
Check wheel alignment. Refer to RSU-7, "Inspection".
Disposal INFOID:0000000010779451
1. Set shock absorber horizontally to the ground with the piston rod fully extracted.
RSU-9
REAR SHOCK ABSORBER
2. Drill 2 – 3 mm (0.08 – 0.12 in) hole at the position ( ) from top
as shown in the figure to release gas gradually.
CAUTION:
• Wear eye protection (safety glass).
• Wear gloves.
• Be careful with metal chips or oil blown out by the com-
pressed gas.
NOTE:
• Drill vertically in this direction ( ).
• Directly to the outer tube avoiding brackets.
• The gas is clear, colorless, odorless, and harmless. JPEIA0161ZZ
A : 20 – 30 mm (0.79 – 1.18 in)

3. Position the drilled hole downward and drain oil by moving the piston rod several times.
CAUTION:
Dispose of drained oil according to the law and local regulations.
RSU-10
LEAF SPRING
LEAF SPRING
A
RSU
G
JSEIA0955GB
Bound bumper Spring upper seat Leaf spring

H
Spring clip Rear suspension beam Inside shackle
Upper bushing Outside shackle
: N·m (kg-m, ft-lb) I

Removal and Installation INFOID:0000000010779453 J
REMOVAL
1. Remove tires. Refer to WT-65, "Removal and Installation". K
2. Remove wheel sensor harness clamp from leaf spring. Refer to BRC-186, "REAR WHEEL SENSOR :
L
3. Set jack under rear suspension beam.
CAUTION:
Check the stable condition when using a jack.
4. Remove mounting nuts from spring upper seat, and then remove spring upper seat and spring clip. M
5. Remove mounting nuts, and then remove inside shackle from the vehicle.
6. Remove leaf spring mounting bolt and nut (front side).
N
7. Remove leaf spring from the vehicle with the following procedure.
a. Slide leaf spring to vehicle rear side.
O
JSEIA1037ZZ
RSU-11
LEAF SPRING
b. Remove leaf spring while turning it.
JSEIA1038ZZ
INSTALLATION
• To install spring upper seat and spring clip, temporarily tighten the
nuts before tightening to the specified torque, referring to the tight-
ening method and the numberical order shown below:
Temporary tightening :1→2→3→4

Final tightening
:1→4→2→3→1→4
(Specified torque)
: Vehicle front
: Vehicle outside
JSEIA0993ZZ
NOTE:
This figure shows left side and the symmetric figure shows right side.
• Perform final tightening of leaf spring installation position (rubber bushing), under unladen conditions with
tires on level ground.
• When tightening bolts and nuts of leaf spring and shackle, be care full with the damage and excessive distor-
tion.

Check leaf spring, shackle, spring seat (upper and lower), and bushing for deformation, crack, and damage.
Replace it if necessary.
• Check wheel alignment. Refer to RSU-7, "Inspection".
• Check wheel sensor harness for proper connection. Refer to BRC-188, "REAR SENSOR ROTOR : Removal
and Installation".
RSU-12
REAR STABILIZER
REAR STABILIZER
A
Exploded View (Except for Hong Kong) INFOID:0000000010779455
NOTE: B
The rear stabilizer is not equipped for the models for Hong Kong.
RSU
JSEIA0956GB
H
Stabilizer bar Stabilizer bushing Stabilizer clamp
Stabilizer connecting rod mount Stabilizer connecting rod Rear suspension beam
bracket I
Removal and Installation (Except for Hong Kong) INFOID:0000000010779456 J
NOTE:
The rear stabilizer is not equipped for the models for Hong Kong. K
REMOVAL
1. Remove stabilizer connecting rods.
2. Remove stabilizer clamps, and then remove stabilizer bushings. L
3. Remove stabilizer bar.
4. Remove stabilizer connecting rod mounting brackets from the vehicle.
M
INSTALLATION
• Tighten the mounting nut to the specified torque while holding a hexagonal part of stabilizer connecting rod N
side.
Inspection (Except for Hong Kong) INFOID:0000000010779457
O
NOTE:
The rear stabilizer is not equipped for the models for Hong Kong.
INSPECTION AFTER REMOVAL P
Check stabilizer bar, stabilizer bushing, stabilizer clamp, stabilizer connecting rod, and stabilizer connecting
rod mounting bracket for any deformation, crack or damage. Replace if necessary.
RSU-13
REAR SUSPENSION BEAM
JSEIA0954GB
Shock absorber Rear suspension beam
:N·m (kg-m, ft-lb)
REMOVAL
2. Drain brake fluid. Refer to BR-435, "Draining".
3. Remove parking brake cable and brake drum from rear suspension beam. Refer to PB-10, "Removal and
Installation" and BR-482, "BRAKE CALIPER ASSEMBLY : Removal and Installation".
4. Remove wheel sensor and sensor harness. Refer to BRC-186, "REAR WHEEL SENSOR : Removal and
Installation".
5. Separate brake hose and brake tube. Refer to BR-451, "REAR : Removal and Installation".
6. Set suitable jack under rear suspension beam.
CAUTION:
7. Remove shock absorber mounting bolts and nuts (lower side). Refer to RSU-9, "Removal and Installa-
tion".
8. Remove leaf springs. Refer to RSU-11, "Removal and Installation".
9. Slowly lower jack, remove suspension arm bracket and rear suspension beam from vehicle body.
CAUTION:
10. Remove brake tube from rear suspension beam. Refer to BR-450, "REAR : Exploded View" (LHD) or BR-
930, "REAR : Exploded View" (RHD).
11. Remove wheel hub and bearing assembly. Refer to RAX-7, "Removal and Installation".
INSTALLATION
• Perform final tightening of rear suspension beam installation position (rubber bushing), under unladen condi-
tions with tires on level ground.
• Refill with new brake fluid and perform the air bleeding. Refer to BR-436, "Refilling" (LHD) or BR-916, "Refill-
ing" (RHD).
RSU-14
A
Check rear suspension beam for deformation, cracks or damage. Replace the part if necessary.
B
1. Check wheel sensor harness for proper connection. Refer to BRC-186, "REAR WHEEL SENSOR :
C
2. Adjust parking brake. Refer to PB-7, "Inspection and Adjustment".
3. Check wheel alignment. Refer to RSU-7, "Inspection".
D
RSU
RSU-15
Wheel Alignment INFOID:0000000010779469
Item Standard
Minimum –2° 00′ (–2.00°)
Camber
Nominal –1° 00′ (–1.00°)
Maximum –1° 00′ (–1.00°)
Minimum Out 2.0 mm (0.08 in)
Total toe-in
Nominal In 3.0 mm (0.12 in)
Distance
Maximum In 8.0 mm (0.31 in)
Toe-in
Minimum Out 0° 13′ 22″ (0.22°)
Total toe angle
Nominal In 0° 16′ 48″ (0.28°)
Maximum In 0° 46′ 48″ (0.78°)
Wheelarch Height INFOID:0000000010779470
Item Standard
Front (Hf) 697 mm (27.44 in)
Rear (Hr) 708 mm (27.87 in)
JSEIA0559ZZ

RSU-16
SUSPENSION
SECTION
ROAD WHEELS & TIRES
WT B
WT
CONTENTS
PRECAUTION ............................................... 4 OPERATION ..................................................... 16 F
TPMS reset operation ..............................................16
PRECAUTIONS ................................................... 4
Precaution for Technicians Using Medical Electric...... 4 DIAGNOSIS SYSTEM (LOW TIRE PRES- G
Precaution for Supplemental Restraint System SURE WARNING CONTROL UNIT) ................. 17
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- CONSULT Function .................................................17
SIONER" ................................................................... 4
ECU DIAGNOSIS INFORMATION .............. 20 H
tion after 12V Battery Disconnect .............................. 5
Precautions for Removing Battery Terminal ....

ENV200 Workshop Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ENV200 Workshop Manual

Uploaded by

Copyright:

Available Formats

QUICK REFERENCE INDEX

© 2014 NISSAN INTERNATIONAL SA

IMPORTANT SAFETY NOTICE

Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)

Cap Bleeder valve Cylinder body

1. Test group number and test group title

Each section includes wiring diagrams.

Fuse • “/” means the fuse.

Relay • This shows an internal representation of the relay.

Component name • This shows the name of a component.

Ground (GND) • This shows the ground connection.

Connector Information INFOID:0000000010957616

HOW TO USE CONNECTOR INFORMATION

The following ABBREVIATIONS are used:

ECL Engine coolant level

PFCW Predictive forward collision warning

Hexagonal Tightening torque

PRECAUTION AT TELEMATICS SYSTEM OPERATION

Precautions for Removing Battery Terminal INFOID:0000000010411421

• Before jacking up the vehicle, apply wheel chocks or other tire

• Before starting repairs which do not require battery power:

• To prevent serious burns:

HOSE REMOVAL AND INSTALLATION

• To reinstall the rubber hose securely, check that hose insertion

Air Conditioning INFOID:0000000010411431

PROCEDURE FOR DISCONNECTING HIGH VOLTAGE B

4. Remove fixing screw and disengage fixing metal clips, and

6. Remove service plug as follows.

Touching high voltage components without using the

Check Voltage in High Voltage Circuit INFOID:0000000011061787

• There is the danger of electric shock caused by

• Because there is the danger of electric shock, imme- JSCIA1070ZZ

• Follow the procedure below to disconnect the high-voltage harness connector.

3. Disconnect the Li-ion battery heater harness connector .

• There is the danger of electric shock caused by

LOCATION TO APPLY HIGH VOLTAGE WARNING LABEL

No. Position to apply Refer to

: Hold glove and fold as shown in the figure.

• Insulated safety shoes J

Tool name Description

Safety stand attachment

Board-On Lift INFOID:0000000010411440

Fuse block METER 1 fuse

Destination Body Motor Axle Handle Transmission Grade Model

Information About Identification or Model Code INFOID:0000000010411406

Vehicle identification number plate Vehicle identification label Tire placard

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT H

Type approval number Vehicle identification number Maximum vehicle weight

Built date Vehicle identification number Maximum vehicle weight

For Hong Kong

Vehicle identification number Maximum vehicle weight Maximum train weight

MOTOR SERIAL NUMBER

Overall length 4,560 (179.5)

Road wheel Size 15 × 6J

Road wheel Size 15 × 6J

Control Units and Electrical Parts INFOID:0000000010411445

Connector & Harness

COLD OR HOT START UP L

Continuity Check Method

Resistance Check Method D

VOLTAGE DROP TESTS

Measuring Voltage Drop — Step-by-Step

INPUT-OUTPUT VOLTAGE CHART