Ev Battery System: Section

ELECTRIC POWER TRAIN
SECTION
EV BATTERY SYSTEM
EVB B
EVB
E
CONTENTS
TYPE 1 Circuit Diagram ........................................................34 F
HOW TO USE THIS MANUAL ..................... 14 HANDLING PRECAUTION ............................... 37

EV Battery System ..................................................37
G
APPLICATION NOTICE .....................................14
How to Check Vehicle Type .................................... 14 DIAGNOSIS SYSTEM (LBC) ............................ 38
CONSULT Function .................................................38
PRECAUTION .............................................. 15 H
ECU DIAGNOSIS INFORMATION .............. 40
PRECAUTIONS ..................................................15
Precaution for Technicians Using Medical Electric.... 15 EV BATTERY SYSTEM .................................... 40
Reference Value ......................................................40 I
Point to Be Checked Before Starting Maintenance
Work ........................................................................ 15 Fail-safe ...................................................................45
Precaution for Supplemental Restraint System DTC Index ...............................................................50
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- J
SIONER" ................................................................. 15
WIRING DIAGRAM ...................................... 55
Precaution Necessary for Steering Wheel Rota- VCM ................................................................... 55
tion after 12V Battery Disconnect ............................ 16 Wiring Diagram ........................................................55 K
Precaution for Procedure without Cowl Top Cover.... 17
Precautions for Removing Battery Terminal ........... 17 BASIC INSPECTION ................................... 59
High Voltage Precautions ........................................ 17 L
DIAGNOSIS AND REPAIR WORK FLOW ....... 59
PREPARATION ........................................... 20 Work Flow ................................................................59
Diagnostic Work Sheet ............................................60
PREPARATION ..................................................20 M
Special Service Tools .............................................. 20 ADDITIONAL SERVICE WHEN REPLACING
Commercial Service Tools ...................................... 20 LI-ION BATTERY CONTROLLER .................... 62
Description ...............................................................62 N
SYSTEM DESCRIPTION ............................. 25 Work Procedure .......................................................62
COMPONENT PARTS .......................................25 MODULE CHARGE BALANCE ........................ 63
Component Parts Location ...................................... 25 Description ...............................................................63 O
Li-ion Battery ........................................................... 26 Work Procedure .......................................................63
Li-ion Battery Controller .......................................... 26
Module .................................................................... 27 DTC/CIRCUIT DIAGNOSIS ......................... 65 P
Battery Temperature Sensor ................................... 28
Battery Junction Box ............................................... 28 P0A0D HV SYSTEM INTERLOCK ERROR ..... 65
Service Plug ............................................................ 29 DTC Logic ................................................................65
High Voltage Warning Label ................................... 29 Diagnosis Procedure ...............................................65
SYSTEM .............................................................31 P0A1F BATTERY ENERGY CONTROL MOD-

System Description ................................................. 31 ULE .................................................................... 67
Revision: 2014 June EVB-1 2012 LEAF

DTC Logic ............................................................... 67 DTC Logic ............................................................... 88
Diagnosis Procedure .............................................. 67 Diagnosis Procedure ............................................... 88
P3030 CELL CONTROLLER LIN ...................... 68 P30FE 12V BATTERY VOLTAGE .................... 89
P3031-P303C CELL CONTROLLER ASIC ....... 69 P318D COMMUNICATION ERROR .................. 91

P303D-P3048 CELL CONTROLLER ASIC ....... 70 P318E COMMUNICATION ERROR .................. 92

P3049-P3054 CELL CONTROLLER ASIC P3191 COMMUNICATION ERROR .................. 93

VOLTAGE .......................................................... 71 DTC Logic ............................................................... 93
DTC Logic ............................................................... 71 Diagnosis Procedure ............................................... 93
Diagnosis Procedure .............................................. 71
P3196 COMMUNICATION ERROR .................. 94
P3055-P3060 CELL CONTROLLER ASIC DTC Logic ............................................................... 94
VOLTAGE .......................................................... 73 Diagnosis Procedure ............................................... 94
DTC Logic ............................................................... 73
P3199 COMMUNICATION ERROR .................. 95
DTC Logic ............................................................... 95
P3061 CELL BATTERY VOLTAGE .................. 75 Diagnosis Procedure ............................................... 95
DTC Logic ............................................................... 75
P319C COMMUNICATION ERROR .................. 96
DTC Logic ............................................................... 96
P3062 BYPASS SWITCH .................................. 76 Diagnosis Procedure ............................................... 96
DTC Logic ............................................................... 76
P31A4 CAN ERROR VCM ................................ 97
DTC Logic ............................................................... 97
P308B-P3096 CELL CONTROLLER ASIC Diagnosis Procedure ............................................... 97
OPEN ................................................................. 77
P31A7 CAN ERROR INV/MC ............................ 98
DTC Logic ............................................................... 77
DTC Logic ............................................................... 98
Diagnosis Procedure ............................................... 98
P3097-P30A2 CELL CONTROLLER ASIC
P3300 TOTAL VOLTAGE OVER ...................... 99
OPEN ................................................................. 80 DTC Logic ............................................................... 99
DTC Logic ............................................................... 80 Diagnosis Procedure ............................................... 99
P3302-P330D CELL OVER VOLTAGE ............ 100
P30F3 TOTAL VOLTAGE SENSOR ................. 83 DTC Logic ............................................................. 100
DTC Logic ............................................................... 83
Diagnosis Procedure ............................................. 100
Component Inspection .......................................... 102
P30F4 TOTAL VOLTAGE SENSOR ................. 84 P330E-P3319 CELL OVER VOLTAGE ............ 103
DTC Logic ............................................................... 84
DTC Logic ............................................................. 103
Component Inspection ............................................ 85
P30F5 TOTAL VOLTAGE SENSOR ................. 86 P331A-P3325 CELL OVER VOLTAGE ............ 106
DTC Logic ............................................................... 86
DTC Logic ............................................................. 106
P30FC OVER CURRENT .................................. 87 Component Inspection .......................................... 108
DTC Logic ............................................................... 87 P3326-P3331 CELL OVER VOLTAGE ............ 109
DTC Logic ............................................................. 109
P30FD TOTAL VOLTAGE MONITOR Diagnosis Procedure ............................................. 109
SWITCH ............................................................. 88 Component Inspection .......................................... 111

P3373 TOTAL VOLTAGE OVER DIS- Component Inspection ........................................... 137
CHARGE .......................................................... 112 A
DTC Logic ............................................................. 112
P33E6 CELL VOLTAGE DEVIATION DIAG ... 138
DTC Logic .............................................................. 138
B
P3375-P3380 CELL OVER DISCHARGE ........ 113
DTC Logic ............................................................. 113
P33E7 CELL CONTROLLER .......................... 142
DTC Logic .............................................................. 142
Diagnosis Procedure ............................................. 142 EVB
P3381-P338C CELL OVER DISCHARGE ....... 116 P33ED BATTERY PARALLEL DIAGNOSIS .. 143
DTC Logic .............................................................. 143
DTC Logic ............................................................. 116 D
Component Inspection .......................................... 118 U1000 CAN COMM CIRCUIT ......................... 145
P338D-P3398 CELL OVER DISCHARGE ....... 119 Description ............................................................. 145 E
DTC Logic .............................................................. 145
DTC Logic ............................................................. 119
Component Inspection .......................................... 121 LI-ION BATTERY INSULATION RESIS- F
P3399-P33A4 CELL OVER DISCHARGE ....... 122 TANCE LOSS CHECK .................................... 146
DTC Logic ............................................................. 122 Component Inspection ........................................... 146
Diagnosis Procedure ............................................. 122 G
POWER SUPPLY AND GROUND CIRCUIT .. 156
P33D4 BATT GRADUAL CAPA LOSS DIAG.. 125 H
SYMPTOM DIAGNOSIS ............................ 159
DTC Logic ............................................................. 125
Diagnosis Procedure ............................................. 125 REDUCTION IN THE DRIVING RANGE ......... 159
Description ............................................................. 159 I
P33D5 CURRENT SENSOR ............................ 126
DTC Logic ............................................................. 126
Diagnosis Procedure ............................................. 126 PERIODIC MAINTENANCE ...................... 160
J
P33D6 CURRENT SENSOR ............................ 128 EV BATTERY USAGE REPORT .................... 160
DTC Logic ............................................................. 128 Inspection .............................................................. 160
UNIT REMOVAL AND INSTALLATION .... 161 K
P33D7, P33D9, P33DB, P33DD TEMPERA-
TURE SENSOR ................................................ 130 LI-ION BATTERY ............................................ 161
DTC Logic ............................................................. 130 Exploded View ....................................................... 161 L
Diagnosis Procedure ............................................. 130 Removal and Installation ....................................... 161
Component Inspection .......................................... 131 Inspection .............................................................. 167
P33DF BAT VOLTAGE ISOLATION SEN ....... 132 UNIT DISASSEMBLY AND ASSEMBLY . 168 M
DTC Logic ............................................................. 132
Diagnosis Procedure ............................................. 132 LI-ION BATTERY ............................................ 168
Exploded view ....................................................... 168 N
P33E0 BAT VOLTAGE ISOLATION SEN ....... 133
DTC Logic ............................................................. 133 BATTERY JUNCTION BOX .................................... 174
Diagnosis Procedure ............................................. 133 BATTERY JUNCTION BOX : Disassembly and
Assembly ............................................................... 174 O
P33E1 BAT VOLTAGE ISOLATION SEN ....... 134 BATTERY JUNCTION BOX : Inspection ............... 179
DTC Logic ............................................................. 134
Diagnosis Procedure ............................................. 134 LI-ION BATTERY CONTROLLER ........................... 181
P
LI-ION BATTERY CONTROLLER : Disassembly
P33E2 BATT PACK OVER TEMP ................... 135 and Assembly ........................................................ 181
DTC Logic ............................................................. 135 LI-ION BATTERY CONTROLLER : Inspection ..... 186
FRONT MODULE STACK ....................................... 188
P33E4, P33E5 TEMPERATURE SENSOR ...... 136 FRONT MODULE STACK : Disassembly and As-
DTC Logic ............................................................. 136 sembly ................................................................... 188
Diagnosis Procedure ............................................. 136 FRONT MODULE STACK : Inspection ................. 196

REAR MODULE STACK ..........................................198 LI-ION BATTERY HEATER CONTROL SYSTEM
REAR MODULE STACK : Disassembly and As- : System Description ............................................. 238
sembly ...................................................................198 Circuit Diagram ..................................................... 240
REAR MODULE STACK : Inspection ....................212
HANDLING PRECAUTION .............................. 245
SERVICE DATA AND SPECIFICATIONS EV Battery System ................................................ 245
(SDS) .......................................................... 215
DIAGNOSIS SYSTEM (LBC) ........................... 246
SERVICE DATA AND SPECIFICATIONS CONSULT Function .............................................. 246
(SDS) ................................................................ 215
ECU DIAGNOSIS INFORMATION ............ 248
Li-ion Battery .........................................................215
TYPE 2 EV BATTERY SYSTEM .................................... 248
Reference Value ................................................... 248
HOW TO USE THIS MANUAL ................... 216 Fail-safe ................................................................ 253
DTC Index ............................................................. 258
APPLICATION NOTICE .................................. 216
How to Check Vehicle Type ..................................216 WIRING DIAGRAM ................................... 264
PRECAUTION ............................................ 217 VCM .................................................................. 264
Wiring Diagram ..................................................... 264
PRECAUTIONS ............................................... 217
Precaution for Technicians Using Medical Electric..217 BASIC INSPECTION ................................. 268
Point to Be Checked Before Starting Maintenance
Work ......................................................................217 DIAGNOSIS AND REPAIR WORK FLOW ....... 268
Precaution for Supplemental Restraint System Work Flow ............................................................. 268
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Diagnostic Work Sheet ......................................... 269
SIONER" ................................................................217
Precaution Necessary for Steering Wheel Rota- ADDITIONAL SERVICE WHEN REPLACING
tion after 12V Battery Disconnect ..........................218 LI-ION BATTERY CONTROLLER ................... 271
Precaution for Procedure without Cowl Top Cover..219 Description ............................................................ 271
Precautions for Removing Battery Terminal ..........219 Work Procedure .................................................... 271
High Voltage Precautions ......................................219
MODULE CHARGE BALANCE ....................... 272
PREPARATION .......................................... 222 Description ............................................................ 272
Work Procedure .................................................... 272
PREPARATION ............................................... 222
Special Service Tools ............................................222 DTC/CIRCUIT DIAGNOSIS ....................... 274
Commercial Service Tools .....................................222
P0A0D HV SYSTEM INTERLOCK ERROR ..... 274
SYSTEM DESCRIPTION ........................... 227 DTC Logic ............................................................. 274
COMPONENT PARTS ..................................... 227
Component Parts Location ....................................227 P0A1F BATTERY ENERGY CONTROL MOD-
Li-ion Battery .........................................................229 ULE ................................................................... 276
Li-ion Battery Controller .........................................229 DTC Logic ............................................................. 276
Module ...................................................................230 Diagnosis Procedure ............................................. 276
Heater Relay Unit ..................................................231
Li-ion Battery Heater ..............................................231 P3030 CELL CONTROLLER LIN ..................... 277
Battery Temperature Sensor .................................232 DTC Logic ............................................................. 277
Battery Junction Box ..............................................232 Diagnosis Procedure ............................................. 277
Service Plug ..........................................................233 P3031-P303C CELL CONTROLLER ASIC ...... 278
High Voltage Warning Label ..................................233
DTC Logic ............................................................. 278
SYSTEM ........................................................... 235 Diagnosis Procedure ............................................. 278
LI-ION BATTERY CONTROL SYSTEM ..................235 P303D-P3048 CELL CONTROLLER ASIC ...... 279
LI-ION BATTERY CONTROL SYSTEM : System DTC Logic ............................................................. 279
Description .............................................................235 Diagnosis Procedure ............................................. 279
LI-ION BATTERY HEATER CONTROL SYSTEM ..237 P3049-P3054 CELL CONTROLLER ASIC
VOLTAGE ......................................................... 280

DTC Logic ............................................................. 280 Diagnosis Procedure ............................................. 302
Diagnosis Procedure ............................................. 280 A
P3196 COMMUNICATION ERROR ................ 303
P3055-P3060 CELL CONTROLLER ASIC DTC Logic .............................................................. 303
VOLTAGE ......................................................... 282 Diagnosis Procedure ............................................. 303
B
DTC Logic ............................................................. 282
Diagnosis Procedure ............................................. 282 P3199 COMMUNICATION ERROR ................ 304
DTC Logic .............................................................. 304
P3061 CELL BATTERY VOLTAGE ................. 284 Diagnosis Procedure ............................................. 304 EVB
DTC Logic ............................................................. 284
Diagnosis Procedure ............................................. 284 P319C COMMUNICATION ERROR ............... 305
DTC Logic .............................................................. 305
P3062 BYPASS SWITCH ................................. 285 Diagnosis Procedure ............................................. 305 D
DTC Logic ............................................................. 285
Diagnosis Procedure ............................................. 285 P31A4 CAN ERROR VCM .............................. 306
DTC Logic .............................................................. 306 E
P308B-P3096 CELL CONTROLLER ASIC Diagnosis Procedure ............................................. 306
OPEN ................................................................ 286
DTC Logic ............................................................. 286
P31A7 CAN ERROR INV/MC ......................... 307
DTC Logic .............................................................. 307 F
P3300 TOTAL VOLTAGE OVER .................... 308
OPEN ................................................................ 289 G
DTC Logic .............................................................. 308
DTC Logic ............................................................. 289
P3302-P330D CELL OVER VOLTAGE .......... 309 H
P30F3 TOTAL VOLTAGE SENSOR ................ 292
DTC Logic .............................................................. 309
DTC Logic ............................................................. 292
Component Inspection ........................................... 311 I
P330E-P3319 CELL OVER VOLTAGE .......... 312
DTC Logic ............................................................. 293
DTC Logic .............................................................. 312
Diagnosis Procedure ............................................. 293 J
Component Inspection ........................................... 314
P331A-P3325 CELL OVER VOLTAGE .......... 315 K
DTC Logic ............................................................. 295
DTC Logic .............................................................. 315
P30FC OVER CURRENT ................................. 296 Component Inspection ........................................... 317
L
DTC Logic ............................................................. 296
P3326-P3331 CELL OVER VOLTAGE ........... 318
DTC Logic .............................................................. 318
P30FD TOTAL VOLTAGE MONITOR Diagnosis Procedure ............................................. 318 M
SWITCH ............................................................ 297 Component Inspection ........................................... 320
DTC Logic ............................................................. 297 P3373 TOTAL VOLTAGE OVER DIS-
Diagnosis Procedure ............................................. 297 N
CHARGE ......................................................... 321
P30FE 12V BATTERY VOLTAGE ................... 298 DTC Logic .............................................................. 321
Diagnosis Procedure ............................................. 298 O
P3375-P3380 CELL OVER DISCHARGE ....... 322
P318D COMMUNICATION ERROR ................. 300 DTC Logic .............................................................. 322
Component Inspection ........................................... 324 P
P318E COMMUNICATION ERROR ................. 301 P3381-P338C CELL OVER DISCHARGE ...... 325
DTC Logic ............................................................. 301 DTC Logic .............................................................. 325
Diagnosis Procedure ............................................. 301 Diagnosis Procedure ............................................. 325
P3191 COMMUNICATION ERROR ................. 302
DTC Logic ............................................................. 302 P338D-P3398 CELL OVER DISCHARGE ...... 328

DTC Logic ..............................................................328 Diagnosis Procedure ............................................. 354
Diagnosis Procedure .............................................328
Component Inspection ...........................................330 P33EE BATTERY HEATER CONTROL SYS-
TEM ................................................................... 356
P3399-P33A4 CELL OVER DISCHARGE ....... 331 DTC Logic ............................................................. 356
Component Inspection ...........................................333 U1000 CAN COMM CIRCUIT ........................... 358
Description ............................................................ 358
P33D4 BATT GRADUAL CAPA LOSS DIAG . 334 DTC Logic ............................................................. 358
LI-ION BATTERY INSULATION RESIS-
P33D5 CURRENT SENSOR ............................ 335 TANCE LOSS CHECK ..................................... 359
DTC Logic ..............................................................335 Component Inspection .......................................... 359
LI-ION BATTERY HEATER SYSTEM INSU-
P33D6 CURRENT SENSOR ............................ 337 LATION RESISTANCE CHECK ....................... 369
POWER SUPPLY AND GROUND CIRCUIT .... 372
P33D7, P33D9, P33DB, P33DD TEMPERA- Diagnosis Procedure ............................................. 372
TURE SENSOR ............................................... 339
DTC Logic ..............................................................339 SYMPTOM DIAGNOSIS ........................... 375
Component Inspection ...........................................340 REDUCTION IN THE DRIVING RANGE .......... 375
Description ............................................................ 375
P33DF BAT VOLTAGE ISOLATION SEN ...... 341 Diagnosis Procedure ............................................. 375
DTC Logic ..............................................................341
Diagnosis Procedure .............................................341 PERIODIC MAINTENANCE ...................... 376
P33E0 BAT VOLTAGE ISOLATION SEN ....... 342 EV BATTERY USAGE REPORT ...................... 376
DTC Logic ..............................................................342 Inspection .............................................................. 376
UNIT REMOVAL AND INSTALLATION ... 377
DTC Logic ..............................................................343 LI-ION BATTERY ............................................. 377
Diagnosis Procedure .............................................343 Exploded View ...................................................... 377
Removal and Installation ....................................... 377
P33E2 BATT PACK OVER TEMP ................... 344 Inspection .............................................................. 383
DTC Logic ..............................................................344
Diagnosis Procedure .............................................344 UNIT DISASSEMBLY AND ASSEMBLY .. 384
P33E4, P33E5 TEMPERATURE SENSOR ..... 345 LI-ION BATTERY ............................................. 384
DTC Logic ..............................................................345 Exploded view ....................................................... 384
BATTERY JUNCTION BOX .................................... 392
Component Inspection ...........................................346
BATTERY JUNCTION BOX : Disassembly and
P33E6 CELL VOLTAGE DEVIATION DIAG ... 347 Assembly .............................................................. 392
DTC Logic ..............................................................347 BATTERY JUNCTION BOX : Inspection .............. 397
Diagnosis Procedure .............................................347 LI-ION BATTERY CONTROLLER .......................... 399
P33E7 CELL CONTROLLER .......................... 351 LI-ION BATTERY CONTROLLER : Disassembly
and Assembly ....................................................... 399
DTC Logic ..............................................................351
LI-ION BATTERY CONTROLLER : Inspection ..... 403
FRONT MODULE STACK ....................................... 405
P33EA BATTERY HEATER RELAY ............... 352
FRONT MODULE STACK : Disassembly and As-
DTC Logic ..............................................................352
sembly ................................................................... 405
FRONT MODULE STACK : Inspection ................. 412
P33ED BATTERY PARALLEL DIAGNOSIS ... 354 REAR MODULE STACK ......................................... 414
DTC Logic ..............................................................354

REAR MODULE STACK : Disassembly and As- SYSTEM .......................................................... 462
sembly ................................................................... 414 System Description ................................................ 462 A
REAR MODULE STACK : Inspection ................... 426 Circuit Diagram ...................................................... 465
HEATER RELAY UNIT ............................................ 428 HANDLING PRECAUTION ............................. 468
HEATER RELAY UNIT : Disassembly and As- B
EV Battery System ................................................ 468
sembly ................................................................... 428
HEATER RELAY UNIT : Inspection ...................... 433 DIAGNOSIS SYSTEM (LBC) .......................... 469
CONSULT Function ............................................... 469 EVB
HEATER UNIT ......................................................... 435
HEATER UNIT : Disassembly and Assembly ....... 435 ECU DIAGNOSIS INFORMATION ............ 471
HEATER UNIT : Inspection ................................... 441
EV BATTERY SYSTEM .................................. 471 D
SERVICE DATA AND SPECIFICATIONS Reference Value .................................................... 471
(SDS) .......................................................... 444 Fail-safe ................................................................. 476
DTC Index ............................................................. 481 E
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................ 444 WIRING DIAGRAM .................................... 486
Li-ion Battery ......................................................... 444
VCM ................................................................. 486 F
TYPE 3 Wiring Diagram ...................................................... 486
HOW TO USE THIS MANUAL ................... 445 BASIC INSPECTION ................................. 490 G
APPLICATION NOTICE ................................... 445 DIAGNOSIS AND REPAIR WORK FLOW ..... 490
How to Check Vehicle Type .................................. 445
Work Flow .............................................................. 490
Diagnostic Work Sheet .......................................... 491 H
PRECAUTION ............................................ 446
PRECAUTIONS ................................................ 446 ADDITIONAL SERVICE WHEN REPLACING
Precaution for Technicians Using Medical Electric.. 446 LI-ION BATTERY CONTROLLER .................. 493 I
Point to Be Checked Before Starting Maintenance Description ............................................................. 493
Work ...................................................................... 446 Work Procedure ..................................................... 493
Precaution for Supplemental Restraint System MODULE CHARGE BALANCE ...................... 494 J
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Description ............................................................. 494
SIONER" ............................................................... 446
Work Procedure ..................................................... 494
Precaution Necessary for Steering Wheel Rota-
tion after 12V Battery Disconnect .......................... 447 K
DTC/CIRCUIT DIAGNOSIS ....................... 496
Precaution for Procedure without Cowl Top Cover.. 448
Precautions for Removing Battery Terminal ......... 448 P0A0D HV SYSTEM INTERLOCK ERROR ... 496
High Voltage Precautions ...................................... 448 DTC Logic .............................................................. 496 L
PREPARATION ......................................... 451
P0A1F BATTERY ENERGY CONTROL MOD-
PREPARATION ................................................ 451 M
ULE .................................................................. 498
Special Service Tools ............................................ 451 DTC Logic .............................................................. 498
Commercial Service Tools .................................... 452 Diagnosis Procedure ............................................. 498
Sealant or/and Lubricant ....................................... 455 N
P3030 CELL CONTROLLER LIN ................... 499
SYSTEM DESCRIPTION ........................... 456 DTC Logic .............................................................. 499
COMPONENT PARTS ..................................... 456
Component Parts Location .................................... 456 P3031-P303C CELL CONTROLLER ASIC .... 500
Li-ion Battery ......................................................... 457 DTC Logic .............................................................. 500
Li-ion Battery Controller ........................................ 458 Diagnosis Procedure ............................................. 500 P
Module .................................................................. 458
Battery Current Sensor ......................................... 459 P303D-P3048 CELL CONTROLLER ASIC .... 501
Battery Temperature Sensor ................................. 460 DTC Logic .............................................................. 501
Battery Junction Box ............................................. 460 Diagnosis Procedure ............................................. 501
Service Plug .......................................................... 460
High Voltage Warning Label ................................. 461 P3049-P3054 CELL CONTROLLER ASIC
VOLTAGE ....................................................... 502

P3055-P3060 CELL CONTROLLER ASIC DTC Logic ............................................................. 525
VOLTAGE ........................................................ 504 Diagnosis Procedure ............................................. 525
DTC Logic ..............................................................504
Diagnosis Procedure .............................................504 P3199 COMMUNICATION ERROR ................. 526
DTC Logic ............................................................. 526
P3061 CELL BATTERY VOLTAGE ................ 506 Diagnosis Procedure ............................................. 526
DTC Logic ..............................................................506
Diagnosis Procedure .............................................506 P319C COMMUNICATION ERROR ................. 527
DTC Logic ............................................................. 527
P3062 BYPASS SWITCH ................................ 507 Diagnosis Procedure ............................................. 527
DTC Logic ..............................................................507
Diagnosis Procedure .............................................507 P31A4 CAN ERROR VCM ............................... 528
DTC Logic ............................................................. 528
OPEN ............................................................... 508
DTC Logic ..............................................................508
P31A7 CAN ERROR INV/MC ........................... 529
DTC Logic ............................................................. 529
P3300 TOTAL VOLTAGE OVER ..................... 530
OPEN ............................................................... 511
DTC Logic ............................................................. 530
DTC Logic ..............................................................511
P3302-P330D CELL OVER VOLTAGE ............ 531
P30F3 TOTAL VOLTAGE SENSOR ............... 514
DTC Logic ............................................................. 531
DTC Logic ..............................................................514
P330E-P3319 CELL OVER VOLTAGE ............ 535
DTC Logic ..............................................................515
DTC Logic ............................................................. 535
P331A-P3325 CELL OVER VOLTAGE ............ 539
DTC Logic ..............................................................517
DTC Logic ............................................................. 539
P30FC OVER CURRENT ................................ 518 Component Inspection .......................................... 541
DTC Logic ..............................................................518
P3326-P3331 CELL OVER VOLTAGE ............ 542
DTC Logic ............................................................. 542
P30FD TOTAL VOLTAGE MONITOR Diagnosis Procedure ............................................. 542
SWITCH ........................................................... 519 Component Inspection .......................................... 544
DTC Logic ..............................................................519 P3373 TOTAL VOLTAGE OVER DIS-
CHARGE ........................................................... 545
P30FE 12V BATTERY VOLTAGE ................... 520 DTC Logic ............................................................. 545
P3375-P3380 CELL OVER DISCHARGE ........ 546
P318D COMMUNICATION ERROR ................ 522 DTC Logic ............................................................. 546
Diagnosis Procedure .............................................522 Component Inspection .......................................... 549
P318E COMMUNICATION ERROR ................ 523 P3381-P338C CELL OVER DISCHARGE ....... 550
DTC Logic ..............................................................523 DTC Logic ............................................................. 550
Diagnosis Procedure .............................................523 Diagnosis Procedure ............................................. 550
DTC Logic ..............................................................524 P338D-P3398 CELL OVER DISCHARGE ....... 554

Diagnosis Procedure ............................................. 554 Diagnosis Procedure ............................................. 581 A
P3399-P33A4 CELL OVER DISCHARGE ....... 557 TANCE LOSS CHECK .................................... 582
DTC Logic ............................................................. 557 B
Component Inspection .......................................... 559 POWER SUPPLY AND GROUND CIRCUIT .. 592
Diagnosis Procedure ............................................. 592 EVB
P33D4 BATT GRADUAL CAPA LOSS DIAG.. 560
DTC Logic ............................................................. 560 SYMPTOM DIAGNOSIS ............................ 595
REDUCTION IN THE DRIVING RANGE ......... 595 D
P33D5 CURRENT SENSOR ............................ 561 Description ............................................................. 595
Diagnosis Procedure ............................................. 561 E
PERIODIC MAINTENANCE ...................... 596
P33D6 CURRENT SENSOR ............................ 563
DTC Logic ............................................................. 563 EV BATTERY USAGE REPORT .................... 596
Diagnosis Procedure ............................................. 563 Inspection .............................................................. 596 F
P33D7, P33D9, P33DB, P33DD TEMPERA- UNIT REMOVAL AND INSTALLATION .... 597
TURE SENSOR ................................................ 565 G
LI-ION BATTERY ............................................ 597
DTC Logic ............................................................. 565
Exploded View ....................................................... 597
Component Inspection .......................................... 566 H
Inspection .............................................................. 603
P33DF BAT VOLTAGE ISOLATION SEN ....... 567
DTC Logic ............................................................. 567
UNIT DISASSEMBLY AND ASSEMBLY . 605
Diagnosis Procedure ............................................. 567 LI-ION BATTERY ............................................ 605 I
P33E0 BAT VOLTAGE ISOLATION SEN ....... 568 BATTERY PACK UPPER CASE ............................. 605
DTC Logic ............................................................. 568 BATTERY PACK UPPER CASE : Exploded View.. 605 J
Diagnosis Procedure ............................................. 568 BATTERY PACK UPPER CASE : Removal and
Installation ............................................................. 606
DTC Logic ............................................................. 569 LI-ION BATTERY CONTROLLER ........................... 615 K
Diagnosis Procedure ............................................. 569 LI-ION BATTERY CONTROLLER : Exploded
View ....................................................................... 616
P33E2 BATT PACK OVER TEMP ................... 570 LI-ION BATTERY CONTROLLER : Removal and L
DTC Logic ............................................................. 570 Installation ............................................................. 616
BATTERY JUNCTION BOX AND BATTERY HAR-
P33E4, P33E5 TEMPERATURE SENSOR ...... 571 NESS ........................................................................ 618 M
DTC Logic ............................................................. 571 BATTERY JUNCTION BOX AND BATTERY
Diagnosis Procedure ............................................. 571 HARNESS : Exploded View .................................. 619
Component Inspection .......................................... 572 BATTERY JUNCTION BOX AND BATTERY N
P33E6 CELL VOLTAGE DEVIATION DIAG .... 573 HARNESS : Disassembly and Assembly .............. 621
DTC Logic ............................................................. 573 FRONT MODULE STACK ....................................... 628
Diagnosis Procedure ............................................. 573 FRONT MODULE STACK : Exploded View .......... 628 O
FRONT MODULE STACK : Removal and Installa-
P33E7 CELL CONTROLLER ........................... 578
tion ......................................................................... 631
DTC Logic ............................................................. 578
FRONT MODULE STACK : Disassembly and As- P
sembly ................................................................... 636
P33ED BATTERY PARALLEL DIAGNOSIS .. 579 REAR MODULE STACK ......................................... 641
DTC Logic ............................................................. 579
REAR MODULE STACK : Exploded View ............ 642
REAR MODULE STACK : Removal and Installa-
U1000 CAN COMM CIRCUIT ........................... 581 tion ......................................................................... 644
Description ............................................................ 581

REAR MODULE STACK : Disassembly and As- LI-ION BATTERY HEATER CONTROL SYSTEM
sembly ...................................................................651 : System Description ............................................. 685
Inspection ..............................................................658 Circuit Diagram ..................................................... 687
SERVICE DATA AND SPECIFICATIONS HANDLING PRECAUTION .............................. 692

(SDS) .......................................................... 662 EV Battery System ................................................ 692
SERVICE DATA AND SPECIFICATIONS DIAGNOSIS SYSTEM (LBC) ........................... 693

(SDS) ................................................................ 662 CONSULT Function .............................................. 693
Li-ion Battery .........................................................662
ECU DIAGNOSIS INFORMATION ............ 695
TYPE 4
EV BATTERY SYSTEM .................................... 695
HOW TO USE THIS MANUAL ................... 663 Reference Value ................................................... 695
Fail-safe ................................................................ 700
APPLICATION NOTICE .................................. 663
DTC Index ............................................................. 705
How to Check Vehicle Type ..................................663
WIRING DIAGRAM ................................... 711
PRECAUTION ............................................ 664
VCM .................................................................. 711
PRECAUTIONS ............................................... 664
Wiring Diagram ..................................................... 711
Precaution for Technicians Using Medical Electric..664
Point to Be Checked Before Starting Maintenance BASIC INSPECTION ................................. 715
Work ......................................................................664
Precaution for Supplemental Restraint System DIAGNOSIS AND REPAIR WORK FLOW ....... 715
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Work Flow ............................................................. 715
SIONER" ................................................................664 Diagnostic Work Sheet ......................................... 716
Precaution Necessary for Steering Wheel Rota-
tion after 12V Battery Disconnect ..........................665 ADDITIONAL SERVICE WHEN REPLACING
Precaution for Procedure without Cowl Top Cover..666 LI-ION BATTERY CONTROLLER ................... 718
Precautions for Removing Battery Terminal ..........666 Description ............................................................ 718
High Voltage Precautions ......................................666 Work Procedure .................................................... 718
PREPARATION .......................................... 669 MODULE CHARGE BALANCE ....................... 719

Description ............................................................ 719
PREPARATION ............................................... 669 Work Procedure .................................................... 719
Special Service Tools ............................................669
Commercial Service Tools .....................................670 DTC/CIRCUIT DIAGNOSIS ....................... 721
Sealant or/and Lubricant .......................................673
P0A0D HV SYSTEM INTERLOCK ERROR ..... 721
SYSTEM DESCRIPTION ........................... 674 DTC Logic ............................................................. 721
COMPONENT PARTS ..................................... 674
Component Parts Location ....................................674 P0A1F BATTERY ENERGY CONTROL MOD-
Li-ion Battery .........................................................676 ULE ................................................................... 723
Li-ion Battery Controller .........................................676 DTC Logic ............................................................. 723
Module ...................................................................677 Diagnosis Procedure ............................................. 723
Heater Relay Unit ..................................................678
Li-ion Battery Heater ..............................................678 P3030 CELL CONTROLLER LIN ..................... 724
Battery Current Sensor ..........................................679 DTC Logic ............................................................. 724
Battery Temperature Sensor .................................679 Diagnosis Procedure ............................................. 724
Battery Junction Box ..............................................680 P3031-P303C CELL CONTROLLER ASIC ...... 725
Service Plug ..........................................................680
DTC Logic ............................................................. 725
High Voltage Warning Label ..................................680
SYSTEM ........................................................... 682 P303D-P3048 CELL CONTROLLER ASIC ...... 726
LI-ION BATTERY CONTROL SYSTEM ..................682 DTC Logic ............................................................. 726
LI-ION BATTERY CONTROL SYSTEM : System Diagnosis Procedure ............................................. 726
Description .............................................................682
P3049-P3054 CELL CONTROLLER ASIC
LI-ION BATTERY HEATER CONTROL SYSTEM ..684 VOLTAGE ......................................................... 727

Diagnosis Procedure ............................................. 727 A
P3196 COMMUNICATION ERROR ................ 750
P3055-P3060 CELL CONTROLLER ASIC DTC Logic .............................................................. 750
VOLTAGE ......................................................... 729 Diagnosis Procedure ............................................. 750
B
DTC Logic ............................................................. 729
Diagnosis Procedure ............................................. 729 P3199 COMMUNICATION ERROR ................ 751
DTC Logic .............................................................. 751
P3061 CELL BATTERY VOLTAGE ................. 731 Diagnosis Procedure ............................................. 751 EVB
DTC Logic ............................................................. 731
Diagnosis Procedure ............................................. 731 P319C COMMUNICATION ERROR ............... 752
DTC Logic .............................................................. 752
P3062 BYPASS SWITCH ................................. 732 Diagnosis Procedure ............................................. 752 D
DTC Logic ............................................................. 732
Diagnosis Procedure ............................................. 732 P31A4 CAN ERROR VCM .............................. 753
DTC Logic .............................................................. 753 E
OPEN ................................................................ 733
DTC Logic ............................................................. 733
P31A7 CAN ERROR INV/MC ......................... 754
DTC Logic .............................................................. 754 F
P3300 TOTAL VOLTAGE OVER .................... 755
OPEN ................................................................ 736 G
DTC Logic .............................................................. 755
DTC Logic ............................................................. 736
P3302-P330D CELL OVER VOLTAGE .......... 756 H
DTC Logic .............................................................. 756
DTC Logic ............................................................. 739
Component Inspection ........................................... 759 I
P330E-P3319 CELL OVER VOLTAGE .......... 760
DTC Logic ............................................................. 740
DTC Logic .............................................................. 760
Diagnosis Procedure ............................................. 740 J
P331A-P3325 CELL OVER VOLTAGE .......... 764 K
DTC Logic ............................................................. 742
DTC Logic .............................................................. 764
P30FC OVER CURRENT ................................. 743 Component Inspection ........................................... 766
L
DTC Logic ............................................................. 743
P3326-P3331 CELL OVER VOLTAGE ........... 767
DTC Logic .............................................................. 767
P30FD TOTAL VOLTAGE MONITOR Diagnosis Procedure ............................................. 767 M
SWITCH ............................................................ 744 Component Inspection ........................................... 769
DTC Logic ............................................................. 744 P3373 TOTAL VOLTAGE OVER DIS-
Diagnosis Procedure ............................................. 744 N
CHARGE ......................................................... 770
P30FE 12V BATTERY VOLTAGE ................... 745 DTC Logic .............................................................. 770
P3375-P3380 CELL OVER DISCHARGE ....... 771
P318D COMMUNICATION ERROR ................. 747 DTC Logic .............................................................. 771
Component Inspection ........................................... 774 P
P318E COMMUNICATION ERROR ................. 748 P3381-P338C CELL OVER DISCHARGE ...... 775
Diagnosis Procedure ............................................. 748 Diagnosis Procedure ............................................. 775
DTC Logic ............................................................. 749 P338D-P3398 CELL OVER DISCHARGE ...... 779

Component Inspection ...........................................781 P33EE BATTERY HEATER CONTROL SYS-
TEM ................................................................... 808
P3399-P33A4 CELL OVER DISCHARGE ....... 782 DTC Logic ............................................................. 808
Component Inspection ...........................................784 U1000 CAN COMM CIRCUIT ........................... 810
Description ............................................................ 810
P33D4 BATT GRADUAL CAPA LOSS DIAG . 785 DTC Logic ............................................................. 810
P33D5 CURRENT SENSOR ............................ 786 TANCE LOSS CHECK ..................................... 811
DTC Logic ..............................................................786 Component Inspection .......................................... 811
LI-ION BATTERY HEATER SYSTEM INSU-
P33D6 CURRENT SENSOR ............................ 788 LATION RESISTANCE CHECK ....................... 821
POWER SUPPLY AND GROUND CIRCUIT .... 824
P33D7, P33D9, P33DB, P33DD TEMPERA- Diagnosis Procedure ............................................. 824
TURE SENSOR ............................................... 790
DTC Logic ..............................................................790 SYMPTOM DIAGNOSIS ........................... 827
Component Inspection ...........................................791 REDUCTION IN THE DRIVING RANGE .......... 827
Description ............................................................ 827
P33DF BAT VOLTAGE ISOLATION SEN ...... 792 Diagnosis Procedure ............................................. 827
DTC Logic ..............................................................792
Diagnosis Procedure .............................................792 PERIODIC MAINTENANCE ...................... 828
P33E0 BAT VOLTAGE ISOLATION SEN ....... 793 EV BATTERY USAGE REPORT ...................... 828
DTC Logic ..............................................................793 Inspection .............................................................. 828
UNIT REMOVAL AND INSTALLATION ... 829
DTC Logic ..............................................................794 LI-ION BATTERY ............................................. 829
Diagnosis Procedure .............................................794 Exploded View ...................................................... 829
P33E2 BATT PACK OVER TEMP ................... 795 Inspection .............................................................. 835
DTC Logic ..............................................................795
Diagnosis Procedure .............................................795 UNIT DISASSEMBLY AND ASSEMBLY .. 837
P33E4, P33E5 TEMPERATURE SENSOR ..... 796 LI-ION BATTERY ............................................. 837
DTC Logic ..............................................................796
BATTERY PACK UPPER CASE ............................ 837
BATTERY PACK UPPER CASE : Exploded View. 837
BATTERY PACK UPPER CASE : Removal and
P33E6 CELL VOLTAGE DEVIATION DIAG ... 798 Installation ............................................................. 838
DTC Logic ..............................................................798 LI-ION BATTERY CONTROLLER .......................... 847
Diagnosis Procedure .............................................798 LI-ION BATTERY CONTROLLER : Exploded
P33E7 CELL CONTROLLER .......................... 803 View ...................................................................... 848
LI-ION BATTERY CONTROLLER : Removal and
DTC Logic ..............................................................803
Installation ............................................................. 848
BATTERY JUNCTION BOX AND BATTERY HAR-
P33EA BATTERY HEATER RELAY ............... 804
NESS ....................................................................... 850
DTC Logic ..............................................................804
BATTERY JUNCTION BOX AND BATTERY
HARNESS : Exploded View .................................. 851
P33ED BATTERY PARALLEL DIAGNOSIS ... 806 BATTERY JUNCTION BOX AND BATTERY
DTC Logic ..............................................................806 HARNESS : Disassembly and Assembly .............. 853

LI-ION BATTERY HEATER ..................................... 860 REAR MODULE STACK ......................................... 883
LI-ION BATTERY HEATER : Exploded view ........ 861 REAR MODULE STACK : Exploded View ............ 884 A
LI-ION BATTERY HEATER : Disassembly and REAR MODULE STACK : Removal and Installa-
Assembly ............................................................... 862 tion ......................................................................... 886
REAR MODULE STACK : Disassembly and As- B
LI-ION BATTERY HEATER RELAY UNIT .............. 866 sembly ................................................................... 893
LI-ION BATTERY HEATER RELAY UNIT : Ex- Inspection .............................................................. 901
ploded view ........................................................... 867
LI-ION BATTERY HEATER RELAY UNIT : Disas- SERVICE DATA AND SPECIFICATIONS EVB
sembly and Assembly ........................................... 868 (SDS) .......................................................... 904
FRONT MODULE STACK ....................................... 869 SERVICE DATA AND SPECIFICATIONS
FRONT MODULE STACK : Exploded View .......... 869 D
(SDS) ............................................................... 904
FRONT MODULE STACK : Removal and Installa-
Li-ion Battery ......................................................... 904
tion ........................................................................ 872
FRONT MODULE STACK : Disassembly and As- E
sembly ................................................................... 878

APPLICATION NOTICE
< HOW TO USE THIS MANUAL > [TYPE 1]
HOW TO USE THIS MANUAL

APPLICATION NOTICE
How to Check Vehicle Type INFOID:0000000007634267
Check the vehicle type to confirm the service information in EVB section.
Service information Vehicle type Service plug type

Type 1 Without Li-ion battery heater
Type A
Type 2 With Li-ion battery heater
JSCIA0277ZZ
Type B
JSCIA0706ZZ

PRECAUTIONS
< PRECAUTION > [TYPE 1]
PRECAUTION A
PRECAUTIONS
Precaution for Technicians Using Medical Electric INFOID:0000000007634268
B
OPERATION PROHIBITION
WARNING: EVB
• Parts with strong magnet is used in this vehicle.
• Technicians using a medical electric device such as pacemaker must never perform operation on the
vehicle, as magnetic field can affect the device function by approaching to such parts.
D
NORMAL CHARGE PRECAUTION
WARNING:
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an E
implantable cardioverter defibrillator, the possible effects on the devices must be checked with the
device manufacturer before starting the charge operation.
• As radiated electromagnetic wave generated by on board charger at normal charge operation may
F
effect medical electric devices, a technician using a medical electric device such as implantable car-
diac pacemaker or an implantable cardioverter defibrillator must not enter the vehicle compartment
(including luggage room) during normal charge operation.
G
PRECAUTION AT TELEMATICS SYSTEM OPERATION
WARNING:
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), H
avoid the device implanted part from approaching within approximately 220 mm (8.66 in) from inte-
rior/exterior antenna.
• The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or
the implantable cardioverter defibrillator (ICD), when using the service, etc. I
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant-
able cardioverter defibrillator (ICD), the electromagnetic wave of TCU might affect the function of the
device. The possible effects on the devices must be checked with the device manufacturer before J
TCU use.
PRECAUTION AT INTELLIGENT KEY SYSTEM OPERATION
WARNING: K
• If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD),
rior/exterior antenna. L
• The electromagnetic wave of Intelligent Key might affect the function of the implantable cardiac
pacemaker or the implantable cardioverter defibrillator (ICD), at door operation, at each request
switch operation, or at engine starting.
• If a technician uses other medical electric devices than implantable cardiac pacemaker or implant- M
able cardioverter defibrillator (ICD), the electromagnetic wave of Intelligent Key might affect the
function of the device. The possible effects on the devices must be checked with the device manu-
facturer before Intelligent Key use. N
Point to Be Checked Before Starting Maintenance Work INFOID:0000000007634269
The high voltage system may starts automatically. It is required to check that the timer air conditioner O
and timer charge (during EVSE connection) are not set before starting maintenance work.
NOTE:
If the timer air conditioner or timer charge (during EVSE connection) is set, the high voltage system starts
P
automatically even when the power switch is in OFF state.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000007634270
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS

PRECAUTIONS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the “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 that 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 “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:0000000007634271
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.

PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000007634272
A
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. B
EVB
D
PIIB3706J
Precautions for Removing Battery Terminal INFOID:0000000007634273

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.
High Voltage Precautions INFOID:0000000007634274
DANGER:

PRECAUTIONS
Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
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.
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform-
ing inspection or maintenance of high voltage system harnesses and parts.
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
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
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:
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.
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.
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”

PRECAUTIONS
Indicate "HIGH VOLTAGE. DO NOT TOUCH" on the vehicle under repair/inspection to call attention to other
workers. A
EVB
JSAIA1600GB P

PREPARATION
< PREPARATION > [TYPE 1]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000007634275
Tool name
Tool number Description
(Kent-Moore No.)
Palette
— When removing/installing Li-ion battery.
(J-50583)
JPCIA0239ZZ
Battery location guide pin

When installing Li-ion battery.
KV99111300
2 piece/set
(J-50306)
JPCIA0023ZZ
Air leak checker

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

Protect module terminals (for LEAF)
KV99111500
24 pieces/set
(—)
JPCIA0069ZZ
Module charge balancer

— Module voltage adjustment
(J-50346)
JPCIA0070ZZ
Commercial Service Tools INFOID:0000000007634276

PREPARATION
Tool name Description
A
Removing and installing high voltage components

B
Insulated gloves [Guaranteed insulation performance for 1000V/
300A]
EVB
JMCIA0149ZZ
D
• Removing and installing high voltage compo-
nents
Leather gloves
• Protect insulated gloves
[Use leather gloves that can fasten the wrist tight] E
JPCIA0066ZZ
Insulated safety shoes Removing and installing high voltage components G
JPCIA0011ZZ
H

nents I
Safety glasses • To protect eye from the spatter on the work to
electric line
[ANSI Z87.1]
J
JPCIA0012ZZ
K
nents
Face shield
• To protect face from the spatter on the work to
electric line L
JPCIA0167ZZ
Insulated helmet Removing and installing high voltage components N
JPCIA0013ZZ
O
P
Insulated rubber sheet Removing and installing high voltage components
JPCIA0019ZZ

PREPARATION
Insulated cover sheet Removing and installing high voltage components
JPCIA0018ZZ
Battery lift table Removing and installing Li-ion battery
JPCIA0024ZZ
Stacker Removing and installing Li-ion battery
JPCIA0015ZZ
Insulation resistance tester Measuring insulation resistance, voltage, and re-

(Multi tester) sistance
JPCIA0014ZZ
Insulated hand tools Removing and installing high voltage components
JPCIA0067ZZ
Insulated torque wrench Removing and installing high voltage components
JPCIA0068ZZ
Removing and installing battery module stack

NOTE:
• D: 8.0 mm (0.31 in)
Carabineer [small]
• L: 74.0 mm (2.91 in)
• S: 10.0 mm (0.39 in)
• W: 22.5 mm (0.89 in)
JPCIA0016ZZ

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

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

(Cut the adhesive) N
Piano wire with handles
NOTE:
Wire size: φ 0.5 mm (0.02 in)
JSCIA0641ZZ
O
P
Scraper
(Smooth the adhesive)
JSCIA0643ZZ

PREPARATION
Tube presser [Gasket material ap- Installing battery pack upper case
plicator] (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

COMPONENT PARTS
< SYSTEM DESCRIPTION > [TYPE 1]
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000007634277
B
EVB
JPCIA0064ZZ M
A. Center of rear seat legroom B. Center of battery pack right side C. Center of battery pack front side
D. Center of battery pack left side E. Back of battery pack left side F. Back of battery pack
N
: Vehicle front
No. Component Function O

1. Li-ion battery EVB-26, "Li-ion Battery"
2. Service plug EVB-29, "Service Plug"
P
3. Front module stack RH EVB-27, "Module"
4. Battery temperature sensor (Front RH) EVB-28, "Battery Temperature Sensor"
5. Battery junction box EVB-28, "Battery Junction Box"
6. Front module stack LH EVB-27, "Module"
7. Battery temperature sensor (Front LH) EVB-28, "Battery Temperature Sensor"
8. Li-ion battery controller EVB-26, "Li-ion Battery Controller"

COMPONENT PARTS
No. Component Function
9. Rear module stack EVB-27, "Module"
10. Battery temperature sensor (Rear center) EVB-28, "Battery Temperature Sensor"
11. Battery temperature sensor (Rear RH) EVB-28, "Battery Temperature Sensor"
Li-ion Battery INFOID:0000000007634278
• 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.
JSCIA0272ZZ
• Four cells are integrated into a single module. The Li-ion battery consists of 48 modules placed in series.
JPCIA0083ZZ
Li-ion Battery Controller INFOID:0000000007634279
• Li-ion battery controller (LBC) is included in the battery pack and

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

COMPONENT PARTS
3. Prevention of overvoltage and overcurrent
4. Prevention of overheat A
5. Detection of decrease in insulation resistance of high-voltage circuit
6. Detection of a fit of high voltage harness connector and service plug
B
Module INFOID:0000000007634280
• Four laminated cells are integrated into one module.

EVB
• The Li-ion battery is equipped with 48 modules.
• There are two kinds of modules, according to the location of posi-
tive and negative terminals.
D
Positive terminal : Red
Negative terminal : Black
E
JSCIA0273ZZ
F
MODULE INTERNAL CIRCUIT
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 G
parallel-connected cell pairs are connected in series.
NOTE:
Cell voltage displayed on the data monitor of CONSULT means the
potential difference between the upstream and the downstream of H
the parallel circuit.
JPCIA0197GB
J
MODULE LAYOUT
O
JPCIA0084GB
NOTE:
The highest potential is module (MD) 1 and the lowest is module (MD) 48. P
CELL

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

• Large surface area with excellent cooling performance reduces heat load to the battery and improves bat-
tery life.
• Light and thin structure increases flexibility in layout.
Battery Temperature Sensor INFOID:0000000007634281
• Four battery temperature sensors mounted in the battery pack

measure the temperature.
• Right and left front module stacks have one battery temperature
sensor, respectively, and the rear module stack has two.
JSCIA0275ZZ
• The sensor uses a thermistor with a resistance value that varies

according to changes in temperature. The electrical resistance of
the thermistor decreases as the temperature increases.
JPCIA0295GB
Battery Junction Box INFOID:0000000007634282
• The battery junction box is installed to the front side in the battery
pack.
• The battery junction box includes:
System main relay to provide/interrupt DC current sent from Li-
ion battery.
Pre-charge relay to protect the high voltage circuit from a high
current immediately after power switch ON.
Current sensor to calculate battery capacity.
• Installed to both positive side and negative side, the system main
relay provides DC current to each high voltage part. In addition, the
system main relay provides DC current to the Li-ion battery during
JSCIA0276ZZ
motor regeneration or charge.
• When an error occurs in the system, the system main relay is turned OFF and the Li-ion battery is inter-
rupted for ensuring safety, based on a command from VCM (Vehicle control module).

COMPONENT PARTS
Service Plug INFOID:0000000007634283
A
• The service plug is included in the Li-ion battery to securely dis-
connect the high voltage during high voltage part inspection and
maintenance. B
• The service plug is installed on the upper surface of the battery
pack. The plug can be removed when the leg-room mounted ser-
vice plug cover is removed.
• Always use insulating protective equipment when removing and EVB
installing service plug.
D
JSCIA0277ZZ
High Voltage Warning Label INFOID:0000000007634284

E
High voltage warning label is affixed to each of the following component parts.
After replacing a part, check that the part is affixed with a label. If the label is not affixed, be sure to affix the
label in the original position. F
Li-ion Battery
• The label (A) is affixed to the rear end of Li-ion battery.
G
JPCIA0207ZZ J
: Vehicle front : Direction of the label
• The label (A) is affixed to the body panel near the high voltage har- K
ness connector.
: Vehicle front L
: Direction of the label
N
JPCIA0208ZZ
Li-ion Battery Controller

The label is affixed to the main body of controller.
O
JSCIA0111ZZ

COMPONENT PARTS
Service Plug
The label is affixed to the inspection hole cover (1).
JPCIA0209ZZ

SYSTEM
SYSTEM
A
System Description INFOID:0000000007634285
SYSTEM DIAGRAM B
EVB
JSCIA0413GB
INPUT/OUTPUT SIGNAL ITEM K
Input Signal Item

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

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
VCM EV system CAN
Li-ion battery dischargeable power signal
Li-ion battery chargeable completion signal
Li-ion battery available charge signal
Li-ion battery capacity signal
Li-ion battery gradual capacity loss signal
Insulation resistance 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.
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
Gradual control of charging/discharging energy as Li-ion bat-
Charging/discharging energy
tery temperature approaches the upper limit of the temperature
control
Excessive temperature rise pro- capable of use.
tection Li-ion battery temperature exceeds the temperature judged as
System main relay cut excessive temperature rise and maintains the temperature for
more than the specified time.

SYSTEM
HOW TO ADJUST CELL CAPACITY
During cell capacity adjustment, the capacity of each cell is estimated based on the no-load voltage when the A
system starts, and the capacities are adjusted so that they are all at the target level. The voltage of each cell is
detected inside the Li-ion battery controller. The bypass switches are then turned ON to discharge the cells
that have excess capacity. In this way, capacity adjustment by the Li-ion battery controller allows the capacity B
of all cells to be fully utilized.
EVB
JPCIA0094GB
G
INSULATION RESISTANCE LOSS DETECTION FUNCTION
The insulation resistance detection circuit mounted inside the Li-ion battery controller measures the insulation
resistance of each high voltage part and sends the measurement results to VCM via EV system CAN commu- H
nication.
VCM judges abnormal insulation resistance in each high voltage part, based on the received insulation resis-
tance value.
I
M
JSCIA0415GB

SYSTEM
Circuit Diagram INFOID:0000000007634286
JSCIA0432GB

SYSTEM
EVB
JPCIA0088GB I
HARNESS LAYOUT
J

SYSTEM
JPCIA0089GB
: Vehicle front

HANDLING PRECAUTION
HANDLING PRECAUTION
A
EV Battery System INFOID:0000000007634287
• To improve the Li-ion battery life, never perform quick charge heavily. B
• 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.
EVB
PRECAUTIONS FOR STORAGE OF THE LI-ION BATTERY
• Apply insulating tape to the service plug and high voltage harness connector, and protect the terminals so
that nothing contacts them.
D
• Store in a well-ventilated location that is not exposed to direct sunlight.
(Storing outdoors or unprotected is prohibited.)
• Never set directly on the floor.
• Lay an anti-static rubber sheet underneath the battery. E
• Never invert the battery.
• Never stack batteries.
• Cover with an anti-static cover sheet.
F
• Put a caution display stating "CAUTION! HIGH VOLTAGE" on the insulated cover sheet.
• Put identification display showing the name of person in charge on the insulated cover sheet.
• Never allow water to contact the battery.
• Prevent other objects from falling onto the battery. G

DIAGNOSIS SYSTEM (LBC)
CONSULT Function INFOID:0000000007634288
APPLICATION ITEM
CONSULT performs the following functions via CAN communication with Li-ion battery controller (LBC).
Item Function
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.
This mode enables a technician to adjust some devices faster and more accurately by following the in-
Work Support
dications on the CONSULT.
CAN Diagnosis Displays the CAN diagnosis results.
CAN Diagnosis Support Mon-
Displays the CAN communication status.
itor
*: The following diagnosis information is cleared when the VCM memory is erased.
• Diagnostic trouble codes
• Freeze frame data
ECU IDENTIFICATION
Part number of LBC can be checked.
SELF-DIAGNOSTIC RESULTS
Self Diagnostic Item
Regarding items of DTC, refer to EVB-50, "DTC Index".
How to Erase DTC
1. Select “HV BAT”with CONSULT.
2. “SELF-DIAGNOSTIC RESULTS”.
3. Touch “ERASE”. (DTC in LBC will be erased.)
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
BATT ELECTRIC CURRENT A Displays the Li-ion battery current value
12V BATTERY VOLTAGE mV Displays 12V battery power supply voltage
Displays the maximum to minimum difference of voltage magnitude of the on-
IR SEN SHORT PULSE mV
board isolation resistance monitoring system
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug
CLOSE
CELL VOLTAGE 01 - 96 mV Displays each cell voltage
TOTAL BATTERY VOLTAGE V Displays the total voltage of the Li-ion battery
Displays the temperature calculated with a signal voltage from battery temper-
BATTERY TEMPERATURE 1 °C
ature 1 [Rear center]
ature 2 [Front RH]
ature 3 [Rear RH]
ature 4 [Front LH]
DATA MONITOR

Monitored item Unit Remark A

B
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug EVB
CLOSE
D
MAXIMUM CELL VOLTAGE mV Displays the maximum cell voltage value
MINIMUM CELL VOLTAGE mV Displays the minimum cell voltage value
Displays the temperature calculated with a signal voltage from battery temper- E
ature 2 [Front RH] F
ature 3 [Rear RH]
Displays the temperature calculated with a signal voltage from battery temper- G
ature 4 [Front LH]
WORK SUPPORT
H
Work item Description Usage
SAVE BATTERY INFORMATION When Li-ion battery and LBC are
Data saved in LBC is stored in CONSULT.
DATA replaced. I
WRITE BATTERY INFORMA- When Li-ion battery and LBC are
The CONSULT-stored data can be written in LBC.
TION DATA replaced.
CLEAR BATTERY GRADUAL When all modules of Li-ion bat- J
Battery capacity data stored in LBC can be erased.
CAPACITY LOSS DATA tery are replaced.
CLEAR BATT CHARGE/DIS- Battery charge/discharge data stored in LBC can be When all modules of Li-ion bat-
CHARGE INFORMATION DATA erased. tery are replaced. K
This inspection identifies a cell of which cell voltage is on
CELL VOLTAGE LOSS INSPEC- When checking voltage of all
the decrease. If identified, this type of cell may be judged as
TION cells.
an abnormal cell, unless it is replaced. L

EV BATTERY SYSTEM
< ECU DIAGNOSIS INFORMATION > [TYPE 1]
ECU DIAGNOSIS INFORMATION

EV BATTERY SYSTEM
Reference Value INFOID:0000000007634289
VALUE ON THE DIAGNOSIS TOOL

NOTE:
Specification data are reference values.
Monitor item Condition Values / Status

BATT ELECTRIC CURRENT READY Stop the vehicle Approx. (−10) - (+20) A
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

LOCK READY Disconnect service plug NOT REQ
Total battery voltage 317 V Approx. 3,200 - 3,400 mV
CELL VOLTAGE 01 READY

EV BATTERY SYSTEM
A
Total battery voltage 317 V Approx. 3,200 - 3,400 mV B
CELL VOLTAGE 18 READY EVB
D
Total battery voltage 317 V Approx. 3,200 - 3,400 mV E
CELL VOLTAGE 22 READY F
Total battery voltage 393 V Approx. 4,000 - 4,200 mV G
H
Total battery voltage 317 V Approx. 3,200 - 3,400 mV I
CELL VOLTAGE 27 READY J
K
Total battery voltage 317 V Approx. 3,200 - 3,400 mV L
CELL VOLTAGE 31 READY M
Total battery voltage 393 V Approx. 4,000 - 4,200 mV N
O
Total battery voltage 317 V Approx. 3,200 - 3,400 mV P

EV BATTERY SYSTEM

EV BATTERY SYSTEM
A
D
H
K
O

EV BATTERY SYSTEM
TOTAL BATTERY VOLTAGE READY Approx. 240 - 420 V
MAXIMUM CELL VOLTAGE READY
MINIMUM CELL VOLTAGE READY
20°C - 30°C (68°F - 86°F)
READY (Stop the vehi-
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)
cle)
around front RH module stack]
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
cle)
around front LH module stack]

EV BATTERY SYSTEM
Fail-safe INFOID:0000000007634290
A
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. B
FAIL-SAFE PATTERN
• Pattern A: No driving and Charge stop
• Pattern B: Driving output power limit, and Charge stop EVB
• Pattern C: Driving output power limit, and Charge limit
• Pattern D: EV system warning lamp illuminate
FAIL-SAFE LIST D
Pattern
DTC CONSULT screen items
A B C D E
P0A0D HV SYSTEM INTERLOCK ERROR ×
P0A1F BATTERY ENERGY CONTROL MODULE × × ×
F
P3030 CELL CONT LIN ×
P3031 CELL CONT ASIC1 ×
P3032 CELL CONT ASIC2 × G
H
P3037 CELL CONT ASIC7 × I
P303A CELL CONT ASIC10 × J
P303B CELL CONT ASIC11 ×
P303C CELL CONT ASIC12 ×
K
P303D CELL CONT ASIC13 ×
P303E CELL CONT ASIC14 ×
P303F CELL CONT ASIC15 × L
M
P3044 CELL CONT ASIC20 × N
O
P3049 CELL CONT ASIC1 VOLT × P
P304A CELL CONT ASIC2 VOLT ×
P304B CELL CONT ASIC3 VOLT ×
P304C CELL CONT ASIC4 VOLT ×
P304D CELL CONT ASIC5 VOLT ×
P304E CELL CONT ASIC6 VOLT ×

EV BATTERY SYSTEM
Pattern
A B C D
P304F CELL CONT ASIC7 VOLT ×
P3050 CELL CONT ASIC8 VOLT ×
P3061 CELL BATTERY VOLT ×
P3062 BYPASS SW ×
P308B CELL CONT ASIC1 OPEN ×
P308C CELL CONT ASIC2 OPEN ×
P308D CELL CONT ASIC3 OPEN ×
P308E CELL CONT ASIC4 OPEN ×
P308F CELL CONT ASIC5 OPEN ×
P3090 CELL CONT ASIC6 OPEN ×
P309A CELL CONT ASIC16 OPEN ×
P30A0 CELL CONT ASIC22 OPEN ×

EV BATTERY SYSTEM
Pattern
DTC CONSULT screen items A
A B C D
P30F3 TOTAL VOLT SENSOR × B
P30F4 TOTAL VOLT SENSOR ×
P30FC OVER CURRENT × EVB
P30FD TOTAL VOLTAGE MONITOR SWITCH No fail-safe
P30FE 12V BATTERY VOLTAGE ×
D
P318D COMMUNICATION ERROR ×
P318E COMMUNICATION ERROR ×
P3191 COMMUNICATION ERROR No fail-safe E
P3196 COMMUNICATION ERROR No fail-safe
P3199 COMMUNICATION ERROR ×
F
P319C COMMUNICATION ERROR No fail-safe
P31A4 CAN ERROR VCM ×
P31A7 CAN ERROR INV/MC No fail-safe G
P3300 TOTAL VOLTAGE OVER ×
P3302 CELL OVER VOLTAGE MODULE1 ×
H
P3305 CELL OVER VOLTAGE MODULE4 × I
J

P330A CELL OVER VOLTAGE MODULE9 ×
K
P330B CELL OVER VOLTAGE MODULE10 ×
P330C CELL OVER VOLTAGE MODULE11 ×
P330D CELL OVER VOLTAGE MODULE12 × L
P330E CELL OVER VOLTAGE MODULE13 ×
P330F CELL OVER VOLTAGE MODULE14 ×
M
P3312 CELL OVER VOLTAGE MODULE17 × N
O
P3317 CELL OVER VOLTAGE MODULE22 × P

EV BATTERY SYSTEM
Pattern
A B C D
P331D CELL OVER VOLTAGE MODULE28 ×
P3373 TOTAL VOLTAGE OVER DISCHARGE ×
P3375 CELL OVER DISCHARGE MODULE1 ×
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 ×

EV BATTERY SYSTEM
Pattern
A B C D
P338B CELL OVER DISCHARGE MODULE23 × B
P338E CELL OVER DISCHARGE MODULE26 × EVB
D
P3393 CELL OVER DISCHARGE MODULE31 × E
F
P3398 CELL OVER DISCHARGE MODULE36 × G
H
P339D CELL OVER DISCHARGE MODULE41 × I
P33A0 CELL OVER DISCHARGE MODULE44 ×
J

K
P33D4 BATT GADUAL CAPA LOSS DIAG × L
P33D5 CURRENT SENSOR ×
M
P33D7 TEMPERATURE SENSOR No fail-safe
P33DB TEMPERATURE SENSOR No fail-safe N
P33DD TEMPERATURE SENSOR No fail-safe
P33DF BATT VOLTAGE ISOLATION SEN ×
O
P33E0 BATT VOLTAGE ISOLATION SEN ×
P33E2 BATT PACK OVER TEMP × P
P33E4 TEMPERATURE SENSOR No fail-safe
P33E6 CELL VOLTAGE DEVIATION DIAG ×
P33E7 CELL CONTROLLER ×

EV BATTERY SYSTEM
Pattern
A B C D
P33ED BATTERY PARALLEL DIAGNOSIS ×
U1000 CAN COMM CIRCUIT ×
DTC Index INFOID:0000000007634291
×: Applicable —: Not applicable
EV system
DTC CONSULT screen items warning Trip Reference
lamp
P0A0D HV SYSTEM INTERLOCK ERROR × 1 EVB-65
P0A1F BATTERY ENERGY CONTROL MODULE × 1 EVB-67
P3030 CELL CONT LIN × 1 EVB-68
P3031 CELL CONT ASIC1 × 1 EVB-69
P303A CELL CONT ASIC10 × 1 EVB-69
P303B CELL CONT ASIC11 × 1 EVB-69
P303C CELL CONT ASIC12 × 1 EVB-69
P303D CELL CONT ASIC13 × 1 EVB-70
P303E CELL CONT ASIC14 × 1 EVB-70
P303F CELL CONT ASIC15 × 1 EVB-70
P3049 CELL CONT ASIC1 VOLT × 1 EVB-71
P304A CELL CONT ASIC2 VOLT × 1 EVB-71
P304B CELL CONT ASIC3 VOLT × 1 EVB-71
P304C CELL CONT ASIC4 VOLT × 1 EVB-71
P304D CELL CONT ASIC5 VOLT × 1 EVB-71
P304E CELL CONT ASIC6 VOLT × 1 EVB-71
P304F CELL CONT ASIC7 VOLT × 1 EVB-71

EV BATTERY SYSTEM
EV system
DTC CONSULT screen items warning Trip Reference A
lamp
P3053 CELL CONT ASIC11 VOLT × 1 EVB-71 B
EVB
P3058 CELL CONT ASIC16 VOLT × 1 EVB-73 D
E
P305D CELL CONT ASIC21 VOLT × 1 EVB-73 F
G
P3061 CELL BATTERY VOLT × 1 EVB-75

P3062 BYPASS SW × 1 EVB-76 H
P308B CELL CONT ASIC1 OPEN × 1 EVB-77
P308C CELL CONT ASIC2 OPEN × 1 EVB-77
P308D CELL CONT ASIC3 OPEN × 1 EVB-77 I
P308E CELL CONT ASIC4 OPEN × 1 EVB-77
P308F CELL CONT ASIC5 OPEN × 1 EVB-77
J
P3090 CELL CONT ASIC6 OPEN × 1 EVB-77
P3092 CELL CONT ASIC8 OPEN × 1 EVB-77 K
L
P3097 CELL CONT ASIC13 OPEN × 1 EVB-80 M
N
P309A CELL CONT ASIC16 OPEN × 1 EVB-80
P309C CELL CONT ASIC18 OPEN × 1 EVB-80 O
P309D CELL CONT ASIC19 OPEN × 1 EVB-80
P309F CELL CONT ASIC21 OPEN × 1 EVB-80 P
P30A0 CELL CONT ASIC22 OPEN × 1 EVB-80
P30F3 TOTAL VOLT SENSOR × 1 EVB-83

EV BATTERY SYSTEM
EV system
lamp
P30FC OVER CURRENT × 1 EVB-87
P30FD TOTAL VOLTAGE MONITOR SWITCH — 1 EVB-88
P30FE 12V BATTERY VOLTAGE × 1 EVB-89
P318D COMMUNICATION ERROR × 1 EVB-91
P318E COMMUNICATION ERROR × 1 EVB-92
P3191 COMMUNICATION ERROR — 1 EVB-93
P3199 COMMUNICATION ERROR × 1 EVB-95
P319C COMMUNICATION ERROR — 1 EVB-96
P31A4 CAN ERROR VCM × 1 EVB-97
P31A7 CAN ERROR INV/MC — 1 EVB-98
P3300 TOTAL VOLTAGE OVER × 1 EVB-99
P3302 CELL OVER VOLTAGE MODULE1 × 1 EVB-100
P330A CELL OVER VOLTAGE MODULE9 × 1 EVB-100
P330B CELL OVER VOLTAGE MODULE10 × 1 EVB-100
P330C CELL OVER VOLTAGE MODULE11 × 1 EVB-100
P330D CELL OVER VOLTAGE MODULE12 × 1 EVB-100
P330E CELL OVER VOLTAGE MODULE13 × 1 EVB-103
P330F CELL OVER VOLTAGE MODULE14 × 1 EVB-103

EV BATTERY SYSTEM
EV system
lamp
P3321 CELL OVER VOLTAGE MODULE32 × 1 EVB-106 B
EVB
P3326 CELL OVER VOLTAGE MODULE37 × 1 EVB-109 D
E
P332B CELL OVER VOLTAGE MODULE42 × 1 EVB-109 F
G

P3330 CELL OVER VOLTAGE MODULE47 × 1 EVB-109 H
P3373 TOTAL VOLTAGE OVER DISCHARGE × 1 EVB-112
P3375 CELL OVER DISCHARGE MODULE1 × 1 EVB-113 I
P3376 CELL OVER DISCHARGE MODULE2 × 1 EVB-113
J
P337A CELL OVER DISCHARGE MODULE6 × 1 EVB-113 K
P337B CELL OVER DISCHARGE MODULE7 × 1 EVB-113
P337C CELL OVER DISCHARGE MODULE8 × 1 EVB-113
L
P337D CELL OVER DISCHARGE MODULE9 × 1 EVB-113
P337E CELL OVER DISCHARGE MODULE10 × 1 EVB-113
P337F CELL OVER DISCHARGE MODULE11 × 1 EVB-113 M
N
P3384 CELL OVER DISCHARGE MODULE16 × 1 EVB-116 O
P3387 CELL OVER DISCHARGE MODULE19 × 1 EVB-116 P
P338A CELL OVER DISCHARGE MODULE22 × 1 EVB-116

EV BATTERY SYSTEM
EV system
lamp
P338F CELL OVER DISCHARGE MODULE27 × 1 EVB-119
P33A0 CELL OVER DISCHARGE MODULE44 × 1 EVB-122
P33D4 BATT GRADUAL CAPA LOSS DIAG × 1 EVB-125
P33D5 CURRENT SENSOR × 1 EVB-126
P33D7 TEMPERATURE SENSOR — 1 EVB-130
P33DB TEMPERATURE SENSOR — 1 EVB-130
P33DD TEMPERATURE SENSOR — 1 EVB-130
P33DF BATT VOLTAGE ISOLATION SEN × 1 EVB-132
P33E0 BATT VOLTAGE ISOLATION SEN × 1 EVB-133
P33E2 BATT PACK OVER TEMP × 1 EVB-135
P33E4 TEMPERATURE SENSOR — 1 EVB-136
P33E6 CELL VOLTAGE DEVIATION DIAG × 2 EVB-138
P33E7 CELL CONTROLLER × 1 EVB-142
P33ED BATTERY PARALLEL DIAGNOSIS × 1 EVB-143
U1000 CAN COMM CIRCUIT × 1 EVB-145

VCM
< WIRING DIAGRAM > [TYPE 1]
WIRING DIAGRAM A
VCM
Wiring Diagram INFOID:0000000007634292
B
For connector terminal arrangements, harness layouts, and alphabets in a (option abbreviation; if not
described in wiring diagram), refer to GI-12, "Connector Information". EVB
JCCWA0029GB

VCM
JCCWA0030GB

VCM
EVB
JCCWA0031GB

VCM
JCCWA0032GB

DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TYPE 1]
BASIC INSPECTION A
Work Flow INFOID:0000000007634293
B
DETAILED FLOW
1.GET INFORMATION FOR SYMPTOM EVB
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the “Question sheet”. (Refer to EVB-60, "Diagnostic Work Sheet".)
D
>> GO TO 2.
2.CHECK DTC IN VCM E
1. Check DTC in VCM.
2. Check related service bulletins for information.
Are any DTCs detected? F
YES >> Check the DTC. Refer to EVC-84, "DTC Index".
NO >> GO TO 3.
3.CHECK DTC G
1. Check DTC.
2. Perform the following procedure if DTC is displayed.
H
- Record DTC and freeze frame data. (Print them out with CONSULT.)
- Erase DTC.
- Study the relationship between the cause detected by DTC and the symptom described by the customer.
(Symptom Matrix Chart is useful. Refer to EVC-347, "Symptom Index".) I
Are any symptoms described and any DTCs detected?
Symptom is described, DTC is detected>>GO TO 4. J
Symptom is described, DTC is not detected>>GO TO 5.
Symptom is not described, DTC is detected>>GO TO 6.
4.CONFIRM THE SYMPTOM K
Try to confirm the symptom described by the customer.
Also study the normal operation and fail-safe related to the symptom. Refer to EVC-347, "Symptom Index"
and EVB-45, "Fail-safe". L
Diagnosis Work Sheet is useful to verify the incident.
Verify relation between the symptom and the condition when the symptom is detected.
M
>> GO TO 6.
5.CONFIRM THE SYMPTOM
N
and EVB-45, "Fail-safe".
Diagnosis Work Sheet is useful to verify the incident. O
>> GO TO 7. P
6.PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC CONFIRMATION PROCEDURE for the displayed DTC, and then check that DTC is detected
again.
NOTE:
• Freeze frame data is useful if the DTC is not detected.

• Perform Component Function Check if DTC CONFIRMATION PROCEDURE is not included on Service
Manual. This simplified check procedure is an effective alternative though DTC cannot be detected during
this check.
If the result of Component Function Check is NG, it is the same as the detection of DTC by DTC CONFIR-
MATION PROCEDURE.
Is DTC detected?
YES >> GO TO 8.
NO >> Check according to GI-51, "Intermittent Incident".
7.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
Detect malfunctioning system according to EVC-347, "Symptom Index" based on the confirmed symptom in
step 4, and determine the trouble diagnosis order based on possible causes and symptoms.
Is the symptom described?
YES >> GO TO 8.
NO >> Monitor input data from related sensors using CONSULT.
8.DETECT MALFUNCTIONING PART BY DIAGNOSIS PROCEDURE
Inspect according to Diagnosis Procedure of the system.
Is a malfunctioning part detected?
YES >> GO TO 9.
9.REPAIR OR REPLACE THE MALFUNCTIONING PART
1. Repair or replace the malfunctioning part.
2. Reconnect parts or connectors disconnected during Diagnosis Procedure again after repair and replace-
ment.
3. Check DTC. If DTC is displayed, erase it.
>> GO TO 10.
10.FINAL CHECK
When DTC was detected in step 3, perform DTC CONFIRMATION PROCEDURE or Component Function
Check again, and then check that the malfunction have been completely repaired.
When symptom was described from the customer, refer to confirmed symptom in step 4 or 5, and check that
the symptom is not detected.
Is DTC detected and does symptom remain?
YES-1 >> DTC is detected: GO TO 8.
YES-2 >> Symptom remains: GO TO 5.
NO >> Before returning the vehicle to the customer, always erase DTC.
Diagnostic Work Sheet INFOID:0000000007634294
DESCRIPTION
There are many operating conditions that lead to the malfunction of
“EV battery system” components. A good grasp of such conditions
can make troubleshooting faster and more accurate.
In general, each customer feels differently about symptoms. It is
important to fully understand the symptoms or conditions for a cus-
tomer complaint.
Utilize the diagnostic worksheet in order to organize all the informa-
tion for troubleshooting.
NOTE:
Some conditions may cause a DTC to be detected.
JSCIA0412GB
WORKSHEET SAMPLE

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

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

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

ADDITIONAL SERVICE WHEN REPLACING LI-ION BATTERY CONTROLLER
ADDITIONAL SERVICE WHEN REPLACING LI-ION BATTERY CONTROL-
LER
Description INFOID:0000000007634295
When a Li-ion Battery Controller (LBC) is replaced, it is necessary to save the battery information stored in
LBC to the new LBC.
Whenever any of the following work is performed, make sure to perform the above operation.
• Replace LBC
Work Procedure INFOID:0000000007634296
1.SAVE THE LI-ION BATTERY CONTROLLER (LBC) INTERNAL INFORMATION

With CONSULT
1. Select “SAVE BATTERY INFORMATION DATA” in “WORK SUPPOTRT” mode.
2. Save the LBC internal information.
>> GO TO 2.
2.REPLACE LI-ION BATTERY OR LBC
Replace Li-ion battery or LBC. Refer to EVB-161, "Removal and Installation" (Li-ion battery) or EVB-181, "LI-
ION BATTERY CONTROLLER : Disassembly and Assembly" (LBC).
>> GO TO 3.
3.WRITE THE LBC INTERNAL INFORMATION
With CONSULT
1. Select “WRITE BATTERY INFORMATION DATA” in “WORK SUPPOTRT” mode.
2. Write the information that has been read out before LBC replacement.
>> GO TO 4.
4.WRITE THE LBC INTERNAL INFORMATION TO VCM
Refer to “Li-ion Battery Registration Operation Manual.
>> END

MODULE CHARGE BALANCE
A
If a malfunction (e.g. abnormal voltage) occurs in a Li-ion battery cell, the module which includes the malfunc- B
tioning cell must be replaced. When replacing a module with a new one, its voltage is required to be adjusted
to the adjusting voltage calculated from the maximum cell voltage of normal cells.
Work Procedure INFOID:0000000007634298 EVB
NOTE:
Voltage adjustment under low temperature conditions may require a long time. To prevent this from occurring,
it is advisable to adjust voltage under room temperature conditions [20°C ± 10°C (68°F ±18°F)]. D
1.CHECK ADJUSTMENT VOLTAGE VALUE

With CONSULT E
1. Power switch ON.
2. Select “DATA MONITOR”of “HV BAT”.
3. Check “MAXIMUM CELL VOLTAGE”. F
4. Double the “MAXIMUM CELL VOLTAGE” and use that value as the module adjustment value.
Adjustment voltage value : MAXIMUM CELL VOLTAGE× 2

G
Example: 3.925 V (MAXIMUM CELL VOLTAGE) × 2 = 7.850 V (Adjustment voltage value)
>> GO TO 2. H
2.CHECK MODULE VOLTAGE
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual. I
1. Set the new module to the module charge balancer.
2. Measure module voltage and compare it with “adjustment voltage value” confirmed in Step1.
J
Module voltage is lower than adjustment voltage value>>GO TO 4.
Module voltage is higher than adjustment voltage value>>GO TO 3.
3.DISCAHRGE OF MODULE VOLTAGE K
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual. L
Discharge the module to 5.0 V using module charge balancer.
Discharge voltage : 5.0 V

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

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

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

Standard : Adjustment voltage value ± 10 mV
>> GO TO 6.
6.CHECK CELL VOLTAGE
With CONSULT
1. After adjusting the voltage, install the module to the vehicle.
2. Select “DATA MONITOR” of “HV BAT”.
3. Check “CELL VOLTAGE” of install module.
4. Check that the difference from the “MAXIMUM CELL VOLTAGE” confirmed in Step1 is within the specified
range.
Standard : MAXIMUM CELL VOLTAGE ± 33 mV
>> WORK END

P0A0D HV SYSTEM INTERLOCK ERROR
< DTC/CIRCUIT DIAGNOSIS > [TYPE 1]
DTC/CIRCUIT DIAGNOSIS A
DTC Logic INFOID:0000000007634301
B
DTC DETECTION LOGIC

EVB
DTC Trouble diagnosis name DTC detecting condition Possible causes
HV SYSTEM INTERLOCK Self diagnosis program of Li-ion battery controller de-
P0A0D Li-ion battery controller
ERROR tects a malfunction in the CPU.
D
DTC CONFIRMATION PROCEDURE
1.PERFORM DTC CONFIRMATION PROCEDURE E
With CONSULT
1. Power switch ON and wait for 10 seconds or more.
2. Select “Self Diagnostic Result” of “HV BAT”. F
3. Check DTC.
Is P0A1F detected?
YES >> Refer to EVB-65, "Diagnosis Procedure". G
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000007634302
H
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec-
tric shock, electric leakage, or similar accidents if the high voltage component and vehicle are han- I
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and
maintenance.
ing inspection or maintenance of high voltage system harnesses and parts. J
• To prevent the removed service plug from being connected by mistake during the procedure, always
carry it in your pocket or put it in the tool box.
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses K
before beginning work on the high voltage system.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not
touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or sim-
L
ilar item to prevent other persons from contacting them.
• Refer to EVB-17, "High Voltage Precautions".
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the M
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.
1.PRECONDITIONING N
WARNING:
Disconnect high voltage. Refer to GI-31, "How to Disconnect High Voltage".
1. Remove Li-ion battery. Refer to EVB-161, "Removal and Installation". O
2. Remove battery pack upper case. Refer to EVB-174, "BATTERY JUNCTION BOX : Disassembly and
Assembly", see Step-1 to Step-3.
P
>> GO TO 2.
2.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-1
1. Disconnect Li-ion battery controller (LBC) harness connector.
2. Disconnect interlock detecting switch (high voltage harness connector) harness connector.
3. Check the continuity between Li-ion battery controller harness connector and ground.

LBC
— Continuity
Connector Terminal
LB9 8 Ground Not existed
Is the inspection result normal?
YES >> GO TO 3.
NO >> Replace Li-ion battery vehicle communication harness.
1. Disconnect interlock detecting switch (service plug) harness connector.
LBC
— Continuity
Connector Terminal
YES >> GO TO 4.
Check the continuity between interlock detecting switch (service plug) harness connector and ground.
Interlock detecting switch

(Service plug) — Continuity
Connector Terminal
YES >> Replace Li-ion battery controller. Refer to EVB-181, "LI-ION BATTERY CONTROLLER : Disas-
sembly and Assembly".

P0A1F BATTERY ENERGY CONTROL MODULE
A
DTC DETECTION LOGIC B

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

D
With CONSULT
1. Power switch ON and wait for 10 seconds or more. E
2. Select “Self Diagnostic Result” of “HV BAT”.
3. Check DTC.
Is P0A1F detected? F
YES >> Refer to EVB-67, "Diagnosis Procedure".
G
When this DTC is detected, replace Li-ion battery controller. Refer to EVB-181, "LI-ION BATTERY CONTROL-
LER : Disassembly and Assembly". H

P3030 CELL CONTROLLER LIN
DTC DETECTION LOGIC

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

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

With CONSULT
2. Check to see if “P30F3” is detected simultaneously with “P3030”.
Is P30F3 detected?
YES >> Replace Li-ion battery. Refer to EVB-161, "Removal and Installation".
NO >> Replace Li-ion battery controller. Refer to EVB-181, "LI-ION BATTERY CONTROLLER : Disas-

P3031-P303C CELL CONTROLLER ASIC
A

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

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

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

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P3031 -P303C”. M
Is P3030 detected?
YES >> Perform diagnosis on the detected P3030. Refer to EVB-68, "Diagnosis Procedure".
NO >> Replace Li-ion battery controller. Refer to EVB-181, "LI-ION BATTERY CONTROLLER : Disas- N

P303D-P3048 CELL CONTROLLER ASIC
DTC DETECTION LOGIC

P303D CELL CONT ASIC13
P303E CELL CONT ASIC14
P303F CELL CONT ASIC15
P3042 CELL CONT ASIC18 A malfunction occurs with the communication function


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

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P303D” -“P3048”.
Is P3030 detected?

P3049-P3054 CELL CONTROLLER ASIC VOLTAGE
A

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

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check DTC. M
YES-1 >> “P3302” - “P3331” are detected simultaneously.
• When “P3302” - “P330D” are detected simultaneously, perform the diagnosis procedure of N
“P3302” - “P330D”. Refer to EVB-100, "Diagnosis Procedure".
• When “P330E” - “P3319” are detected simultaneously, perform the diagnosis procedure of
“P330E” - “P3319”. Refer to EVB-103, "Diagnosis Procedure".
• When “P331A” - “P3325” are detected simultaneously, perform the diagnosis procedure of O
“P331A” - “P3325”. Refer to EVB-106, "Diagnosis Procedure".
• When “P3326” - “P3331” are detected simultaneously, perform the diagnosis procedure of
“P3326” - “P3331”. Refer to EVB-109, "Diagnosis Procedure". P
YES-2 >> “P3375” - “P33A4” are detected simultaneously.
“P3375” - “P3380”. Refer to EVB-113, "Diagnosis Procedure".
• When “P3381” - “P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381” - “P338C”. Refer to EVB-116, "Diagnosis Procedure".
• When “P338D” - “P3398” are detected simultaneously, perform the diagnosis procedure of
“P338D” - “P3398”. Refer to EVB-119, "Diagnosis Procedure".

• When “P3399” - “P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399” - “P33A4”. Refer to EVB-122, "Diagnosis Procedure".
NO >> When only “P3049” - “P3054” are detected, replace Li-ion battery controller. Refer to EVB-181,
"LI-ION BATTERY CONTROLLER : Disassembly and Assembly".

A

D
P305A CELL CONT ASIC18 VOLT • Li-ion battery controller E
• Module
P305B CELL CONT ASIC19 VOLT tioning.
F
P305E CELL CONT ASIC22 VOLT
P305F CELL CONT ASIC23 VOLT G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check DTC. M


P3061 CELL BATTERY VOLTAGE
A

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

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

P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
DTC DETECTION LOGIC

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

With CONSULT
3. Check DTC.
Is P3062 detected?

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

P308B-P3096 CELL CONTROLLER ASIC OPEN
A

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

F
P3095 CELL CONT ASIC11 OPEN G
DTC DETECTION LOGIC H

With CONSULT
3. Check DTC.
Is P308B-P30A2 detected? J
K
WARNING:
L
tric shock, electric leakage, or similar accidents if the high voltage component and vehicle are han-
maintenance. M
N
• Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not O
P
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the
With CONSULT

2. Check to see if “P3049”-“P3060” (CELL CONT ASIC VOLT related codes) or “P3375”-“P33A4” (CELL
OVER DISCHARGE related codes) is detected simultaneously with “P308B”-“P3096”.
Is P3049-P3060 or P3375-P33A4 detected?
YES-1 >> “P3049”-“P3060” are detected simultaneously.
• When “P3049”-“P3054” are detected simultaneously, perform the diagnosis procedure of
“P3049”-“P3054”. Refer to EVB-113, "Diagnosis Procedure".
YES-2 >> “P3375”-“P33A4” are detected simultaneously.
• When “P3381”-“P338C” are detected simultaneously, perform the diagnosis procedure of
“P3381”-“P338C”. Refer to EVB-116, "Diagnosis Procedure".
• When “P338D”-“P3398” are detected simultaneously, perform the diagnosis procedure of
“P338D”-“P3398”. Refer to EVB-119, "Diagnosis Procedure"
• When “P3399”-“P33A4” are detected simultaneously, perform the diagnosis procedure of
“P3399”-“P33A4”. Refer to EVB-122, "Diagnosis Procedure".
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
1. Remove Li-ion battery. Refer to EVB-161, "Removal and Installation".
>> GO TO 3.
3.CHECK CONNECTION STATUS
1. Power switch OFF.
2. Check connection status of Li-ion battery controller harness connector and module harness connector.
YES >> GO TO 4.
NO >> Recover the connection status.
4.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE
1. Disconnect Li-ion battery controller harness connector and Module harness connector.
2. Refer to below table and continuity between Li-ion battery controller and Module, according to detected
DTC.
Module Module Li-ion battery controller

DTC Continuity
No. Connector Terminal Connector Terminal
1 2 50
P308B LB9 LB13 Existed
2 3 51
3 4 52
P308C LB9 LB13 Existed
4 5 53
5 6 54
P308D LB9 LB13 Existed
6 7 55
7 8 56
P308E LB9 LB13 Existed
8 9 57
9 26 58
P308F LB9 LB13 Existed
10 27 59
11 28 60
P3090 LB9 LB13 Existed
12 29 61


DTC Continuity A
13 30 62
14 31 63 B
15 45 77
16 46 78
17 36 80 EVB
18 37 81
19 38 82
P3094 LB10 LB14 Existed D
20 39 83
21 52 84
22 53 85 E
23 54 86
24 55 87
F
sembly and Assembly". G
NO >> Repair harness or connector.

P3097-P30A2 CELL CONTROLLER ASIC OPEN
DTC DETECTION LOGIC

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

P30A0 CELL CONT ASIC22 OPEN
DTC DETECTION LOGIC

With CONSULT
3. Check DTC.
Is P308B-P30A2 detected?
WARNING:
maintenance.
CAUTION:
With CONSULT
1. Select “Self Diagnostic Result” mode of “HV BAT” using CONSULT.

OVER DISCHARGE related codes) is detected simultaneously with “P3097”-“P30A2”. A
• When “P3049”-“P3054” are detected simultaneously, perform the diagnosis procedure of B
“P3049”-“P3054”. Refer to EVB-71, "Diagnosis Procedure"
EVB
• When “P3381”-“P338C” are detected simultaneously, perform the diagnosis procedure of D
“P338D”-“P3398”. Refer to EVB-119, "Diagnosis Procedure". E
“P3399”-“P33A4”. Refer to EVB-122, "Diagnosis Procedure"
NO >> GO TO 2.
F
2.PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to GI-31, "How to Disconnect High Voltage". G
Assembly", see Step-1 to Step-3. H
>> GO TO 3.
3.CHECK CONNECTION STATUS I
Is the inspection result normal? J
YES >> GO TO 4.
K
2. Refer to below table and continuity between Li-ion battery controller and Module, according to detected L
DTC.
Module Module Li-ion battery controller M

DTC Continuity
25 73 110
26 74 111 N
27 60 112
28 77 113
O
29 78 114
30 64 115
31 81 116 P
P309A LB8 LB15 Existed
32 82 117
33 68 118
34 85 119
35 86 120
36 72 121


DTC Continuity
37 89 122
38 90 123
39 91 124
40 92 125
41 93 127
42 94 128
43 95 130
P30A0 LB7 LB15 Existed
44 96 138
45 97 140
46 98 141
47 99 142
48 100 143

P30F3 TOTAL VOLTAGE SENSOR
A

• Li-ion battery controller EVB
P30F3 TOTAL VOLT SENSOR • Module
DTC CONFIRMATION PROCEDURE D

With CONSULT E
3. Check DTC. F
Is P30F3 detected?
NO >> INSPECTION END G
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER H
With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P30F3”. I
Is any P3030 detected?
YES >> Perform diagnosis on the detected “P3030”. Refer to EVB-68, "Diagnosis Procedure".
J

DTC DETECTION LOGIC

When the voltage recognized by total voltage sensor in • Bus bar between stack
P30F4 TOTAL VOLT SENSOR
Li-ion battery controller is excessively high or low. • Service plug (fuse)
• Module

With CONSULT
3. Check DTC.
Is P30F4 detected?
WARNING:
maintenance.
CAUTION:
With CONSULT
2. Check if any DTC is detected in “Self Diagnostic Result”.
“P3030” is detected in addition to “P30F4” (Cannot be monitored)>>GO TO 3.
Just “P30F4” is detected>>GO TO 2.
2.CHECK FUSE
2. Check fuse of service plug.
YES >> Replace Li-ion battery controller.
NO >> Replace service plug.

3.PRECONDITIONING A
WARNING:
1. Remove Li-ion battery. Refer to EVB-161, "Removal and Installation". B
EVB
>> GO TO 4.
4.CHECK CONNECTION STATUS STACK AND BUS BAR.
Check connection status between each stack and connection status of each bus bar. D
YES >> GO TO 5.
NO >> Recover the connection status. E

Check the voltage of all modules. F
NO >> Replace corresponding module. Refer to EVB-168, "Exploded view".
Component Inspection INFOID:0000000007634327
H
Check voltage of module.
I
A : Positive terminal (Red)
B : Negative terminal (Black)
J
Terminals
Voltage K
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V
L
YES >> INSPECTION END
NO >> Replace module. Refer to EVB-188, "FRONT MODULE M
STACK : Disassembly and Assembly" (Front module) or
EVB-198, "REAR MODULE STACK : Disassembly and
Assembly" (Rear module).
N
O
JSCIA0338ZZ

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
Is P30F5 detected?

With CONSULT
2. Check to see if “P30F4” is detected simultaneously with “P30F5”.
Is any P30F4 detected?
YES >> Perform diagnosis on the detected “P30F4”. Refer to EVB-84, "Diagnosis Procedure".

P30FC OVER CURRENT
P30FC OVER CURRENT
A

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

D
With CONSULT
3. Check DTC.
Is P30FC detected? F
G
1.PERFORM THE SELF-DIAGNOSIS H

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

L
Battery temperature sensor 1
Power switch ON 55°C (131°F) or less
Battery temperature sensor 3 M
Is there temperature increase?
Temperature increase is seen>>Replace Li-ion battery. Refer to EVB-161, "Removal and Installation". N
Temperature increase is not seen>>Replace battery junction box. Refer to EVB-161, "Removal and Installa-
tion".
O

P30FD TOTAL VOLTAGE MONITOR SWITCH
DTC DETECTION LOGIC

• Total voltage detection switch in Li-ion battery control-
TOTAL VOLTAGE MONITOR ler is malfunctioning.
P30FD • Li-ion battery controller
SWITCH • Self diagnosis malfunction of total voltage detection
circuit stop function in Li-ion battery controller.

With CONSULT
3. Check DTC.
Is P30FC detected?
LER : Disassembly and Assembly".

P30FE 12V BATTERY VOLTAGE
A

• 12V battery EVB
P30FE 12V BATTERY VOLTAGE 12V battery voltage lowers to less than 9 V.
• Harness

D
With CONSULT
3. Check DTC.
Is P30FE detected? F
G
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec- H
maintenance. I
carry it in your pocket or put it in the tool box. J
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not K
L
CAUTION:
so in the Service Manual. M
1.CHECK VOLTAGE OF 12 V BATTERY
Check the voltage of 12 V battery using circuit tester. N
Is output more than 9 V?
YES >> GO TO 2.
NO >> Replace 12 V battery. Refer to PG-101, "Removal and Installation". O
2.CHECK FUSE
2. Check 20A fuse [No.43]. P
NOTE:
Refer to PG-39, "Fuse, Connector and Terminal Arrangement" for fuse layout.
YES >> GO TO 3.
NO >> After eliminating the cause of flame cutting, replace the fuse.
3.CHECK LI-ION BATTERY POWER SUPPLY
1. Disconnect Li-ion battery vehicle communication harness connector.
2. Check voltage between Li-ion battery harness connector and ground.
+
Li-ion battery − Voltage
Connector Terminal
Battery
B24 5 Ground
voltage
YES >> GO TO 4.
4.PRECONDITIONING
WARNING:
>> GO TO 5.
5.CHECK HARNESS BETWEEN LI-ION BATTERY AND LI-ION BATTERY CONTROLLER
1. Disconnect Li-ion battery harness connector and Li-ion battery controller harness connector.
2. Check continuity between Li-ion battery harness connector and Li-ion battery controller harness connec-
tor.
Li-ion battery Li-ion battery controller

Continuity
Connector Terminal Connector Terminal
LB1 5 LB11 12 Existed

P318D COMMUNICATION ERROR
A

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

With CONSULT E
3. Check DTC. F
Is P318D detected?
For the diagnosis procedure, refer to LAN-15, "Trouble Diagnosis Flow Chart". H

P318E COMMUNICATION ERROR
DTC DETECTION LOGIC

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

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

With CONSULT
2. After turning the power switch OFF, get out of the vehicle and close all doors (including back door).
3. After turning the power switch OFF, wait for 5 minutes or more to remove the 12 V battery negative termi-
nal. Refer to EVB-17, "Precautions for Removing Battery Terminal".
4. Connect 12 V battery negative terminal.
7. Check DTC.
Is P318E detected?
1.PERFORM THE SELF-DIAGNOSIS

With CONSULT
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P318E” is detected.
Is P318E detected?
YES >> Replace VCM. Refer to EVC-369, "Removal and Installation".
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P318E”.
Is U1000 detected?

P3191 COMMUNICATION ERROR
A

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

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

With CONSULT
F
nal. Refer to EVB-17, "Precautions for Removing Battery Terminal". G
6. Select “Self Diagnostic Result” of “HV BAT”. H
7. Check DTC.
Is P3191 detected?
YES >> Refer to EVB-93, "Diagnosis Procedure". I
J
With CONSULT
1. Perform "All DTC Reading". K
2. Check “Self diagnostic result” of systems other than “HV BAT” to see if “P3191” is detected.
Is P3191 detected?
YES >> Replace traction motor inverter. Refer to TMS-115, "Removal and Installation" L
NO >> GO TO 2.
2.PREFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER M
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P3191”. N
Is U1000 detected?
sembly and Assembly". O

DTC DETECTION LOGIC

NOTE:

• On board charger
When no CAN communication signal is received from on-board
charger continuously.

With CONSULT
7. Check DTC.
Is P3196 detected?

With CONSULT
Is P3196 detected?
YES >> Replace on board charger. Refer to VC-105, "Removal and Installation"
NO >> GO TO 2.
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P3196”.
Is U1000 detected?

A

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

D
With CONSULT
3. Check DTC.
G
When this DTC is detected, replace VCM. Refer to EVC-369, "Removal and Installation".
H

P319C COMMUNICATION ERROR
DTC DETECTION LOGIC

COMMUNICATION ER- • Traction motor inverter
P319C When a CRC error from traction motor inverter is detected.

With CONSULT
3. Check DTC.
Is P319C detected?
When this DTC is detected, replace traction motor inverter. Refer to TMS-115, "Exploded View".

P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
A

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

D
With CONSULT
3. Check DTC.
Is P31A4 detected? F
G
H

P31A7 CAN ERROR INV/MC
DTC DETECTION LOGIC

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

With CONSULT
3. Check DTC.
Is P31A7 detected?

P3300 TOTAL VOLTAGE OVER
A

• Li-ion battery EVB
When total voltage exceeds the allowable working voltage • Li-ion battery controller
range. • VCM
• Traction motor inverter
D
With CONSULT
3. Check DTC. F
Is P3300 detected?
G
H
With CONSULT
1. Perform "All DTC Reading". I
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. J
NO >> GO TO 2.
K
With CONSULT
2. Check “Self Diagnostic Result” to see if “P3302”-“P3331” is detected.
L
Is P3302-P3331 detected?
YES >> “P3302” - “P3331” are detected simultaneously.
• When “P3302” - “P330D” are detected simultaneously, perform the diagnosis procedure of
M
• When “P331A” - “P3325” are detected simultaneously, perform the diagnosis procedure of N
“P3326” - “P3331”. Refer to EVB-109, "Diagnosis Procedure". O

P3302-P330D CELL OVER VOLTAGE
DTC DETECTION LOGIC

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

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT
1. Perform “All DTC Reading” with CONSULT.

2. Check systems other than “HV BAT” if any DTC is detected.
Is any DTC detected? A
NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Disconnect high voltage. Refer to GI-31, "How to Disconnect High Voltage". EVB
D
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER E
1. Disconnect module harness connector and Li-ion battery controller harness connector.
2. Refer to below table and check the continuity between corresponding module and Li-ion battery controller.
F
DTC Continuity
G
17 33
P3302 1 LB9 2 LB13 50 Existed
18 34 H
18 34
19 35
I
19 35
P3304 3 LB9 4 LB13 52 Existed J
20 36
20 36
P3305 4 LB9 5 LB13 53 Existed K
21 37
21 37
L
22 38
22 38 M
23 39
N
23 39
24 40 O
24 40
P
25 42
25 42
P330A 9 LB9 26 LB13 58 Existed
11 43


DTC Continuity
11 43
P330B 10 LB9 27 LB13 59 Existed
12 44
12 44
P330C 11 LB9 28 LB13 60 Existed
13 45
13 45
P330D 12 LB9 29 LB13 61 Existed
14 46
YES >> GO TO 4.
Check voltage of corresponding module. Refer to EVB-102, "Component Inspection".


Terminals
Voltage
(+) (-)
(Approx.)
Module
NO >> Replace module. Refer to EVB-188, "FRONT MODULE
JSCIA0338ZZ

P330E-P3319 CELL OVER VOLTAGE
A

P330E CELL OVER VOLTAGE MODULE13 EVB
P330F CELL OVER VOLTAGE MODULE14
D
P3313 CELL OVER VOLTAGE MODULE18 tion E
• Module
• Harness or connector F
P3318 CELL OVER VOLTAGE MODULE23 G

H
With CONSULT
3. Check DTC.
K
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec- L
maintenance. M
carry it in your pocket or put it in the tool box. N
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
3.CHECK HARNESS BETWEEN MODULE AND LI-ION BATTERY CONTROLLER

DTC Continuity
14 46
P330E 13 LB9 30 LB13 62 Existed
15 47
15 47
P330F 14 LB9 31 LB13 63 Existed
1 48
LB9 1 LB13 48
P3310 15 45 77 Existed
LB10 LB14
34 65
34 65
P3311 16 LB10 46 LB14 78 Existed
35 66
35 66
P3312 17 LB10 36 LB14 80 Existed
48 69
48 69
P3313 18 LB10 37 LB14 81 Existed
49 70
49 70
P3314 19 LB10 38 LB14 82 Existed
50 71
50 71
P3315 20 LB10 39 LB14 83 Existed
51 72
51 72
P3316 21 LB10 52 LB14 84 Existed
41 73


DTC Continuity A
41 73
P3317 22 LB10 53 LB14 85 Existed B
42 74
42 74
P3318 23 LB10 54 LB14 86 Existed EVB
43 75
43 75
D
P3319 24 LB10 55 LB14 87 Existed
44 76
Is the inspection result normal? E
YES >> GO TO 4.
4.CHECK MODULE VOLTAGE F

Is the inspection result normal? G
NO >> Replace corresponding module. Refer to EVB-168, "Exploded view". H
1.CHECK MODULE VOLTAGE I

A : Positive terminal (Red) J

K
Terminals
Voltage
(+) (-)
(Approx.)
Module L
Is the inspection result normal? M
EVB-198, "REAR MODULE STACK : Disassembly and N
JSCIA0338ZZ P

P331A-P3325 CELL OVER VOLTAGE
DTC DETECTION LOGIC

P331E CELL OVER VOLTAGE MODULE29 motor inverter/VCM malfunc-
P331F CELL OVER VOLTAGE MODULE30 tion
• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

2. Check “Self Diagnostic Result” of systems other than “HV BAT” if any DTC is detected.
NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
D
>> GO TO 3.
With CONSULT
2. Identify the malfunctioning module based on detected DTC. F
G
DTC Continuity
57 89 H
58 90
I
58 90
75 91 J
75 91
K
76 92
76 92
P331D 28 LB8 77 LB15 113 Existed L
62 93
62 93
M
79 94
79 94 N
80 95
80 95 O
P3320 31 LB8 81 LB15 116 Existed
66 96
P
66 96
P3321 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity
83 97
P3322 33 LB8 68 LB15 118 Existed
84 99
84 99
P3323 34 LB8 85 LB15 119 Existed
70 100
70 100
P3324 35 LB8 86 LB15 120 Existed
87 101
87 101
P3325 36 LB8 72 LB15 121 Existed
88 102
YES >> GO TO 4.


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

P3326-P3331 CELL OVER VOLTAGE
A

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

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
With CONSULT
2. Identify the malfunctioning module based on detected DTC.

DTC Continuity
LB8 88 102
P3326 37 89 LB15 122 Existed
LB7
101 103
101 103
P3327 38 LB7 90 LB15 123 Existed
102 104
102 104
P3328 39 LB7 91 LB15 124 Existed
103 105
103 105
P3329 40 LB7 92 LB15 125 Existed
104 106
104 106
105 107
105 107
106 108
106 LB15 108
P332C 43 LB7 95 137 Existed
LB16
107 130
107 130
108 131


DTC Continuity A
108 131
P332E 45 LB7 97 LB16 140 Existed B
109 132
109 132
P332F 46 LB7 98 LB16 141 Existed EVB
110 133
110 133
D
P3330 47 LB7 99 LB16 142 Existed
111 134
111 134 E
P3331 48 LB7 100 LB16 143 Existed
112 135
F
YES >> GO TO 4.
NO >> Repair harness or connector. G
H
NO >> Replace corresponding module. Refer to EVB-168, "Exploded view". I
J
K
L
Terminals
Voltage
(+) (-)
(Approx.) M
Module
Is the inspection result normal? N
STACK : Disassembly and Assembly" (Front module) or O
P
JSCIA0338ZZ

P3373 TOTAL VOLTAGE OVER DISCHARGE
DTC DETECTION LOGIC

If DTC P3373 is displayed with DTC P30F4, first perform the trouble diagnosis for P30F4. Refer to EVB-84,
"DTC Logic".

• Module
• Bus bar
TOTAL VOLTAGE OVER When total voltage lowers below the allowable working
P3373 • Service plug fuse
DISCHARGE voltage range.

With CONSULT
3. Check DTC.
Is P3373 detected?

With CONSULT
1. Perform “All DTC Reading”.
NO >> GO TO 2.
2.PERFORM THE SELF-DIAGNOSISS OF LI-ION BATTERY CONTROLLER
With CONSULT
YES >> • When “P3375”-“P3380” are detected simultaneously, perform the diagnosis procedure of
“P338D”-“P3398”. Refer to EVB-119, "Diagnosis Procedure".

P3375-P3380 CELL OVER DISCHARGE
A

P3375 CELL OVER DISCHARGE MODULE1 EVB
P3376 CELL OVER DISCHARGE MODULE2
D
P3379 CELL OVER DISCHARGE MODULE5 • Overcharge caused by traction motor
inverter/VCM malfunction
P337A CELL OVER DISCHARGE MODULE6 When cell voltage lowers below the • Module E
P337B CELL OVER DISCHARGE MODULE7 allowable working voltage range. • Li-ion battery controller
• Bus bar
P337C CELL OVER DISCHARGE MODULE8 • Harness or connector
F
P337D CELL OVER DISCHARGE MODULE9
P337E CELL OVER DISCHARGE MODULE10
P337F CELL OVER DISCHARGE MODULE11 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.

DTC Continuity
17 33
18 34
18 34
19 35
19 35
20 36
20 36
21 37
21 37
22 38
22 38
23 39
23 39
24 40
24 40
25 42
25 42
11 43


DTC Continuity A
11 43
12 44
12 44
13 45
13 45
D
P3380 12 LB9 29 LB13 61 Existed
14 46
YES >> GO TO 4.
NO >> Repair Harness or connector.



K
Terminals
Voltage
(+) (-)
(Approx.)
Module L
JSCIA0338ZZ P

P3381-P338C CELL OVER DISCHARGE
DTC DETECTION LOGIC

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

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Disconnect high voltage circuit. Refer to GI-31, "How to Disconnect High Voltage". EVB
D
>> GO TO 3.
F
DTC Continuity
G
14 46
P3381 13 LB9 30 LB13 62 Existed
15 47 H
15 47
P3382 14 LB9 31 LB13 63 Existed
1 48
I
LB9 1 LB13 48
P3383 15 45 77 Existed J
LB10 LB14
34 65
34 65
P3384 16 LB10 46 LB14 78 Existed K
35 66
35 66
L
P3385 17 LB10 36 LB14 80 Existed
48 69
48 69 M
P3386 18 LB10 37 LB14 81 Existed
49 70
N
49 70
P3387 19 LB10 38 LB14 82 Existed
50 71 O
50 71
P3388 20 LB10 39 LB14 83 Existed
P
51 72
51 72
P3389 21 LB10 52 LB14 84 Existed
41 73


DTC Continuity
41 73
42 74
42 74
43 75
43 75
44 76
YES >> GO TO 4.


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

P338D-P3398 CELL OVER DISCHARGE
A

P338D CELL OVER DISCHARGE MODULE25 EVB
P338F CELL OVER DISCHARGE MODULE27
D
P3392 CELL OVER DISCHARGE MODULE30 function E
• Module
P3397 CELL OVER DISCHARGE MODULE35 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

2. Check “Self Diagnostic Result” of systems other than “” if any DTC is detected.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
With CONSULT

DTC Continuity
57 89
58 90
58 90
75 91
75 91
76 92
76 92
P3390 28 LB8 77 LB15 113 Existed
62 93
62 93
P3391 29 LB8 78 LB15 114 Existed
79 94
79 94
P3392 30 LB8 64 LB15 115 Existed
80 95
80 95
P3393 31 LB8 81 LB15 116 Existed
66 96
66 96
P3394 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity A
83 97
P3395 33 LB8 68 LB15 118 Existed B
84 99
84 99
70 100
70 100
D
P3397 35 LB8 86 LB15 120 Existed
87 101
87 101 E
P3398 36 LB8 72 LB15 121 Existed
88 102
F
YES >> GO TO 4.
NO >> Repair Harness or connector. G
H
J
K
L
Terminals
Voltage
(+) (-)
(Approx.) M
Module
P
JSCIA0338ZZ

P3399-P33A4 CELL OVER DISCHARGE
DTC DETECTION LOGIC

P339D CELL OVER DISCHARGE MODULE41 tion motor inverter/VCM mal-
P339E CELL OVER DISCHARGE MODULE42 function
• Module
P339F CELL OVER DISCHARGE MODULE43 working voltage range.
P33A0 CELL OVER DISCHARGE MODULE44 • Bus bar
P33A1 CELL OVER DISCHARGE MODULE45

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
D
>> GO TO 3.
With CONSULT
G
DTC Continuity
LB8 88 102 H
P3399 37 89 LB15 122 Existed
LB7
101 103
I
101 103
102 104 J
102 104
K
103 105
103 105
P339C 40 LB7 92 LB15 125 Existed L
104 106
104 106
M
105 107
105 107 N
106 108
106 LB15 108 O
P339F 43 LB7 95 137 Existed
LB16
107 130
P
107 130
P33A0 44 LB7 96 LB16 138 Existed
108 131


DTC Continuity
108 131
109 132
109 132
110 133
110 133
111 134
111 134
P33A4 48 LB7 100 LB16 143 Existed
112 135
YES >> GO TO 4.


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

P33D4 BATT GRADUAL CAPA LOSS DIAG
A

BATT GRADUAL CAPA LOSS When the battery charge lowers. EVB
P33D4 Li-ion battery
DIAG (The internal resistance of the battery increases.)

D
With CONSULT
3. Check DTC.
Is P33D4 detected? F
G
When this DTC is detected, replace Li-ion battery. Refer to EVB-161, "Removal and Installation".
H

P33D5 CURRENT SENSOR
DTC DETECTION LOGIC

Deviation in characteristics of battery current sensor sig- • Li-ion battery controller
nal voltage. • Current sensor
(Battery current sensor signal voltage is too high or too • System main relay
low.) • Harness or connector

With CONSULT
3. Check DTC.
Is P33D5 detected?
WARNING:
maintenance.
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS OF VCM
With CONSULT
1. Select “Self Diagnostic Result” mode of “EV/HEV” using CONSULT.
2. Check to see if “P0AA0”, “P0AA1” or “P0AA4” is detected.
YES >> Perform diagnosis on the detected DTC. Refer to EVB-50, "DTC Index".
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:

>> GO TO 3. A
Check connection status of Li-ion battery controller harness connector and battery junction box (current sen- B
sor) harness connector.
YES >> GO TO 4. EVB
4.CHECK HARNESS BETWEEN BATTERY JUNCTION BOX (CURRENT SENSOR) AND LI-ION BATTERY
CONTROLLER D
Check continuity between battery junction box (current sensor) harness connector and Li-ion battery controller
harness connector.
E
Battery junction box (Current
sensor) Continuity
Connector Terminal Connector Terminal F
9 10
LB3 3 LB11 9 Exited
G
10 17
YES >> GO TO 5. H
5.CHECK CURRENT SENSOR
I
Check resistance of current sensor.
Battery junction box (Current sensor) Resistance val- J

Connector Terminal Terminal ue
9 10
LB3 1 kΩ–10 MΩ
3 10 K
YES >> GO TO 6.
L
NO >> Replace current sensor.
6.CHECK LI-ION BATTERY CONTROLLER
Check resistance of Li-ion battery controller. M
Li-ion battery controller Resistance val-

Connector Terminal Terminal ue N
LB11 10 17 Approx. 4.7 kΩ
Is the inspection result normal? O
YES >> Replace battery junction box. Refer to EVB-174, "BATTERY JUNCTION BOX : Disassembly and
Assembly".
P

DTC DETECTION LOGIC

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

With CONSULT
3. Check DTC.
Is P33D6 detected?
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
>> GO TO 2.
1. Disconnect Li-ion battery controller harness connector.
2. Check the resistance of current sensor from Li-ion battery controller side.

Resistance value
Connector Terminal

10 9
LB11 1 kΩ–10 MΩ A
9 17
YES >> Replace Li-ion battery controller. Refer to EVB-181, "LI-ION BATTERY CONTROLLER : Disas- B
NO >> GO TO 3.
3.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND BATTERY JUNCTION BOX (CUR- EVB
RENT SENSOR)
1. Disconnect battery junction box harness connector.
2. Check continuity between Li-ion battery controller and battery junction box (current sensor). D
Battery junction box

(Current sensor) Continuity E
10 9
F
17 10
Assembly".
NO >> Repair harness or connector. H

P33D7, P33D9, P33DB, P33DD TEMPERATURE SENSOR
DTC DETECTION LOGIC

Battery temperature sensor rear center signal voltage is
P33D7
too high or too low.
Battery temperature sensor front RH signal voltage is
P33D9 • Battery temperature sensor 1
TEMPERATURE SENSOR • Li-ion battery controller
Battery temperature sensor rear RH signal voltage is • Harness or connector
P33DB
Battery temperature sensor front LH signal voltage is
P33DD

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
>> GO TO 2.

2.CHECK HARNESS A
2. Check a connection state of harness connector of Li-ion battery controller.
Is the inspection result normal? B
YES >> GO TO 3.
3.CHECK BATTERY TEMPERATURE SENSOR EVB
Refer to EVB-131, "Component Inspection".
D
YES >> GO TO 4.
NO >> Replace battery temperature sensor.
4.CHECK HARNESS BETWEEN BATTERY TEMPERATURE SENSOR AND GROUND E
2. Check continuity between battery temperature sensor harness connector and ground.
F
Battery tem-
perature sen- Connector Terminal — Continuity
sor
G
Rear center LB17 3
Front RH LB5 1
Ground No existed
Rear RH LB17 1 H
Front LH LB4 3
I
J
1.CHECK BATTERY TEMPERATURE SENSOR K

1. Remove battery temperature sensor. Refer to EVB-168, "Exploded view".
2. Check resistance between battery temperature sensor terminals.
L
Battery temperature sensor Terminals Condition Resistance (kΩ)
Rear RH & Front RH 1 and 2 10 (50) Approx. 7.4
Temperature °C (°F) 25 (77) Approx. 4.0
M
Rear center & Front LH 3 and 4
40 (104) Approx. 2.3
O

P33DF BAT VOLTAGE ISOLATION SEN
DTC DETECTION LOGIC

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

With CONSULT
3. Check DTC.
Is P33DF detected?

P33E0 BAT VOLTAGE ISOLATION SEN
A

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

D
With CONSULT
3. Check DTC.
Is P33E0 detected? F
G

DTC DETECTION LOGIC

BATTERY VOLTAGE ISO- Signal voltage of the on-board isolation resistance moni-
LATION SENSOR toring system exhibits no amplitude variation.

With CONSULT
3. Check DTC.
Is P33E1 detected?
When this DTC is detected, perform Li-ion battery insulation resistance loss check. Refer to EVB-146, "Com-
ponent Inspection".

P33E2 BATT PACK OVER TEMP
A

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

D
With CONSULT
3. Check DTC.
G

H
With CONSULT
2. Check to see if “P33E4” or “P33E5” is detected simultaneously with “P33E2”.
I
Is P33E4 or P33E5 detected?
YES >> Perform diagnosis on the detected “P33E4” or “P33E5”. Refer to EVB-136, "Diagnosis Proce-
dure".
NO >> GO TO 2. J

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

Power switch ON 55°C (131°F) or less M
Is there temperature increase? N
Temperature increase is seen>>Replace Li-ion battery. Refer to EVB-161, "Removal and Installation".
Temperature increase is not seen>>Replace battery temperature sensors. Refer to EVB-161, "Removal and
Installation". O

P33E4, P33E5 TEMPERATURE SENSOR
DTC DETECTION LOGIC

Deviation in characteristics of Battery temperature sensor
P33E4
rear center or front RH.
TEMPERATURE SENSOR Battery temperature sensor
P33E5
rear RH or front LH.

With CONSULT
3. Check DTC.
Is P33E4 or P33E5 DTC detected?
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
>> GO TO 2.
2.CHECK BATTERY TEMPARETURE SENSOR
YES >> Replace both battery temperature sensor.

NO >> Replace malfunction battery temperature sensor.
A
1.CHECK BATTERY TEMPERATURE SENSOR B

EVB
Temperature °C (°F) 25 (77) Approx. 4.0 D
40 (104) Approx. 2.3
E
F

P33E6 CELL VOLTAGE DEVIATION DIAG
DTC DETECTION LOGIC

With the power switch ON and no load condition, the dif-
CELL VOLTAGE DEVIA- • Li-ion battery controller
P33E6 ference between the maximum voltage and minimum volt-
TION DIAG • Module
age exceeds the allowable range.

With CONSULT
1. Turn power switch ON and wait for 10 seconds or more.
3. Check DTC.
Is P33E6 detected?
WARNING:
maintenance.
• Be sure to wear insulating protective equipment before beginning work on the high voltage system.
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?
YES-1 >> When “P0A1F” or “P3062” are detected simultaneously, Replace Li-ion battery controller. Refer to
EVB-181, "LI-ION BATTERY CONTROLLER : Disassembly and Assembly".
YES-2 >> When “P33ED” is detected simultaneously, perform the diagnosis procedure of “P33ED”. Refer to
EVB-143, "Diagnosis Procedure".
NO >> GO TO 2.
2.CHECK FREEZE FRAME DATA (FFD)
With CONSULT
1. Check “FFD” when DTC is detected.
2. Calculate the average value of cell voltage by dividing “TOTAL BATTERY VOLTAGE” by 96 (the number
of cells).

Average cell voltage = “TOTAL BETTER VOLTAGE” ÷ 96 (the number of cells) A

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.
B
A = Maximum cell voltage − Average cell voltage
B = Average cell voltage − Minimum cell voltage
EVB
Which voltage is larger, A or B?
A >> Replace module including a cell of the maximum cell voltage. Refer to EVB-188, "FRONT MOD-
ULE STACK : Disassembly and Assembly" (Front module stack) or EVB-198, "REAR MODULE
STACK : Disassembly and Assembly" (Rear module stack). After replacing module, GO TO 3. D
B >> Replace module including a cell of the minimum cell voltage. Refer to EVB-188, "FRONT MOD-
STACK : Disassembly and Assembly" (Rear module stack). After replacing module, GO TO 3. E
3.PERFORM CELL VOLTAGE LOSS INSPECTION
With CONSULT
F
1. Select “WORK SUPPORT” of “HV BAT.”
2. Select “CELL VOLTAGE LOSS INSPECTION.” Touch “START.”
3. Check “MINIMUM CELL VOLTAGE.”
Is “MINIMUM CELL VOLTAGE” 3,712 mV or less? G
YES >> GO TO 5.
NO >> GO TO 4.
H
4.DISCHARGE OF LI-ION BATTERY
With CONSULT
1. Set the vehicle to READY. I
2. Set the vehicle, according to the following conditions.
A/C set temperature : Full hot J

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

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

P
6 Approx. 90 minute
5 Approx. 70 minute

The number of light-
ing segments of Li-
Time to 2 segments
charge gauge
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-188, "FRONT MODULE STACK : Disassembly and Assem-
bly" (Front module stack) or EVB-198, "REAR MODULE STACK : Disassembly and Assembly"
(Rear module stack).
6.PRECONDITIONING
WARNING:
Disconnect the high voltage. Refer to GI-31, "How to Disconnect High Voltage".
2. Remove battery pack upper case. Refer to EVB-161, "Exploded View", see Step-1 to Step-3.
>> GO TO 2.
7.CHECK CONDENSATION
Check condensation in battery pack.
YES >> GO TO 8.
NO >> Replace Li-ion battery. Refer to EVB-161, "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
NO >> Repair or replace error-detected parts.
Check module voltage within determined cell at step 3 and check the divergence of the voltage and cell volt-
age with “DATA MONITOR”.
DANGER:
When check module voltage, be careful not to short.
Is Divergence within 40mV?
YES >> GO TO 10.
10.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND MODULE HARNESS CONNEC-
TOR
1. Disconnect Li-ion battery controller harness connector and module harness connector.

2. Check the resistance Li-ion battery controller harness connector and module harness connector of the
determined cell at step 3. A
Resistance val-
Terminal
ue B
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. EVB
YES >> Replace module within the determined cell at step 5.
NO >> Repair or replace harness or connectors. D

P33E7 CELL CONTROLLER
DTC DETECTION LOGIC

P33E7 CELL CONTROLLER Li-ion battery controller
tioning.

With CONSULT
3. Check DTC.
Is P33E7 detected?

P33ED BATTERY PARALLEL DIAGNOSIS
A

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

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

Headlamp : High beam ON I
3. Let the Li-ion battery discharge until the Li-ion battery available charge gauge shows segment 1 or below. J
>> GO TO 3.
3.CHARGE OF LI-ION BATTERY K
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. L
>> GO TO 4.
M
With CONSULT
1. Power switch ON and wait for 10 seconds or more. N
3. Check DTC.
Is P33ED detected? O
P
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-161, "Exploded View".
NO >> GO TO 2.
2.DTC CONFIRMATION PROCEDURE OPERATION
1. If abnormal cell is not identified, perform DTC confirmation procedure. Refer to EVB-143, "DTC Logic".
2. Check cell voltage again using “DATA MONITOR” or “FFD” to identify malfunctioning cell.
>> Replace corresponding Module. Refer to EVB-168, "Exploded view".

U1000 CAN COMM CIRCUIT
A
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul- B
tiplexcommunication line with high data communication speed and excellent error detection ability. Modern
vehicle is equipped with many electronic control units, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN-H, CAN-L) allowing a high rate of information transmission with less wiring. EVB
Each control unit transmits/receives data but selectively reads the required data only.
CAN communication signal chart. Refer to LAN-33, "CAN COMMUNICATION SYSTEM : CAN Communica-
tion Signal Chart". D
DTC DETECTION LOGIC E

When no CAN communication signal is received continu- F
U1000 CAN COMM CIRCUIT CAN communication system
ously for 2 seconds or more.
Diagnosis Procedure INFOID:0000000007634408 G
For the diagnosis procedure, refer to LAN-15, "Trouble Diagnosis Flow Chart".
H

LI-ION BATTERY INSULATION RESISTANCE LOSS CHECK
WARNING:
maintenance.
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 INSULATION OF FRONT MODULE STACK LH-1
CAUTION:
Check that high voltage harness and harness shield have no scratches and cracks. If any damage is
found, replace damaged parts.
2. Remove Li-ion battery controller. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly and
Assembly".
3. Remove bus bar that connects front module stack LH and front module stack RH.
4. Measure voltages between positive terminal of front module stack LH and battery pack ground, and
between positive terminal of front module stack LH and battery pack ground.
JSCIA0739ZZ
: Battery pack front

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

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

I
+
Front module stack LH − Voltage J
Terminal

K
YES >> Replace vehicle communication harness of front module stack LH and GO TO 8.
NO >> GO TO 4. L
1. Remove bus bar that connects service plug and front module stack LH.
2. Measure voltages between positive terminal of front module stack LH and battery pack ground, and M
JSCIA0739ZZ

+
Terminal

YES >> GO TO 5.
NO >> GO TO 6.
5.CHECK SERVICE PLUG SWITCH INSULATION RESISTANCE
1. Remove bus bar that connects service plug and front module stack LH from service plug switch bracket.
2. Using insulation resistance tester, measure insulation resistance between service plug switch terminal
and service plug switch bracket.
WARNING:
Unlike the ordinary tester, the insulation resistance tester applies 500 V when measuring. If used
incorrectly, there is the danger of electric shock. If used in the vehicle 12V system, there is the
danger of damage to electronic devices. Read the insulation resistance tester instruction manual
carefully and be sure to work safely.
CAUTION:
Be sure to set the insulation resistance tester to 500 V when 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.
+ — Resistance
Service plug switch terminal Service plug switch bracket 1000 MΩ or more
YES >> Replace bus bar that connects service plug and front module stack LH and GO TO 8.
NO >> Replace service plug switch (Refer to EVB-384, "Exploded view".) and GO TO 8.
6.CHECK MODULE-1
1. Remove front module stack LH. Refer to EVB-405, "FRONT MODULE STACK : Disassembly and Assem-
bly".
NOTE:
Do not disassemble module stack.
2. Measure voltages between terminal / of all modules in front
module stack LH and module body.
JSCIA0740ZZ
+
Module − Voltage
Terminal
Module body Approx. 0 V

YES >> GO TO 7.
NO >> Replace malfunctioning module (Refer to EVB-405, "FRONT MODULE STACK : Disassembly A
and Assembly".) and GO TO 8.
7.CHECK MODULE-2
B
Measure insulation resistance between terminal / of all modules
in front module stack LH and module body.
WARNING:
Unlike the ordinary tester, the insulation resistance tester EVB
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 D
insulation resistance tester instruction manual carefully and be
sure to work safely.
CAUTION:
E
Be sure to set the insulation resistance tester to 500 V when JSCIA0740ZZ
performing this test. Using a setting higher than 500 V can
result in damage to the component being inspected.
F
+
Module − resistance
G
Terminal
Module body 100 MΩ or more

H

YES >> Check insulation resistance of front module stack RH, because front module stack LH is normal. I
GO TO 8.
NO >> Replace malfunctioning module (Refer to EVB-405, "FRONT MODULE STACK : Disassembly
J
8.CHECK INSULATION OF FRONT MODULE STACK RH-1
1. Measure voltages between positive terminal of front module stack RH and battery pack ground, and
between positive terminal of front module stack LH and battery pack ground. K
N
JSCIA0741ZZ

O
+
Front module stack RH − Voltage P
Terminal

YES >> GO TO 14.
NO >> GO TO 9.


1. Disconnect vehicle communication harness connector of front module stack RH.
between positive terminal of front module stack RH and battery pack ground.
JSCIA0741ZZ
+
Front module stack RH − Voltage
Terminal

YES >> Replace vehicle communication harness of front module stack RH and GO TO 14.
NO >> GO TO 10.
1. Remove bus bar that connects front module stack RH and battery junction box.
JSCIA0741ZZ
+
Terminal

YES >> GO TO 11.
NO >> GO TO 12.
11.CHECK BATTERY JUNCTION BOX INSULATION RESISTANCE

1. Using insulation resistance tester, measure insulation resistance
between high voltage terminal / of battery junction box and A
battery pack ground.
: Battery pack front B

WARNING:
Unlike the ordinary tester, the insulation resistance tester
applies 500 V when measuring. If used incorrectly, there is EVB
the danger of electric shock. If used in the vehicle 12V sys-
tem, there is the danger of damage to electronic devices.
Read the insulation resistance tester instruction manual JSCIA0453ZZ
carefully and be sure to work safely. D

CAUTION:
higher than 500 V can result in damage to the component being inspected. E

— Resistance
Terminal F
Battery pack ground 1000 MΩ or more

G
YES >> Replace bus bar that connects front module stack RH and battery junction box and GO TO 14.
NO >> Replace battery junction box (Refer to EVB-392, "BATTERY JUNCTION BOX : Disassembly and H
Assembly") and GO TO 14.
12.CHECK MODULE-3
I
1. Remove front module stack RH. Refer to EVB-405, "FRONT MODULE STACK : Disassembly and Assem-
bly".
NOTE:
Do not disassemble module stack. J
module stack RH and module body.
K
M
JSCIA0740ZZ
N
+
Module − Voltage
O
Terminal

P

YES >> GO TO 13.
13.CHECK MODULE-4

in front module stack RH and module body.
WARNING:
there is the danger of damage to electronic devices. Read the
CAUTION:
+
Terminal

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

YES-1 >> Replace or repair of malfunctioning part is not-yet performed: Replace Li-ion battery controller.
Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly and Assembly".
YES-2 >> Replace or repair of malfunctioning part is complete: INSPECTION END.
NO >> GO TO 15.

1. Disconnect vehicle communication harness connector of rear
module stack. A
EVB
JSCIA0146ZZ
D
E
JSCIA0744ZZ H
+
Front module stack RH − Voltage I
Terminal
, Battery pack ground Approx. 0 V J

YES >> Replace vehicle communication harness of rear module stack.
NO >> GO TO 16. K
1. Remove mounting nuts / and remove high voltage harness from rear module stack. L
JSCIA0743ZZ
O

JSCIA0744ZZ
+
Terminal

YES >> .Replace high voltage harness.
NO >> GO TO 17.
17.CHECK MODULE-5
1. Remove rear module stack. Refer to EVB-414, "REAR MODULE STACK : Disassembly and Assembly".
NOTE:
2. Measure voltages between terminal / of all modules in rear
module stack and module body.
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 18.
NO >> Replace malfunctioning module. Refer to EVB-414, "REAR MODULE STACK : Disassembly and
Assembly".
18.CHECK MODULE-6

in rear module stack and module body. A
WARNING:
applies 500 V when measuring. If used incorrectly, there is the B
sure to work safely. EVB
CAUTION:
performing this test. Using a setting higher than 500 V can D
+ E
Terminal
F

YES-2 >> Replace or repair of malfunctioning part is complete: INSPECTION END. H
Assembly".
I

POWER SUPPLY AND GROUND CIRCUIT
WARNING:
maintenance.
• Be sure to remove the service plug in order to shut off the high voltage circuits before performing
inspection or maintenance of high voltage system harnesses and parts.
• Be sure to put the removed service plug in your pocket and carry it with you so that another person
does not accidentally connect it while work is in progress.
• Be sure to wear insulating protective gear consisting of glove, shoes and face shield before begin-
ning work on the high voltage system.
CAUTION:
1.CHECK FUSE
Check that the following fuse is not fusing.
Power supply Fuse No.

Battery 43
55
Power switch ON
74
Is the fuse fusing?
YES >> Replace the fuse after repairing the applicable circuit.
NO >> GO TO 2.
2.CHECK LI-ION BATTERY CONTROLLER GROUND CIRCUIT
1. Turn power switch OFF.
3. Check the continuity between Li-ion battery vehicle communication harness connector and ground.
+
Li-ion battery − Continuity
Connector Terminal
6
B24 7 Ground Existed
8
YES >> GO TO 3.
3.CHECK BATTERY POWER SUPPLY
Check the voltage between Li-ion battery vehicle communication harness connector and ground.

+ A
Connector Terminal
B
12V battery power
B24 5 Ground
supply
Is the inspection result normal? EVB
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK BATTERY POWER SUPPLY CIRCUIT D
1. Check the continuity between Li-ion battery vehicle communication harness connector and fuse terminal.
E
+
Connector Terminal F
No.43 fuse ter-
B24 5 Existed
minal
2. Also check harness for short to ground. G
YES >> Check power supply circuit for battery power supply.
NO >> Repair or replace error-detected parts. H
5.CHECK IGNITION POWER SUPPLY
1. Turn power switch ON. I
2. Check the voltage between Li-ion battery vehicle communication harness and ground.
+
J
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4 K
B24 Ground 11 – 14 V
21
Is the inspection result normal? L
YES >> GO TO 8.
NO >> GO TO 6.
6.CHECK IGNITION POWER SUPPLY CIRCUIT-1 M
2. Disconnect IPDM E/R harness connector.
3. Check the continuity between Li-ion battery vehicle communication harness and IPDM E/R harness con- N
nector.
Li-ion battery IPDM E/R O

Continuity
B24 4 E15 57 Existed
P
4. Also check harness for short to ground.
YES >> GO TO 7.
7.CHECK IGNITION POWER SUPPLY CIRCUIT-2
1. Check the continuity between Li-ion battery vehicle communication harness and fuse terminal.

Li-ion battery
— Continuity
Connector Terminal
No.74 fuse ter-
B24 21 Existed
minal
8.PRECONDITIONING
WARNING:
Shut off high voltage circuit. Refer to GI-31, "How to Disconnect High Voltage".
>> GO TO 9.
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 21
6 4
21 5
LB11 LB1 Existed
3 8
15 7
16 6

REDUCTION IN THE DRIVING RANGE
< SYMPTOM DIAGNOSIS > [TYPE 1]
SYMPTOM DIAGNOSIS A
B
• The driving range is shorter than before.
• Sudden change (decrease/increase) in possible travel distance indicated on the combination meter.
EVB

NOTE:

YES >> GO TO 3. F
NO >> GO TO 2.

A/C air outlet : Defroster I
J
3. Let the Li-ion battery discharge until the Li-ion battery available charge gauge shows Segment 1 or below.
>> GO TO 3.
K
3.CHARGE OF LI-ION BATTERY
2. After the completion of normal charge, check that the indication of the Li-ion battery available charge L
gauge shows 12 segments.
>> GO TO 4. M
With CONSULT N
3. Check DTC.
O
P

EV BATTERY USAGE REPORT
< PERIODIC MAINTENANCE > [TYPE 1]
PERIODIC MAINTENANCE
Inspection INFOID:0000000007634412
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 III plus
operation manual.

LI-ION BATTERY
< UNIT REMOVAL AND INSTALLATION > [TYPE 1]
UNIT REMOVAL AND INSTALLATION A

LI-ION BATTERY
Exploded View INFOID:0000000007634413
B
EVB
JPCIA0247GB K
1. Li-ion battery 2. Bonding plate (Stamp No.4) 3. Li-ion battery under cover (center)
4. Li-ion battery under cover (front) 5. Clip 6. Li-ion battery under cover (rear) L
7. Battery mounting bracket LH 8. Battery mounting bracket RH
: N·m (kg-m, ft-lb)
M
Removal and Installation INFOID:0000000007634414
N
WARNING:
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and O
maintenance.
ing inspection or maintenance of high voltage system harnesses and parts. P
CAUTION:

LI-ION BATTERY
REMOVAL
WARNING:
Perform high voltage system work preparation. Refer to GI-31, "How to Disconnect High Voltage".
1. Lift up the vehicle and remove the Li-ion battery under covers. Refer to EVB-161, "Exploded View".
2. Disconnect high voltage harness connector (A) from Li-ion bat-
tery.
WARNING:
• To prevent electric shock hazards, be sure to wear

protective gear.
• To prevent electric shock hazards, immediately JPCIA0062ZZ

wrap insulating tape around disconnected high voltage
harness connector and terminals.
• Follow the procedure below to disconnect the high voltage harness connector.
JPCIA0035ZZ
3. Disconnect the Li-ion battery vehicle communication harness

connector (A) while turning it counterclockwise.
WARNING:
To prevent electric shock hazards, be sure to wear

protective gear.
JPCIA0063ZZ
4. Remove the bonding plates (1).
: Vehicle front
WARNING:

protective gear.
JPCIA0248ZZ

LI-ION BATTERY
5. Remove the Li-ion battery mounting bolts (A).
A
: Vehicle front
WARNING:
B
protective gear.
EVB
CAUTION: JSCIA0177ZZ
Never remove the 4 bolts (B) shown in the figure. D

6. Set the pallet onto the lifter table.
• Align center mark (A) of pallet (1) with center mark (B) of bat-
tery lift table (2). E
C. Front
D. Side F
K
JSCIA0178ZZ
7. Set the pallet (1) onto the Li-ion battery.

CAUTION: L
Set the palette and Li-ion battery with transportation fixing
bolts.
M
JSCIA0179ZZ
O
8. Remove the Li-ion battery mounting bolts (4 bolts) (A).

LI-ION BATTERY
JPCIA0206ZZ
: Vehicle front
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
9. Lower the pallet and remove the Li-ion battery (1) from the vehi-
cle.
WARNING:

protective gear.
JSCIA0181ZZ
10. Move Li-ion battery from the lift table together with the pallet.
JPCIA0196ZZ
1. Lift Li-ion battery.

2. Move lift table.
3. Lower Li-ion battery.
4. Move Li-ion battery by operating stacker.
CAUTION:
To prevent stacker from falling, never move the stacker with the Li-ion battery lifted.
INSTALLATION
1. When replacing the Li-ion battery with a new one, perform the following procedure.
a. Enter the date of replacement on the EV battery traceability seal packaged with the new part.
b. Cut the EV battery traceability seal in two and affix each seal to the Li-ion battery and “Li-ion BATTERY
REPLACEMENT RECORD”.
c. Fill in the “Li-ion BATTERY REPLACEMENT RECORD”.

LI-ION BATTERY
2. Install 2 locating pins (1) at the positions on the vehicle body shown in the figure.
A
EVB
JSCIA0182ZZ
F
: Vehicle front
3. Install the Li-ion battery onto the vehicle body.

• Align the Li-ion battery (1) and the locating pin (2). G
WARNING:
To prevent electric shock hazards, be sure to wear H

protective gear.
J
JSCIA0183ZZ
4. Tighten mounting bolts (4 bolts) (A) and remove pallet from Li-ion battery.
K
JPCIA0206ZZ N
: Vehicle front
WARNING: O

P
5. Remove the locating pins from the body.

LI-ION BATTERY
• If the locating pins (1) are tight and cannot be removed, use a
spanner to remove them.
WARNING:

protective gear.
JSCIA0185ZZ
6. Install the Li-ion battery mounting bolts (A).
: Vehicle front
WARNING:

protective gear.
JPCIA0241ZZ
7. Install the bonding plate (1) at the position shown in the figure.
: Vehicle front
WARNING:

protective gear.
JPCIA0248ZZ
8. After installing the bonding plate, check the equipotential. Refer to EVB-167, "Inspection".
9. Turn the vehicle communication harness connector (A) clock-
wise to install.
WARNING:

protective gear.
JPCIA0063ZZ

LI-ION BATTERY
10. Install the high voltage harness connector (A).
WARNING: A

protective gear. B
EVB
JPCIA0062ZZ
D
• Follow the procedure below to install the high voltage harness connector.
G
JPCIA0036ZZ
11. Install the Li-ion battery under covers. Refer to EVB-161, "Exploded View".
12. Install the service plug. Refer to GI-31, "How to Disconnect High Voltage". H
I
EQUIPOTENTIAL TEST
After installing the Li-ion battery, measure the resistance between the body of the battery pack (A) and the
vehicle body (B).
J
WARNING:

K
L
Standard : Less than 0.1 Ω
If the result deviates from the standard values, perform the below inspection and correct the abnormal loca-
tion. M
• Connection conditions of bonding plates
• Corrosion on bonding plate mounting surfaces
• Paint, oil, dust, or other substance on bonding plate mounting surfaces N

LI-ION BATTERY
< UNIT DISASSEMBLY AND ASSEMBLY > [TYPE 1]
UNIT DISASSEMBLY AND ASSEMBLY

LI-ION BATTERY
Exploded view INFOID:0000000007634416
LI-ION BATTERY
JSCIA0442GB

LI-ION BATTERY
1. Service plug 2. Service plug switch 3. Battery pack upper case A

4. Seal 5. Bus bar 6. Front module stack RH
7. Bus bar 8. Bus bar 9. Service plug switch bracket
10. Bus bar 11. Front module stack LH 12. Battery junction box cover B
13. Battery junction box 14. Battery junction box bracket 15. Battery member pipe
16. Drain plug washer 17. Drain plug 18. Connector flange
19. Plastic plate 20. High voltage harness connector 21. Bonding plate EVB
22. Seal 23. Vehicle communication harness con- 24. Snap ring
nector
25. Battery pack lower case 26. Harness bracket 27. High voltage harness D
28. High voltage harness 29. Rear module stack 30. Seal
31. Breather 32. Vehicle communication harness 33. Retainer
34. High voltage warning label E
: Always replace every disassembly
: N·m (kg-m, in-lb)

F
FRONT MODULE STACK

G
Removal
NOTE:
Figure indicates front RH. H
M
JPCIA0007GB
1. Battery temperature sensor (RH 2. Front module stack 3. Bus bar N

front)
4. Bus bar cover 5. Bus bar cover
: N·m (kg-m, in-lb) O
P
Disassembly
NOTE:
Figure indicates front RH.

LI-ION BATTERY
JPCIA0008GB
1. End plate (front) 2. Module B 3. Spacer (back side)

4. Spacer (terminal side) 5. Module A 6. End plate (rear)
7. Sub flame

LI-ION BATTERY
Module Layout
A
EVB
JPCIA0084GB F
LH front module stack RH front module stack

Module No. Module name Cell No. Module No. Module name Cell No. G
MD25 Module B 49 & 50 MD37 Module B 73 & 74
H
MD27 Module A 53 & 54 MD39 Module A 77 & 78
MD29 Module A 57 & 58 MD41 Module B 81 & 82 I
MD30 Module A 59 & 60 MD42 Module B 83 & 84
MD31 Module B 61 & 62 MD43 Module A 85 & 86
J
MD34 Module A 67 & 68 MD46 Module A 91 & 92 K
L
Bus bar Layout
DANGER:
M

LI-ION BATTERY
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal.
JSCIA0875ZZ
: Battery front
REAR MODULE STACK

Removal

LI-ION BATTERY
EVB
H
JPCIA0009GB
1. Rear module stack 2. Bus bar 3. Bus bar cover

4. Harness bracket 5. Control bracket 6. Li-ion battery controller I
7. Battery temperature sensor (rear)
J
Disassembly
JPCIA0191GB

LI-ION BATTERY
1. Through bolt 2. LH end plate 3. Module A

4. Mounting plate (back side) 5. Mounting plate (terminal side) 6. Module B
7. Support plate (back side) 8. Support plate (terminal side) 9. Rear stack member
10. Front stack member 11. RH end plate
Module Layout
JPCIA0084GB
Rear module stack

Module No. Module name Cell No. Module No. Module name Cell No.
MD1 Module B 1&2 MD13 Module B 25 & 26
MD2 Module A 3&4 MD14 Module A 27 & 28
BATTERY JUNCTION BOX

BATTERY JUNCTION BOX : Disassembly and Assembly INFOID:0000000007634417
DANGER:
Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of
maintenance.
WARNING:

LI-ION BATTERY
ing inspection or maintenance of high voltage system harnesses and parts. A
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
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). K
DISASSEMBLY
1. Clean any contamination and dust from the battery pack. L
2. Remove service plug retainer (1).
WARNING:
M
protective gear.
N
O
JSCIA0143ZZ
3. Remove mounting bolts (A), (B) and mounting nuts (C), then remove battery pack upper case. P

LI-ION BATTERY
JSCIA0144ZZ
: Vehicle front
WARNING:
Assembly".
5. Disengage pawls and remove battery junction box cover (1).
: Pawl
WARNING:
To prevent electric shock hazards, be sure to put on

insulated protective gear and use insulated tools.
JSCIA0264ZZ
6. Remove terminal mounting nut (A) of high voltage harness con-

nector.
DANGER:
• To prevent electric shock hazards, be sure to put

on insulated protective gear and use insulated tools.
• To prevent electric shock hazards, immediately JSCIA0265ZZ


LI-ION BATTERY
7. Remove mounting nut (A) and mounting bolt (B), then remove
bonding plate (1). A
WARNING:
To prevent electric shock hazards, be sure to put on B

EVB
JPCIA0169ZZ
D
8. Remove mounting nuts (A), then disconnect high voltage har-
ness connector (1) from battery pack.
WARNING: E
F
G
JPCIA0170ZZ
9. Remove mounting nuts (A), then remove high voltage harness

H
(1) and bus bar (2) from battery junction box.
DANGER:
• To prevent electric shock hazards, be sure to put on I


wrap insulating tape around disconnected high voltage K
10. Remove mounting nut (A) and remove battery junction box (1).
L
WARNING:

insulated protective gear and use insulated tools. M
JSCIA0268ZZ
O
ASSEMBLY
1. Install battery junction box.
WARNING: P
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools.
2. Install high voltage harness connector.

LI-ION BATTERY
WARNING:
lated tools.
3. Install Li-ion battery controller. Refer to EVB-181, "LI-ION BATTERY CONTROLLER : Disassembly and
Assembly".
4. Follow the procedure below and install battery pack upper case.
CAUTION:
Check seal before install battery pack upper case. Refer to EVB-179, "BATTERY JUNCTION BOX :
Inspection".
a. Tighten mounting nuts and bolts in numerical order as shown in the figure.
JPCIA0140ZZ
: Vehicle front
WARNING:
b. Install ground bolt (A).

LI-ION BATTERY
EVB
JPCIA0141ZZ F
: Vehicle front
WARNING: G

H
5. Install service plug retainer (1). I

WARNING:

protective gear. J
K
CAUTION:
• Perform the “LI-ION BATTERY JUNCTION BOX DATA CLEAR”
when battery junction box is replaced. Refer to EVC-102, JSCIA0143ZZ L
"Work Procedure".
• Check the following items after installing battery pack: Refer to EVB-179, "BATTERY JUNCTION BOX
: Inspection".
AIR LEAK INSPECTION M
ELECTRIC EQUIPOTENTIAL TEST
BATTERY JUNCTION BOX : Inspection INFOID:0000000007634418
N
BATTERY PACK SEAL INSPECTION

• Visually check all lips (A) of seal (1) for damage. (e.g. scratches
O
and cracks)
• Replace seal if its lips are damaged.
JPCIA0376ZZ

LI-ION BATTERY
AIR LEAK INSPECTION
1. Remove drain plug and install adapter [SST: KV99111400] (A).
WARNING:

protective gear.
JPCIA0124ZZ
2. Install gauge [SST: KV99111400] (A).

WARNING:

protective gear.
CAUTION:
Handle the gauge carefully so that it will not drop.
JPCIA0125ZZ
3. Install service plug to seal the battery pack.

DANGER:
4. Use vinyl tape (A) or similar means to seal the breather so that
air does not enter it.
• Use the wide vinyl tape which can cover up breather at once.
• Stick it so that tape is not wrinkled.
WARNING:

protective gear.
JPCIA0128ZZ
5. Perform air leak inspection by applying 1.6 kPa (0.0163 kg/cm2, 0.23 psi) of pressure inside the battery
pack for approximately 1 minute.
CAUTION:
• When applying pressure, operate the air pump slowly.
• Do not apply any pressure exceeding 2.0 kPa (0.0204 kg/cm2, 0.29 psi).
Repair limit : 1.4 kPa (0.0143 kg/cm2, 0.20 psi)

6. If the pressure drops below the limit value, use soapy water and check for leakage points.
WARNING:

LI-ION BATTERY
CAUTION:
Never allow soapy water to contact the service plug and each connector terminals.
B
Electric Equipotential Test

After installing the battery pack, measure the resistance between the ground bolt mating surface (A) and the
EVB
high voltage harness connector flange (B).
H
JPCIA0190ZZ
WARNING:
I

K
If the result deviates from the standard value, check the following items and repair malfunctioning parts
• Connection condition of ground bolts
• Rust on the mounting surface of ground bolts
L
• Paint, oil, and dust on the mounting surface of ground bolts
LI-ION BATTERY CONTROLLER
LI-ION BATTERY CONTROLLER : Disassembly and Assembly INFOID:0000000007634419 M
DANGER:
N
maintenance. O
WARNING:
troller before disassembling battery pack.

LI-ION BATTERY
CAUTION:
1. Must be an indoor environment.
• The environment must prevent the entry of sweat during work, and also prevent condensation from
metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.
3. The floor must be dry.
snowing.
4. Work space
than the workers do not enter the work space.
guisher).
DISASSEMBLY
1. Clean any contamination and dust from the battery pack.
WARNING:

protective gear.
JSCIA0143ZZ
3. Remove mounting bolts (A), (B) and mounting nuts (C), then remove battery pack upper case.

LI-ION BATTERY
EVB
JSCIA0144ZZ F
: Vehicle front
WARNING: G

H
4. Disconnect Li-ion battery controller harness connector (A). I

WARNING:

protective gear. J
JSCIA0145ZZ L
5. Remove Li-ion battery controller mounting bolts (A).
WARNING:
M
N
JSCIA0147ZZ

LI-ION BATTERY
6. Remove harness connector (A) and harness clip, then remove
B : Low voltage harness connector

: Vehicle front
WARNING:

protective gear.
JPCIA0204ZZ
• To prevent electric shock hazards, immediately wrap insulating tape around disconnected
high voltage harness connector and terminals.
NOTE:
Remove together with controller bracket.
ASSEMBLY
Assemble in the reverse order of disassembly.
1. Install Li-ion battery controller.
WARNING:
• To prevent electric shock hazards, be sure to put on insulated protective gear and use
insulated tools.
• There are harness connector for high voltage (A) and low
voltage (B) to a Li-ion battery controller. When the high
voltage harness connector is inserted in the low voltage
part, it causes smoking and the part damage. Be careful
enough when install harness connector.
: Vehicle front
JPCIA0204ZZ
CAUTION:
Check seal before install battery pack upper case. Refer to EVB-186, "LI-ION BATTERY CONTROL-
LER : Inspection".
a. Tighten mounting nuts and bolts in the order from 1 to 28 as shown in the figure.

LI-ION BATTERY
EVB
JPCIA0140ZZ F
: Vehicle front
WARNING: G

H
b. Install ground bolt (A). I
N
JPCIA0141ZZ
: Vehicle front O
WARNING:
P

LI-ION BATTERY
3. Install service plug retainer (1).
WARNING:

protective gear.
CAUTION:
• Perform the “ADDITIONAL SERVICE WHEN REPLACING LI-
ION BATTERY CONTROLLER” when Li-ion battery controller JSCIA0143ZZ
is replaced. Refer to EVB-62, "Work Procedure".

• Check the following items after installing battery pack: Refer to EVB-186, "LI-ION BATTERY CON-
TROLLER : Inspection".
AIR LEAK INSPECTION
LI-ION BATTERY CONTROLLER : Inspection INFOID:0000000007634420

and cracks)
JPCIA0376ZZ
AIR LEAK INSPECTION

WARNING:

protective gear.
JPCIA0124ZZ

WARNING:

protective gear.
CAUTION:
JPCIA0125ZZ

DANGER:

LI-ION BATTERY
To prevent electric shock hazards, be sure to wear protective gear. A
B
• Use the wide vinyl tape which can cover up breather at once. EVB
WARNING:
D
protective gear.
E
JPCIA0128ZZ
5. Perform air leak inspection by applying 1.6 kPa (0.0163 kg/cm2, 0.23 psi) of pressure inside the battery F
CAUTION:
• When applying pressure, operate the air pump slowly. G
Repair limit : 1.4 kPa (0.0143 kg/cm2, 0.20 psi) H
WARNING:
I
CAUTION:
Never allow soapy water to contact the service plug and each connector terminals. K

After installing the battery pack, measure the resistance between the ground bolt mating surface (A) and the L
JPCIA0190ZZ
WARNING:

LI-ION BATTERY

FRONT MODULE STACK
FRONT MODULE STACK : Disassembly and Assembly INFOID:0000000007634421
DANGER:
maintenance.
WARNING:
CAUTION:
snowing.
4. Work space
guisher).

LI-ION BATTERY
DISASSEMBLY
1. Remove battery pack upper case. Refer to EVB-181, "LI-ION BATTERY CONTROLLER : Disassembly A
and Assembly".
Assembly". B
3. Remove battery junction box. Refer to EVB-181, "LI-ION BATTERY CONTROLLER : Disassembly and
Assembly".
EVB
4. Remove bus bar (1) that connects service plug switch and left
front module stack.
DANGER: D
• To prevent electric shock hazards, be sure to put on
E
F
• After removing, close bus bar cover. JSCIA0269ZZ
5. Remove mounting bolts (A) and nuts (B) of service plug switch
G
bracket (1).
WARNING:
To prevent electric shock hazards, be sure to put on H

JSCIA0270ZZ
J
6. Disconnect high voltage harness (A) and connector (B) on
reverse side of service plug switch bracket, then remove service
plug switch bracket (1). K
DANGER:
• To prevent electric shock hazards, be sure to put on L

M
JSCIA0271ZZ
• To prevent electric shock hazards, immediately
wrap insulating tape around disconnected high voltage harness connector (high voltage termi- N
nal) and terminals.
7. Remove harness bracket (1).

O
WARNING:

insulated protective gear and use insulated tools. P
JSCIA0307ZZ

LI-ION BATTERY
8. Remove bus bar (1) that connects left and right front module
stacks.
: Vehicle front
DANGER:

JSCIA0258ZZ

wrap insulating tape around disconnected high voltage harness connector and terminals.
9. Remove battery temperature sensor (1) from module (2).
JSCIA0388ZZ
A. Front module stack LH B. Front module stack RH

: Vehicle front
WARNING:
lated tools.
10. Remove battery member pipe (1).

WARNING:

JSCIA0260ZZ

LI-ION BATTERY
11. Remove vehicle communication harness connector.
A
A. Front module stack LH side
B. Front module stack RH side
: Vehicle front B
WARNING:
To prevent electric shock hazards, be sure to wear EVB

protective gear.
JSCIA0261ZZ
12. Remove front module stack mounting bolts (A).

E
1. Front module stack LH
2. Front module stack RH
WARNING: F

insulated protective gear and use insulated tools. G
JSCIA0262ZZ
H
13. Follow the procedure below and remove front module stack from battery pack.
a. Attach a carabiner to the position (A) in the figure and connect a
slinger belt to it. I
WARNING:
• To prevent electric shock hazards, be sure to wear J

protective gear.
JSCIA0439ZZ
L
b. Use mobile floor crane (A) to lift up front module stack (1).
WARNING:
M
protective gear.
N
• Be sure to place an insulating rubber sheet on the O

work bench. JSCIA0440ZZ
c. Move the battery pack and place work bench underneath front module stack. P
WARNING:
• To prevent electric shock hazards, be sure to wear protective gear.
CAUTION:

LI-ION BATTERY
Place removed battery pack upper case onto battery pack for storage.
d. Place front module stack (1) onto work bench.

WARNING:

protective gear.
• Be sure to place an insulating rubber sheet on the

NOTE:
Figure indicates front module stack RH.
14. Follow the procedure below and remove bus bar from front module stack.
a. Remove bus bar (1).
DANGER:


wrap insulating tape around disconnected high voltage JSCIA0184ZZ
b. Remove bus bar cover and remove module terminal mounting bolts (A).
JSCIA0186ZZ
DANGER:
insulated tools.
• Work alone. Failure to do this may cause shock hazards.

LI-ION BATTERY
c. Remove voltage detection terminal mounting screws (A) and remove bus bar (1) from front module stack.
A
EVB
JSCIA0252ZZ
DANGER: D
insulated tools.
E
F
d. Attach module terminal covers [SST: KV99111500] (A) to all module terminals.
G
JPCIA0123ZZ
J
WARNING:

K
L
15. Remove end plate and disassembly front module stack.
WARNING:
M
lated tools.
ASSEMBLY O
Note the following, assemble in the reverse order of disassembly.
DANGER:
P
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter-
minal.

LI-ION BATTERY
- If bus bar contacts a wrong terminal, the circuit becomes energized and a short may occur.
- Always keep the bus bar cover closed until immediately before the installation of bus bar.
- Since the correct installation position for the bus bar connected to both front module stacks is com-
monly-confused with the wrong position (B), install the bus bar to the correct position (A) with
extreme caution.
JSCIA0876ZZ
A. Correct position B. Wrong position

: Battery front
WARNING:
Install Li-ion battery controller immediately before installing battery pack upper case.
CAUTION:
• Perform the “MODULE CHARGE BALANCE” when module is replaced. Refer to EVB-63, "Work Pro-
cedure".
• Check seal before install battery pack upper case. Refer to EVB-196, "FRONT MODULE STACK :
Inspection".
EV Battery Traceability Seal
When replacing the module with a new one, perform the following procedure.
1. Enter the date of replacement on the EV battery traceability seal packaged with the new part.
2. Cut the EV battery traceability seal in two and affix each seal to the old module and “Li-ion BATTERY
3. Fill in the “Li-ion BATTERY REPLACEMENT RECORD”.
Front Module Stack
• Check that terminal of front module stack is arranged as shown in the figure.
JSCIA0308ZZ

LI-ION BATTERY
A. Front module stack RH B. Front module stack LH A

: Vehicle front
• Tighten mounting bolts in numerical order as shown in the figure.

B
EVB
JPCIA0150ZZ
G
A. Front module stack RH B. Front module stack LH
: Vehicle front
H
DANGER:
• To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools. I

K
• Install end plate so that its carabiner mounting hole (A) is posi-
tioned as shown in the figure.
1. Front module stack RH L
NOTE:
There are two kinds of end plates of which carabiner mounting
hole location is different each other. The installation of improper M
end plate results in the carabiner mounting hole being placed
inside. Accordingly, the front stack module cannot be lifted.
N
JSCIA0441ZZ
Battery Temperature Sensor

• Install battery temperature sensor (front) as shown in the figure. O

LI-ION BATTERY
JSCIA0389ZZ

: Vehicle front
• Insert a sensor (A) into module and fix with clip (B).
NOTE:
Do not fix with grommet (C).
JSCIA0390ZZ
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-196, "FRONT MODULE STACK :
Inspection".
AIR LEAK INSPECTION
FRONT MODULE STACK : Inspection INFOID:0000000007634422

and cracks)
JPCIA0376ZZ
AIR LEAK INSPECTION

LI-ION BATTERY
WARNING: A

protective gear. B
EVB
JPCIA0124ZZ
D
WARNING:
E
protective gear.
F
CAUTION:
Handle the gauge carefully so that it will not drop. G
JPCIA0125ZZ

H
DANGER:

I
J
• Stick it so that tape is not wrinkled. K
WARNING:
To prevent electric shock hazards, be sure to wear L

protective gear.
M
JPCIA0128ZZ
5. Perform air leak inspection by applying 1.6 kPa (0.0163 kg/cm2, 0.23 psi) of pressure inside the battery N
CAUTION:
• Do not apply any pressure exceeding 2.0 kPa (0.0204 kg/cm2, 0.29 psi). O
Repair limit : 1.4 kPa (0.0143 kg/cm2, 0.20 psi) P

WARNING:

LI-ION BATTERY
CAUTION:

JPCIA0190ZZ
WARNING:

REAR MODULE STACK
REAR MODULE STACK : Disassembly and Assembly INFOID:0000000007634423
DANGER:
maintenance.
WARNING:
CAUTION:

LI-ION BATTERY
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do A
1. Must be an indoor environment. B
• The environment must prevent the entry of sweat during work, and also prevent condensation from EVB
• In addition to being indoors, the environment must not permit the entry during disassembly work of D
E
snowing.
4. Work space F
than the workers do not enter the work space. G
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin- H
guisher).
DISASSEMBLY
1. Clean any contamination and dust from the battery pack. I
WARNING:
J
protective gear.
K
L
JSCIA0143ZZ
3. Remove mounting bolts (A), (B) and mounting nuts (C), then remove battery pack upper case. M

LI-ION BATTERY
JSCIA0144ZZ
: Vehicle front
WARNING:
Assembly".
5. Remove vehicle communication harness connector (A) on rear
module stack.
WARNING:


6. Disconnect battery temperature sensor harness connector (A)

from bracket.
WARNING:

JSCIA0238ZZ

LI-ION BATTERY
7. Remove harness clip (A) from harness bracket and move vehi-
cle communication harness (1) to the position without the hin- A
drance for work.
WARNING:
B
EVB
JSCIA0149ZZ
D
8. Remove mounting nuts (A) and remove high voltage harness from rear module stack.
G
JSCIA0150ZZ
DANGER:
H
insulated tools.
• To prevent electric shock hazards, immediately wrap insulating tape around disconnected J
9. Remove rear module stack (1) mounting bolts (A).

WARNING: K

insulated protective gear and use insulated tools. L
JPCIA0129ZZ
N
10. Follow the procedure below and remove rear module stack from battery pack.
lashing belt to it. O
WARNING:
To prevent electric shock hazards, be sure to wear P

protective gear.
JSCIA0251ZZ

LI-ION BATTERY
b. Use mobile floor crane (A) to lift up rear module stack (1).
WARNING:

protective gear.
CAUTION:
Do not move engine crane while rear module stack is
hoisted up. JPCIA0130ZZ
c. Move the battery pack and place work bench underneath rear module stack.
WARNING:
CAUTION:
d. Place rear module stack onto work bench.

WARNING:
• Be sure to place an insulating rubber sheet on the work bench.
11. Remove harness bracket (1) from rear module stack.

WARNING:

JSCIA0153ZZ
12. Follow the procedure below and remove bus bars from rear module stack.
a. Remove central bus bar cover and remove module terminal
mounting bolts (A).
DANGER:

• Work alone. Failure to do this may cause shock JSCIA0154ZZ

hazards.
CAUTION:
Remove all bus bar covers at the same time, and do not remove module terminal mounting bolts.

LI-ION BATTERY
b. Remove right-side bus bar cover and remove module terminal
mounting bolts (A). A
DANGER:
• To prevent electric shock hazards, be sure to put B

EVB

hazards. D
c. Remove left-side bus bar cover and remove module terminal
mounting bolts (A).
E
DANGER:

on insulated protective gear and use insulated tools. F
G
hazards.
H
d. Remove voltage detection terminal mounting screws (A), and
then remove bus bar from rear module stack.
DANGER: I

J
K
hazards.
e. Attach module terminal covers [SST: KV99111500] (A) to all L

module terminals.
WARNING:
M
protective gear.
N
O
JSCIA0192ZZ
13. Remove battery temperature sensor (1) from rear module stack.
P

LI-ION BATTERY
JSCIA0391ZZ
: Clip
WARNING:
lated tools.
14. Remove front stack member (1).

WARNING:

JPCIA0126ZZ
15. Remove rear stack member (1).

WARNING:

JSCIA0239ZZ
16. Use lashing belt (A) to fix rear module stack (1) in place.
WARNING:

protective gear.
JSCIA0240ZZ

LI-ION BATTERY
17. Remove through bolt mounting nut (A) (removal side, unfixed)
and disassemble rear module stack (1), refer to following. A
WARNING:

EVB
JPCIA0131ZZ
D
CAUTION:
• Never remove self-locking nut (fixed).
E
A : Self-locking nut (fixed)
B : Mounting nut (removal side, unfixed)
F
JPCIA0258ZZ
H
• Fix the tip of through bolt on the removal side to remove
mounting nut.
NOTE: I
When through bolt is removed, the spacer between the mod-
ules will fall out and it will be difficult to return it to its original
position. Therefore pull the through bolt out only to the position
necessary for the module that will be removed. J
K
JSCIA0347ZZ
ASSEMBLY L
CAUTION:
cedure". M
1. When replacing the module with a new one, perform the following procedure.
b. Cut the EV battery traceability seal in two and affix each seal to the module and “Li-ion BATTERY N
2. Follow procedure below and assemble rear module stack. O
a. Assemble rear module stack, and provisionally fasten it in place with the through bolt.
WARNING:
P
lated tools.

LI-ION BATTERY
• Check that terminal of module is arranged as shown in the figure.
JSCIA0309ZZ
• Check that mounting plate (1) is located at position shown in the figure.
JPCIA0132ZZ
b. Use lashing belt (A) and apply pressure to rear module stack (1).
WARNING:

protective gear.
JSCIA0240ZZ
c. Inspect the module installation condition, and correct it if it is incorrectly installed or a large distortion is
found.
JSCIA0313ZZ
WARNING:
lated tools.
d. Tighten to the specified torque the mounting nuts (removal side, unfixed) for the through bolt that is
attached tentatively.

LI-ION BATTERY
• To tighten rear module stack, fix the tip of through bolt to
tighten mounting nuts. A
WARNING:

EVB
CAUTION:
Never tighten self-locking nut (fixed). If tightened, replace JSCIA0347ZZ
through bolt and nut. D
3. Follow procedure below and assemble rear module member.

a. Temporarily install rear module stack member (1) to rear module E
stack.
WARNING:
To prevent electric shock hazards, be sure to put on F

JSCIA0239ZZ
H
b. Using the scale (A), inspect the module installation condition.
WARNING:
I
protective gear.
J
• If the rear module stack is excessively distorted, loosen the

K
through bolt of rear module stack and correct the condition.
JPCIA0242ZZ
c. Tighten to the specified torque the mounting nuts for the rear stack member. L
4. Install front stack member (1).
WARNING:
M
N
O
JPCIA0126ZZ

LI-ION BATTERY
5. Install battery temperature sensor (rear) (1) in the figure.
JSCIA0392ZZ
WARNING:
• Position module where sensor (1) will be installed so that it is

aligned with concave part (A) of rear stack member.
: Clip
• Position module where clip (2) will be installed so that it is

aligned with concave part (B) of rear stack member.
JSCIA0393ZZ
• Insert a sensor (A) in a module and fix by a clip (B). Do not fix
in the grommet (C).
JSCIA0390ZZ
6. Remove module terminal cover [SST: KV99111500].

WARNING:
7. Follow the procedure below and install bus bars onto rear module stack.
a. Install bus bars onto rear module stack.
WARNING:

LI-ION BATTERY
To prevent electric shock hazards, be sure to wear protective gear. A
B
b. Use an insulated torque driver (A) and tighten the voltage detec-
tion terminal mounting screws.
DANGER:
EVB
D
E
• Work alone. Failure to do this may cause shock JPCIA0135ZZ
hazards.
c. Tighten module terminal mounting bolts in numerical order as shown in the figure. F
• When bolts 1 – 16 have been tightened, install left side bus bar cover.
• When bolts 17 – 32 have been tightened, install right side bus bar cover.
• When bolts 33 – 48 have been tightened, install center bus bar cover. G
JPCIA0136ZZ
J
DANGER:
insulated tools. K

d. Install bus bar cover (1). M
JPCIA0137ZZ
P
WARNING:
CAUTION:
• Be sure not to install with up/down sides facing in wrong directions.

LI-ION BATTERY
• After installation, verify that the joined part does not disconnect.
8. Install harness bracket (1) at position of cut-out (A) in the figure.

WARNING:

JPCIA0138ZZ
9. Follow procedure below and install rear module stack onto battery pack.
a. Use mobile floor crane (A) to lift up rear module stack (1).
WARNING:

protective gear.
CAUTION:
Do not move engine crane while rear module stack is
b. Move work bench so that battery pack is underneath rear module stack.
c. Install rear module stack onto battery pack.
WARNING:
CAUTION:
Align position of locating pin.
10. Tighten rear module stack (1) mounting bolt (A).

WARNING:

JPCIA0129ZZ

LI-ION BATTERY
11. Tighten mounting nuts (A) and connect high voltage harness to rear module stack.
A
EVB
JSCIA0150ZZ
DANGER: D
insulated tools.
E
F
• Be sure to close terminal cover.
12. Install vehicle communication harness.
WARNING: G

H
I
Assembly".
CAUTION:
Check seal before install battery pack upper case. Refer to EVB-212, "REAR MODULE STACK : J
Inspection".
K
P
JPCIA0140ZZ
: Vehicle front
WARNING:

LI-ION BATTERY
JPCIA0141ZZ
: Vehicle front
WARNING:

WARNING:

protective gear.
JSCIA0143ZZ
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-212, "REAR MODULE STACK :
Inspection".
AIR LEAK INSPECTION
REAR MODULE STACK : Inspection INFOID:0000000007634424

LI-ION BATTERY
and cracks) A
EVB
JPCIA0376ZZ
D
AIR LEAK INSPECTION
WARNING: E
protective gear.
F
JPCIA0124ZZ
H
WARNING:
To prevent electric shock hazards, be sure to wear I

protective gear.
CAUTION:
K
JPCIA0125ZZ

DANGER: L

M
4. Use vinyl tape (A) or similar means to seal the breather so that N
• Stick it so that tape is not wrinkled. O
WARNING:

protective gear.
JPCIA0128ZZ

LI-ION BATTERY
CAUTION:

WARNING:
CAUTION:

JPCIA0190ZZ
WARNING:


SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TYPE 1]
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. 300 (661.5)
E
JPCIA0065ZZ
External dimension “a” [mm (in)] 1188.0 (46.77) M

“b” [mm (in)] 1007.0 (39.65)
“c” [mm (in)] 264.9 (10.43)
N
“d” [mm (in)] 1570.5 (61.83)

APPLICATION NOTICE
HOW TO USE THIS MANUAL

APPLICATION NOTICE

Type A
JSCIA0277ZZ
Type B
JSCIA0706ZZ

PRECAUTIONS
PRECAUTION A
PRECAUTIONS
B
WARNING: EVB
D
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
The high voltage system may starts automatically. It is required to check that the timer air conditioner O
NOTE:
P

PRECAUTIONS
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Service Manual.
WARNING:
an authorized NISSAN/INFINITI dealer.
Module, see “SRS AIR BAG”.
connectors.
WARNING:
injury.
INFOID:0000000007634430
For vehicle with steering lock unit, if the 12V battery is disconnected or discharged, the steering wheel will lock
OPERATION PROCEDURE
NOTE:
(At this time, the steering lock will be released.)
4. Perform the necessary repair operation.
NOTE:
tion.

PRECAUTIONS
A
windshield. B
EVB
D
PIIB3706J

E
NOTE: F
• Always disconnect the battery terminal within 60 minutes after G
start after a lapse of 60 minutes from power switch OFF. H
SEF289H
WORK PROCEDURE
I
NOTE:
J
tion.
K
NOTE:
detected.
4. Remove 12V battery terminal within 60 minutes after turning the power switch OFF → ON → OFF. L
CAUTION:
battery terminals are disconnected, start over from Step 1. M
NOTE:
Once the power switch is turned ON → OFF, the 12V battery automatic charge control does not start for N
the power switch. O
NOTE:
then DTC may be detected. P
NOTE:
DANGER:

PRECAUTIONS
maintenance.
WARNING:
• The removed service plug must always be carried in a pocket of the responsible worker or placed in
• Never allow workers other than the responsible person to touch the vehicle containing high voltage
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise
HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS
WARNING:
nets. Such persons must not perform work on the vehicle.
metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT”

PRECAUTIONS
workers. A
EVB
JSAIA0091GB P

PREPARATION
PREPARATION
PREPARATION
Tool name
(Kent-Moore No.)
Palette
(J-50583)
JPCIA0239ZZ

When installing Li-ion battery.
KV99111300
2 piece/set
(J-50306)
JPCIA0023ZZ
Air leak checker

When checking air leaks after disassem-
KV99111400
bling/assembling Li-ion battery.
(—)
JSCIA0257ZZ

Protect module terminals (for LEAF)
KV99111500
24 pieces/set
(—)
JPCIA0069ZZ

(J-50346)
JPCIA0070ZZ

PREPARATION
A

B
300A]
EVB
JMCIA0149ZZ
D
nents
Leather gloves
[Use leather gloves that can fasten the wrist tight] E
JPCIA0066ZZ
Insulated safety shoes Removing and installing high voltage components G
JPCIA0011ZZ
H

nents I
electric line
[ANSI Z87.1]
J
JPCIA0012ZZ
K
nents
Face shield
electric line L
JPCIA0167ZZ
Insulated helmet Removing and installing high voltage components N
JPCIA0013ZZ
O
P
JPCIA0019ZZ

PREPARATION
JPCIA0018ZZ
Battery lift table Removing and installing Li-ion battery
JPCIA0024ZZ
JPCIA0015ZZ

JPCIA0014ZZ
Insulated hand tools Removing and installing high voltage components
JPCIA0067ZZ
JPCIA0068ZZ

NOTE:
• D: 8.0 mm (0.31 in)
Carabineer [small]
• L: 74.0 mm (2.91 in)
• S: 10.0 mm (0.39 in)
• W: 22.5 mm (0.89 in)
JPCIA0016ZZ

PREPARATION
A
NOTE:
• D: 14.0 mm (0.55 in) B
Carabineer [large]
• L: 204.0 mm (8.03 in)
• S: 47.0 mm (1.85 in)
• W: 105.0 mm (4.13 in)
EVB
JPCIA0017ZZ
D
Belt slinger NOTE:
Length: 2.0 m (6.562 ft)
E
JPCIA0021ZZ
Mobile floor crane Removing and installing battery module stack G
JPCIA0020ZZ
H
I
J
JPCIA0022ZZ

(Cut the adhesive)
L
JSCIA0640ZZ

(Cut the adhesive) N
NOTE:
JSCIA0641ZZ
O
P
Scraper
JSCIA0643ZZ

PREPARATION
JSCIA0639ZZ

NOTE:
Metal bar
• D: φ 7 mm (0.28 in)
• L: 1 m (3.28 ft)
JSCIA0735ZZ

COMPONENT PARTS
SYSTEM DESCRIPTION A
COMPONENT PARTS
B
EVB
JPCIA0064ZZ M
A. Center of rear seat legroom B. Center of battery pack right side C. Center of battery pack front side
D. Center of battery pack left side E. Back of battery pack left side F. Back of battery pack
N
: Vehicle front
No. Component Function O

P
4. Battery temperature sensor (Front RH) EVB-232, "Battery Temperature Sensor"
7. Battery temperature sensor (Front LH) EVB-232, "Battery Temperature Sensor"

COMPONENT PARTS
10. Battery temperature sensor (Rear center) EVB-232, "Battery Temperature Sensor"
11. Battery temperature sensor (Rear RH) EVB-232, "Battery Temperature Sensor"
JPCIA0215ZZ
A. Under the service plug

: Vehicle front

1. Li-ion battery heater RH 1 EVB-231, "Li-ion Battery Heater"
4. Li-ion battery heater RR 2 EVB-231, "Li-ion Battery Heater"
5. Li-ion battery heater LH 1 EVB-231, "Li-ion Battery Heater"
7. Heater relay unit EVB-231, "Heater Relay Unit"

COMPONENT PARTS
A
ion battery controller, battery junction box, and service plug in addi- B
EVB
D
JSCIA0272ZZ
• Four cells are integrated into a single module. The Li-ion battery consists of 48 modules placed in series. E
JPCIA0083ZZ H
I
J
L
JSCIA0071ZZ
• The LBC is the core of battery control. Li-ion battery controller detects the voltage and current of the assem- M
N
• State of charge O
• Temperature
P
4. Prevention of overheat

COMPONENT PARTS


JSCIA0273ZZ

The Li-ion battery has 48 modules placed in series in total. Ninety-six
NOTE:
potential difference between the upstream and the downstream of
JPCIA0197GB
MODULE LAYOUT
JPCIA0084GB
NOTE:
The highest potential is module (MD) 1 and the lowest is module (MD) 48.
CELL

COMPONENT PARTS
A
EVB
JSCIA0274ZZ
D
tery life.
• Light and thin structure increases flexibility in layout. E
Heater Relay Unit INFOID:0000000007634440

F
• The heater relay unit is installed in the battery pack (under the ser-
vice plug).
• When receiving a relay control signal from LBC (Li-ion battery con- G
troller), the heater relay unit turns ON the built-in relay and sup-
plies high-voltage power to each Li-ion battery heater.
H
I
JPCIA0205ZZ
Li-ion Battery Heater INFOID:0000000007634441

J
• Li-ion battery heater is installed in the battery pack.
• High voltage power is supplied from the heater relay unit.
• Each Li-ion battery heater is connected in parallel. K
FRONT LI-ION BATTERY HEATER
• Three front Li-ion battery heaters are installed to each front module
stack. L
JPCIA0212ZZ
O
REAR LI-ION BATTERY HEATER

COMPONENT PARTS
• Two rear Li-ion battery heaters are installed to the rear module
stack.
JPCIA0213ZZ

JSCIA0275ZZ

JPCIA0295GB
pack.
System main relay to provide/interrupt DC current sent from Li-
ion battery.
Pre-charge relay to protect the high voltage circuit from a high
current immediately after power switch ON.
Current sensor to calculate battery capacity.
JSCIA0276ZZ

COMPONENT PARTS
A
maintenance. B
• Always use insulating protective equipment when removing and EVB
D
JSCIA0277ZZ

E
label in the original position. F
Li-ion Battery
G
JPCIA0207ZZ J
• The label (A) is affixed to the body panel near the high voltage har- K
ness connector.
: Vehicle front L
N
JPCIA0208ZZ

O
JSCIA0111ZZ

COMPONENT PARTS
Service Plug
JPCIA0209ZZ

SYSTEM
SYSTEM
A
LI-ION BATTERY CONTROL SYSTEM
LI-ION BATTERY CONTROL SYSTEM : System Description INFOID:0000000007634446
B
SYSTEM DIAGRAM
EVB
JSCIA0413GB K
INPUT/OUTPUT SIGNAL ITEM
Input Signal Item L

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

N

SYSTEM
Received unit Signal name

Li-ion battery current signal
VCM EV system CAN
Li-ion battery capacity signal
DESCRIPTION
information, such as the charging status of Li-ion battery and possible power, to VCM (vehicle control module)
as overvoltage, over discharge or excessive temperature rise in the battery.
charge/charge line.
transfers the detected state to VCM so that the vehicle does not start with an unsteady state.
• Estimates a battery charge state and low battery state, based on the data obtained with the battery state
BATTERY PROTECTION
The Li-ion battery has a voltage range capable of charge/discharge. If charged/discharged exceeding the
voltage stays within the voltage range.

Charging energy control
control

SYSTEM
During cell capacity adjustment, the capacity of each cell is estimated based on the no-load voltage when the A
that have excess capacity. In this way, capacity adjustment by the Li-ion battery controller allows the capacity B
EVB
JPCIA0094GB
G
resistance of each high voltage part and sends the measurement results to VCM via EV system CAN commu- H
nication.
tance value.
I
M
JSCIA0415GB
LI-ION BATTERY HEATER CONTROL SYSTEM

N

SYSTEM
LI-ION BATTERY HEATER CONTROL SYSTEM : System Description INFOID:0000000007634447
SYSTEM DIAGRAM
JPCIA0214GB

Input Signal Item

VCM EV system CAN communication Keep SOC request signal
Output Signal Item
Receive unit Signal name

VCM EV system CAN communication Next start time signal
DESCRIPTION
• When the temperature decreases [approximately −20°C (−4°F)] extremely in the battery pack, the Li-ion bat-
tery heater control system automatically activates the Li-ion battery heater to warm the inside of the battery
pack for protecting Li-ion battery from freezing and preventing the decline in battery output. In addition, when
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 and judges the activation of the Li-ion
battery heater.
• When the relay built in the heater relay unit turns ON, high voltage power is supplied to each Li-ion battery
heater.
• 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.

SYSTEM
• When the temperature in Li-ion battery pack is low with no necessity of Li-ion battery heater operation, LBC
estimates the time that Li-ion battery may freeze and transmits a next start time signal to VCM via EV sys- A
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),
B
LBC activates the Li-ion battery heater.
When EVSE is connected (normal charge)
EVB
G
JSCIA0430ZZ
• When the temperature in the battery pack is low outside the timer charge set time, VCM transmits a keep
SOC request signal to LBC via EV system CAN communication. In this case Li-ion battery is not charged,
and only Li-ion battery heater is activated. H
• 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)
I
M
JSCIA0431ZZ
• 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. N

SYSTEM
JSCIA0396GB

SYSTEM
EVB
JSCIA0397GB

SYSTEM
JSCIA0398GB
HARNESS LAYOUT

SYSTEM
EVB
JSCIA0399GB
P
: Vehicle front

SYSTEM
JSCIA0400GB
: Vehicle front

HANDLING PRECAUTION
HANDLING PRECAUTION
A
• To improve the Li-ion battery life, never perform quick charge heavily. B
EVB
D
• Lay an anti-static rubber sheet underneath the battery. E
F
• Prevent other objects from falling onto the battery. G

APPLICATION ITEM
Item Function
Data Monitor Input/Output data in LBC can be read.
Work Support
itor
ECU IDENTIFICATION
SELF-DIAGNOSTIC RESULTS
Regarding items of DTC, refer to EVB-258, "DTC Index".
How to Erase DTC
2. “SELF-DIAGNOSTIC RESULTS”.
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT.

DTC Displays the DTC which caused FFD memory
OPEN /
CLOSE
ature 2 [Front RH]
ature 3 [Rear RH]
ature 4 [Front LH]
DATA MONITOR

Monitored item Unit Remark A

B
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug EVB
CLOSE
D
Displays the temperature calculated with a signal voltage from battery temper- E
ature 2 [Front RH] F
ature 3 [Rear RH]
Displays the temperature calculated with a signal voltage from battery temper- G
ature 4 [Front LH]
WORK SUPPORT
H
DATA replaced. I
TION DATA replaced.
CLEAR BATTERY GRADUAL When all modules of Li-ion bat- J
CHARGE INFORMATION DATA erased. tery are replaced. K
TION cells.
an abnormal cell, unless it is replaced. L

EV BATTERY SYSTEM
ECU DIAGNOSIS INFORMATION

EV BATTERY SYSTEM

NOTE:

IR SEN SHORT PULSE READY Approx. 4,100 – 4,300 mV


EV BATTERY SYSTEM
A
D
H
K
O

EV BATTERY SYSTEM

EV BATTERY SYSTEM
A
D
H
K
O

EV BATTERY SYSTEM
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
cle)
around front LH module stack]

EV BATTERY SYSTEM
A
The fail-safe mode differs depending on the contents of the detected malfunction. B
FAIL-SAFE PATTERN
• Pattern B: Driving output power limit, and Charge stop EVB
FAIL-SAFE LIST D
Pattern
A B C D E
F
P3032 CELL CONT ASIC2 × G
H
P3037 CELL CONT ASIC7 × I
P303A CELL CONT ASIC10 × J
K
P303F CELL CONT ASIC15 × L
M
P3044 CELL CONT ASIC20 × N
O
P3049 CELL CONT ASIC1 VOLT × P

EV BATTERY SYSTEM
Pattern
A B C D
P3062 BYPASS SW ×

EV BATTERY SYSTEM
Pattern
A B C D
P30F3 TOTAL VOLT SENSOR × B
P30FC OVER CURRENT × EVB
D
P3191 COMMUNICATION ERROR No fail-safe E
F
P31A7 CAN ERROR INV/MC No fail-safe G
H
J

K
P330D CELL OVER VOLTAGE MODULE12 × L
M
P3312 CELL OVER VOLTAGE MODULE17 × N
O
P3317 CELL OVER VOLTAGE MODULE22 × P

EV BATTERY SYSTEM
Pattern
A B C D

EV BATTERY SYSTEM
Pattern
A B C D
P338B CELL OVER DISCHARGE MODULE23 × B
P338E CELL OVER DISCHARGE MODULE26 × EVB
D
P3393 CELL OVER DISCHARGE MODULE31 × E
F
P3398 CELL OVER DISCHARGE MODULE36 × G
H
P339D CELL OVER DISCHARGE MODULE41 × I
J

K
P33D4 BATT GRADUAL CAPA LOSS DIAG × L
M
P33DB TEMPERATURE SENSOR No fail-safe N
O
P33E2 BATT PACK OVER TEMP × P
P33EA BATTERY HEATER RELAY ×

EV BATTERY SYSTEM
Pattern
A B C D
P33EE BATTERY HEATER CONTROL SYSTEM ×
EV system
lamp

EV BATTERY SYSTEM
EV system
lamp
P3052 CELL CONT ASIC10 VOLT × 1 EVB-280 B
EVB
P3057 CELL CONT ASIC15 VOLT × 1 EVB-282 D
E
P305C CELL CONT ASIC20 VOLT × 1 EVB-282 F
G

P3061 CELL BATTERY VOLT × 1 EVB-284 H
P3062 BYPASS SW × 1 EVB-285
P308C CELL CONT ASIC2 OPEN × 1 EVB-286 I
J
P3091 CELL CONT ASIC7 OPEN × 1 EVB-286 K
L
P3096 CELL CONT ASIC12 OPEN × 1 EVB-286 M
N
P309B CELL CONT ASIC17 OPEN × 1 EVB-289 O
P309E CELL CONT ASIC20 OPEN × 1 EVB-289 P

EV BATTERY SYSTEM
EV system
lamp

EV BATTERY SYSTEM
EV system
lamp
P3320 CELL OVER VOLTAGE MODULE31 × 1 EVB-315 B
EVB
P3325 CELL OVER VOLTAGE MODULE36 × 1 EVB-315 D
E
P332A CELL OVER VOLTAGE MODULE41 × 1 EVB-318 F
G

P332F CELL OVER VOLTAGE MODULE46 × 1 EVB-318 H
P3373 TOTAL VOLTAGE OVER DISCHARGE × 1 EVB-321 I
J
P3379 CELL OVER DISCHARGE MODULE5 × 1 EVB-322 K
L
P337E CELL OVER DISCHARGE MODULE10 × 1 EVB-322 M
N
P3383 CELL OVER DISCHARGE MODULE15 × 1 EVB-325 O
P3386 CELL OVER DISCHARGE MODULE18 × 1 EVB-325 P

EV BATTERY SYSTEM
EV system
lamp
P33EA BATTERY HEATER RELAY × 1 EVB-352

EV BATTERY SYSTEM
EV system
lamp
P33EE BATTERY HEATER CONTROL SYSTEM × 1 EVB-356
U1000 CAN COMM CIRCUIT × 1 EVB-358 B
EVB

VCM
WIRING DIAGRAM
VCM
described in wiring diagram), refer to GI-12, "Connector Information".
JCCWA0029GB

VCM
EVB
JCCWA0030GB

VCM
JCCWA0031GB

VCM
EVB
JCCWA0032GB

BASIC INSPECTION
DETAILED FLOW
1.GET INFORMATION FOR SYMPTOM
>> GO TO 2.
2.CHECK DTC IN VCM
Are any DTCs detected?
NO >> GO TO 3.
3.CHECK DTC
1. Check DTC.
- Erase DTC.
(Symptom Matrix Chart is useful. Refer to EVC-347, "Symptom Index".)
Symptom is described, DTC is detected>>GO TO 4.
>> GO TO 6.
>> GO TO 7.
again.
NOTE:

Manual. This simplified check procedure is an effective alternative though DTC cannot be detected during A
this check.
MATION PROCEDURE.
B
Is DTC detected?
YES >> GO TO 8.
EVB
7. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
step 4, and determine the trouble diagnosis order based on possible causes and symptoms. D
YES >> GO TO 8.
NO >> Monitor input data from related sensors using CONSULT. E
Inspect according to Diagnosis Procedure of the system. F
YES >> GO TO 9.
NO >> Monitor input data from related sensors using CONSULT. G
2. Reconnect parts or connectors disconnected during Diagnosis Procedure again after repair and replace- H
ment.
I
>> GO TO 10.
10.FINAL CHECK J
the symptom is not detected. K
L
M
DESCRIPTION
There are many operating conditions that lead to the malfunction of N
important to fully understand the symptoms or conditions for a cus- O
tomer complaint.
tion for troubleshooting. P
NOTE:
JSCIA0412GB
WORKSHEET SAMPLE

Question Sheet
Incident Date VIN
Customer name
MR/MS
lamp is on
Does not charge Other* *: If applied, enter in detail
Detailed symptom
Onomatopoeia

Weather
Not affected
conditions
Temp. [Approx. °C
( °F)]
road
Other
Driving conditions Not affected
D position (stop the vehicle)
Does not disappear
Other
Other

A
LER
B
When a Li-ion Battery Controller (LBC) is replaced, it is necessary to save the battery information stored in
LBC to the new LBC.
EVB
Whenever any of the following work is performed, make sure to perform the above operation.
• Replace LBC
D

With CONSULT E
F
>> GO TO 2.
G
Replace Li-ion battery or LBC. Refer to EVB-377, "Removal and Installation" (Li-ion battery) or EVB-399, "LI-
ION BATTERY CONTROLLER : Disassembly and Assembly" (LBC).
H
>> GO TO 3.
With CONSULT I
J
>> GO TO 4.
4.WRITE THE LBC INTERNAL INFORMATION TO VCM K
>> END L

If a malfunction (e.g. abnormal voltage) occurs in a Li-ion battery cell, the module which includes the malfunc-
NOTE:
it is advisable to adjust voltage under room temperature conditions [20°C ± 10°C (68°F ±18°F)].
With CONSULT
1. Power switch ON.
3. Check “MAXIMUM CELL VOLTAGE”.

>> GO TO 2.
CAUTION:

3.DISCAHRGE OF MODULE VOLTAGE
CAUTION:
>> 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.


Standard : Adjustment voltage value ± 10 mV A
>> GO TO 6.
B
With CONSULT
1. After adjusting the voltage, install the module to the vehicle. EVB
range. D

E
>> WORK END

F

DTC/CIRCUIT DIAGNOSIS
DTC DETECTION LOGIC


With CONSULT
3. Check DTC.
Is P0A1F detected?
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
>> GO TO 2.

LBC A
— Continuity
Connector Terminal
B
YES >> GO TO 3.
NO >> Replace Li-ion battery vehicle communication harness. EVB
2. Check the continuity between Li-ion battery controller harness connector and ground. D
LBC
— Continuity E
Connector Terminal
Is the inspection result normal? F
YES >> GO TO 4.
4.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-3 G
H
Connector Terminal
I
YES >> Replace Li-ion battery controller. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disas- J
K

DTC DETECTION LOGIC

BATTERY ENERGY CON- Self diagnosis program of Li-ion battery controller de-

With CONSULT
3. Check DTC.
Is P0A1F detected?

A


With CONSULT E
3. Check DTC. F
Is P3030 detected?
With CONSULT
2. Check to see if “P30F3” is detected simultaneously with “P3030”. I
Is P30F3 detected?
J

DTC DETECTION LOGIC


P303B CELL CONT ASIC11

With CONSULT
3. Check DTC.

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P3031 -P303C”.
Is P3030 detected?

A

P303D CELL CONT ASIC13 EVB
D

F
P3047 CELL CONT ASIC23 G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P303D” -“P3048”. M
Is P3030 detected?
NO >> Replace Li-ion battery controller. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disas- N

DTC DETECTION LOGIC

P304E CELL CONT ASIC6 VOLT • Li-ion battery controller
• Module

With CONSULT
3. Check DTC.

With CONSULT
2. Check DTC.
• When “P331A” - “P3325” are detected simultaneously, perform the diagnosis procedure of

“P3399” - “P33A4”. Refer to EVB-331, "Diagnosis Procedure". A
B
EVB

DTC DETECTION LOGIC

P305A CELL CONT ASIC18 VOLT • Li-ion battery controller
• Module
P305F CELL CONT ASIC23 VOLT

With CONSULT
3. Check DTC.

With CONSULT
2. Check DTC.

B
EVB

DTC DETECTION LOGIC

An open circuit diagnosis detection circuit in Li-ion battery

With CONSULT
3. Check DTC.
Is P3061 detected?

P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
A

DTC DETECTION LOGIC D

With CONSULT E
3. Check DTC. F
Is P3062 detected?
With CONSULT
2. Check to see if “P3375”-“P33A4” is detected simultaneously with “P3062”. I
J
• When “P338D” - “P3398” are detected simultaneously, perform the diagnosis procedure of K
“P3399” - “P33A4”. Refer to EVB-331, "Diagnosis Procedure". L

DTC DETECTION LOGIC

P3090 CELL CONT ASIC6 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller

DTC DETECTION LOGIC

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

OVER DISCHARGE related codes) is detected simultaneously with “P308B”-“P3096”. A
EVB
“P338D”-“P3398”. Refer to EVB-328, "Diagnosis Procedure" E
NO >> GO TO 2.
F
2.PRECONDITIONING
WARNING:
Assembly", see Step-1 to Step-3. H
>> GO TO 3.
YES >> GO TO 4.
K
DTC.

DTC Continuity
1 2 50
2 3 51 N
3 4 52
4 5 53
O
5 6 54
6 7 55
7 8 56 P
8 9 57
9 26 58
10 27 59
11 28 60
12 29 61


DTC Continuity
13 30 62
14 31 63
15 45 77
16 46 78
17 36 80
18 37 81
19 38 82
20 39 83
21 52 84
22 53 85
23 54 86
24 55 87

A

P3097 CELL CONT ASIC13 OPEN EVB
D
P309C CELL CONT ASIC18 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller E

F
P30A1 CELL CONT ASIC23 OPEN G

With CONSULT
3. Check DTC.
K
WARNING:
L
maintenance. M
N
P
CAUTION:
With CONSULT

OVER DISCHARGE related codes) is detected simultaneously with “P3097”-“P30A2”.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
YES >> GO TO 4.
DTC.

DTC Continuity
25 73 110
26 74 111
27 60 112
28 77 113
29 78 114
30 64 115
31 81 116
32 82 117
33 68 118
34 85 119
35 86 120
36 72 121


DTC Continuity A
37 89 122
38 90 123 B
39 91 124
40 92 125
41 93 127 EVB
42 94 128
43 95 130
P30A0 LB7 LB15 Existed D
44 96 138
45 97 140
46 98 141 E
47 99 142
48 100 143
F

DTC DETECTION LOGIC


With CONSULT
3. Check DTC.
Is P30F3 detected?

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P30F3”.

A

• Module
D
With CONSULT
3. Check DTC.
Is P30F4 detected?
H
WARNING:
maintenance.
ilar item to prevent other persons from contacting them. L
CAUTION:
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER N
With CONSULT
2. Check if any DTC is detected in “Self Diagnostic Result”. O
Just “P30F4” is detected>>GO TO 2. P
2.CHECK FUSE

3.PRECONDITIONING
WARNING:
>> GO TO 4.
Check connection status between each stack and connection status of each bus bar.
YES >> GO TO 5.
Check the voltage of all modules.


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

A

• Module
D
With CONSULT
3. Check DTC.
Is P30F5 detected?
H
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. I
YES >> Perform diagnosis on the detected “P30F4”. Refer to EVB-293, "Diagnosis Procedure". J
K

P30FC OVER CURRENT
P30FC OVER CURRENT
DTC DETECTION LOGIC

When the temperature of the entire battery pack estimat- • Battery current sensor
P30FC OVER CURRENT

With CONSULT
3. Check DTC.
Is P30FC detected?

With CONSULT
NO >> GO TO 2.
With CONSULT
Using FFD, check the values of four temperature sensors when DTC is detected.

Temperature increase is not seen>>Replace battery junction box. Refer to EVB-392, "BATTERY JUNCTION
BOX : Disassembly and Assembly".

A

• Total voltage detection switch in Li-ion battery control- EVB
D
With CONSULT
3. Check DTC. F
Is P30FC detected?
G
H
I

DTC DETECTION LOGIC

• 12V battery
• Harness

With CONSULT
3. Check DTC.
Is P30FE detected?
WARNING:
maintenance.
CAUTION:
Check the voltage of 12 V battery using circuit tester.
YES >> GO TO 2.
NO >> Replace 12 V battery. Refer to PG-101, "Removal and Installation".
2.CHECK FUSE
2. Check 20A fuse [No.43].
NOTE:
YES >> GO TO 3.
2. Check voltage between Li-ion battery harness connector and ground. A
+
Li-ion battery − Voltage B
Connector Terminal
Battery
B24 5 Ground
voltage
EVB

YES >> GO TO 4. D
4.PRECONDITIONING
E
WARNING:
2. Remove battery pack upper case. Refer to EVB-392, "BATTERY JUNCTION BOX : Disassembly and F
>> GO TO 5. G
1. Disconnect Li-ion battery harness connector and Li-ion battery controller harness connector. H
tor.
I
Continuity
LB1 5 LB11 12 Existed J
sembly and Assembly". K

DTC DETECTION LOGIC

ROR uously.
• VCM

With CONSULT
3. Check DTC.
Is P318D detected?

A

NOTE:

• VCM D
ROR continuously.

With CONSULT
F
7. Check DTC.
Is P318E detected?
J
With CONSULT
Is P318E detected?
YES >> Replace VCM. Refer to EVC-369, "Removal and Installation". L
NO >> GO TO 2.
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P318E”. N
Is U1000 detected?

DTC DETECTION LOGIC

NOTE:


With CONSULT
7. Check DTC.
Is P3191 detected?

With CONSULT
Is P3191 detected?
YES >> Replace traction motor inverter. Refer to TMS-115, "Removal and Installation"
NO >> GO TO 2.
With CONSULT
Is U1000 detected?

A

NOTE:

• On board charger D

With CONSULT
F
7. Check DTC.
Is P3196 detected?
J
With CONSULT
Is P3196 detected?
YES >> Replace on board charger. Refer to VC-105, "Removal and Installation" L
NO >> GO TO 2.
With CONSULT
Is U1000 detected?

DTC DETECTION LOGIC

COMMUNICATION ER- • VCM

With CONSULT
3. Check DTC.
Is P3199 detected?

A

COMMUNICATION ER- • Traction motor inverter EVB

D
With CONSULT
3. Check DTC.
Is P319C detected? F
G
H

P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
DTC DETECTION LOGIC

If the CAN data from VCM has not change from the value

With CONSULT
3. Check DTC.
Is P31A4 detected?

A

If the CAN data from traction motor inverter has not EVB

D
With CONSULT
3. Check DTC.
G
H

DTC DETECTION LOGIC

• Li-ion battery
range. • VCM

With CONSULT
3. Check DTC.
Is P3300 detected?

With CONSULT
NO >> GO TO 2.
With CONSULT

A

D
• Module
P330C CELL OVER VOLTAGE MODULE11 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.

DTC Continuity
17 33
18 34
18 34
19 35
19 35
20 36
20 36
21 37
21 37
22 38
22 38
23 39
23 39
24 40
24 40
25 42
25 42
11 43


DTC Continuity A
11 43
P330B 10 LB9 27 LB13 59 Existed B
12 44
12 44
P330C 11 LB9 28 LB13 60 Existed EVB
13 45
13 45
D
14 46
YES >> GO TO 4.



K
Terminals
Voltage
(+) (-)
(Approx.)
Module L
JSCIA0338ZZ P

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
D
>> GO TO 3.
F
DTC Continuity
G
14 46
15 47 H
15 47
1 48
I
LB9 1 LB13 48
P3310 15 45 77 Existed J
LB10 LB14
34 65
34 65
P3311 16 LB10 46 LB14 78 Existed K
35 66
35 66
L
P3312 17 LB10 36 LB14 80 Existed
48 69
48 69 M
P3313 18 LB10 37 LB14 81 Existed
49 70
N
49 70
P3314 19 LB10 38 LB14 82 Existed
50 71 O
50 71
P3315 20 LB10 39 LB14 83 Existed
P
51 72
51 72
P3316 21 LB10 52 LB14 84 Existed
41 73


DTC Continuity
41 73
P3317 22 LB10 53 LB14 85 Existed
42 74
42 74
P3318 23 LB10 54 LB14 86 Existed
43 75
43 75
P3319 24 LB10 55 LB14 87 Existed
44 76
YES >> GO TO 4.


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

A

P331A CELL OVER VOLTAGE MODULE25 EVB
D
P331F CELL OVER VOLTAGE MODULE30 tion E
• Module

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
With CONSULT

DTC Continuity
57 89
58 90
58 90
75 91
75 91
76 92
76 92
62 93
62 93
79 94
79 94
80 95
80 95
P3320 31 LB8 81 LB15 116 Existed
66 96
66 96
P3321 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity A
83 97
P3322 33 LB8 68 LB15 118 Existed B
84 99
84 99
70 100
70 100
D
P3324 35 LB8 86 LB15 120 Existed
87 101
87 101 E
P3325 36 LB8 72 LB15 121 Existed
88 102
F
YES >> GO TO 4.
H
J
K
L
Terminals
Voltage
(+) (-)
(Approx.) M
Module
P
JSCIA0338ZZ

DTC DETECTION LOGIC

P332B CELL OVER VOLTAGE MODULE42 When cell voltage exceeds the allowable • Module
• Bus bar

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
D
>> GO TO 3.
With CONSULT
G
DTC Continuity
LB8 88 102 H
P3326 37 89 LB15 122 Existed
LB7
101 103
I
101 103
P3327 38 LB7 90 LB15 123 Existed
102 104 J
102 104
P3328 39 LB7 91 LB15 124 Existed
K
103 105
103 105
P3329 40 LB7 92 LB15 125 Existed L
104 106
104 106
M
105 107
105 107 N
106 108
106 LB15 108 O
LB16
107 130
P
107 130
108 131


DTC Continuity
108 131
109 132
109 132
110 133
110 133
P3330 47 LB7 99 LB16 142 Existed
111 134
111 134
P3331 48 LB7 100 LB16 143 Existed
112 135
YES >> GO TO 4.


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

A

"DTC Logic".
EVB
• Module
D
• Bus bar
motor inverter/VCM malfunction E

1.CHECK SELF-DIAGNOSIS RESULTS F
With CONSULT
1. Power switch ON and wait for 10 seconds or more. G
3. Check DTC.
Is P3373 detected? H
Diagnosis Procedure INFOID:0000000007634529 I

With CONSULT J
Is any DTC detected? K
NO >> GO TO 2.
2.PERFORM THE SELF-DIAGNOSISS OF LI-ION BATTERY CONTROLLER L
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. M
YES >> • When “P3375”-“P3380” are detected simultaneously, perform the diagnosis procedure of N
• When “P338D”-“P3398” are detected simultaneously, perform the diagnosis procedure of O
“P3399”-“P33A4”. Refer to EVB-331, "Diagnosis Procedure". P

DTC DETECTION LOGIC

P337A CELL OVER DISCHARGE MODULE6 When cell voltage lowers below the • Module
• Bus bar

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
D
>> GO TO 3.
F
DTC Continuity
G
17 33
18 34 H
18 34
19 35
I
19 35
P3377 3 LB9 4 LB13 52 Existed J
20 36
20 36
P3378 4 LB9 5 LB13 53 Existed K
21 37
21 37
L
22 38
22 38 M
23 39
N
23 39
24 40 O
24 40
P
25 42
25 42
11 43


DTC Continuity
11 43
12 44
12 44
13 45
13 45
P3380 12 LB9 29 LB13 61 Existed
14 46
YES >> GO TO 4.


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

A

D
• Module
P338B CELL OVER DISCHARGE MODULE23 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Disconnect high voltage circuit. Refer to GI-31, "How to Disconnect High Voltage".
>> GO TO 3.

DTC Continuity
14 46
P3381 13 LB9 30 LB13 62 Existed
15 47
15 47
P3382 14 LB9 31 LB13 63 Existed
1 48
LB9 1 LB13 48
P3383 15 45 77 Existed
LB10 LB14
34 65
34 65
P3384 16 LB10 46 LB14 78 Existed
35 66
35 66
P3385 17 LB10 36 LB14 80 Existed
48 69
48 69
P3386 18 LB10 37 LB14 81 Existed
49 70
49 70
P3387 19 LB10 38 LB14 82 Existed
50 71
50 71
P3388 20 LB10 39 LB14 83 Existed
51 72
51 72
P3389 21 LB10 52 LB14 84 Existed
41 73


DTC Continuity A
41 73
P338A 22 LB10 53 LB14 85 Existed B
42 74
42 74
P338B 23 LB10 54 LB14 86 Existed EVB
43 75
43 75
D
44 76
YES >> GO TO 4.



K
Terminals
Voltage
(+) (-)
(Approx.)
Module L
JSCIA0338ZZ P

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
D
>> GO TO 3.
With CONSULT
G
DTC Continuity
57 89 H
58 90
I
58 90
75 91 J
75 91
K
76 92
76 92
P3390 28 LB8 77 LB15 113 Existed L
62 93
62 93
M
P3391 29 LB8 78 LB15 114 Existed
79 94
79 94 N
P3392 30 LB8 64 LB15 115 Existed
80 95
80 95 O
P3393 31 LB8 81 LB15 116 Existed
66 96
P
66 96
P3394 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity
83 97
P3395 33 LB8 68 LB15 118 Existed
84 99
84 99
P3396 34 LB8 85 LB15 119 Existed
70 100
70 100
P3397 35 LB8 86 LB15 120 Existed
87 101
87 101
P3398 36 LB8 72 LB15 121 Existed
88 102
YES >> GO TO 4.


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

A

D
P339E CELL OVER DISCHARGE MODULE42 function E
• Module
P33A3 CELL OVER DISCHARGE MODULE47 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
>> GO TO 3.
With CONSULT

DTC Continuity
LB8 88 102
P3399 37 89 LB15 122 Existed
LB7
101 103
101 103
102 104
102 104
103 105
103 105
104 106
104 106
105 107
105 107
106 108
106 LB15 108
LB16
107 130
107 130
108 131


DTC Continuity A
108 131
P33A1 45 LB7 97 LB16 140 Existed B
109 132
109 132
P33A2 46 LB7 98 LB16 141 Existed EVB
110 133
110 133
D
111 134
111 134 E
P33A4 48 LB7 100 LB16 143 Existed
112 135
F
YES >> GO TO 4.
H
J
K
L
Terminals
Voltage
(+) (-)
(Approx.) M
Module
P
JSCIA0338ZZ

DTC DETECTION LOGIC

BATT GRADUAL CAPA LOSS When the battery charge lowers.

With CONSULT
3. Check DTC.
Is P33D4 detected?

A

Deviation in characteristics of battery current sensor sig- • Li-ion battery controller EVB
D
With CONSULT
3. Check DTC.
Is P33D5 detected?
H
WARNING:
maintenance.
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS OF VCM N
With CONSULT
2. Check to see if “P0AA0”, “P0AA1” or “P0AA4” is detected. O
NO >> GO TO 2. P
2.PRECONDITIONING
WARNING:

>> GO TO 3.
Check connection status of Li-ion battery controller harness connector and battery junction box (current sen-
sor) harness connector.
YES >> GO TO 4.
4.CHECK HARNESS BETWEEN BATTERY JUNCTION BOX (CURRENT SENSOR) AND LI-ION BATTERY
CONTROLLER
Check continuity between battery junction box (current sensor) harness connector and Li-ion battery controller
harness connector.
Battery junction box (Current

sensor) Continuity
9 10
LB3 3 LB11 9 Exited
10 17
YES >> GO TO 5.
Battery junction box (Current sensor) Resistance val-

9 10
3 10
YES >> GO TO 6.
Check resistance of Li-ion battery controller.


Assembly".

A

Deviation from the specified voltage characteristics of EVB

D
With CONSULT
3. Check DTC.
G
WARNING:
maintenance. I
L
CAUTION:
1.PRECONDITIONING
WARNING: N
Assembly", see Step-1 to Step-3. O
>> GO TO 2.
P

Resistance value
Connector Terminal

10 9
9 17
NO >> GO TO 3.
3.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND BATTERY JUNCTION BOX (CUR-
RENT SENSOR)
1. Disconnect battery junction box harness connector.
2. Check continuity between Li-ion battery controller and battery junction box (current sensor).

(Current sensor) Continuity
10 9
17 10
Assembly".

A

Battery temperature sensor rear center signal voltage is EVB
P33D7
Battery temperature sensor front RH signal voltage is
too high or too low. D
Battery temperature sensor rear RH signal voltage is • Harness or connector
P33DB
Battery temperature sensor front LH signal voltage is E
P33DD

F
With CONSULT
3. Check DTC.
Is any DTC detected? H
I
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec- J
maintenance.
K
carry it in your pocket or put it in the tool box. L
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not M
CAUTION: N
so in the Service Manual. O
1.PRECONDITIONING
WARNING:
P
>> GO TO 2.

2.CHECK HARNESS
YES >> GO TO 3.
YES >> GO TO 4.
4.CHECK HARNESS BETWEEN BATTERY TEMPERATURE SENSOR AND GROUND
Battery tem-
sor
Rear center LB17 3
Front RH LB5 1
Ground No existed
Rear RH LB17 1
Front LH LB4 3


40 (104) Approx. 2.3

A

BAT VOLTAGE ISOLA- Signal voltage of the on-board isolation resistance moni- EVB

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

DTC DETECTION LOGIC

BATTERY VOLTAGE ISO- Signal Voltage of the on-board isolation resistance mon-

With CONSULT
3. Check DTC.
Is P33E0 detected?

A

BATTERY VOLTAGE ISO- Signal voltage of the on-board isolation resistance moni- EVB

D
With CONSULT
3. Check DTC.
G
ponent Inspection". H

DTC DETECTION LOGIC

BATTERY PACK OVER When the battery (battery pack) temperature is excessively Overcharge caused by traction
P33E2

With CONSULT
3. Check DTC.
Is P33E2 detected?

With CONSULT
dure".
NO >> GO TO 2.
With CONSULT

Temperature increase is not seen>>Replace battery temperature sensors. Refer to EVB-168, "Exploded
view".

A

Deviation in characteristics of Battery temperature sensor EVB
P33E4
P33E5
rear RH or front LH. D
With CONSULT
3. Check DTC.
H
WARNING:
maintenance.
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- J
touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or sim- L
CAUTION:
1.PRECONDITIONING N
WARNING:
Disconnect high voltage. Refer to GI-31, "How to Disconnect High Voltage". O
P
>> GO TO 2.



40 (104) Approx. 2.3

A

With the power switch ON and no load condition, the dif- EVB

With CONSULT E
3. Check DTC. F
Is P33E6 detected?
WARNING: H
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and I
maintenance.
• To prevent the removed service plug from being connected by mistake during the procedure, always J
L
CAUTION:
With CONSULT N
O
EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly and Assembly".
EVB-354, "Diagnosis Procedure". P
NO >> GO TO 2.
With CONSULT
of cells).

Average cell voltage = “TOTAL BETTER VOLTAGE” ÷ 96 (the number of cells)


STACK : Disassembly and Assembly" (Rear module stack). After replacing module, GO TO 3.
STACK : Disassembly and Assembly" (Rear module stack). After replacing module, GO TO 3.
With CONSULT
Is “MINIMUM CELL VOLTAGE” 3,712 mV or less?
YES >> GO TO 5.
NO >> GO TO 4.
With CONSULT
1. Set the vehicle to READY.
A/C set temperature : Full hot

3. Check “DATA MONITOR” and let the Li-ion battery discharge until the “MINIMUM CELL VOLTAGE”
NOTE:

ing segments of Li-
Time to 2 segments
charge gauge
6 Approx. 90 minute
5 Approx. 70 minute

ing segments of Li- A
Time to 2 segments
charge gauge
4 Approx. 40 minute B
3 Approx. 20 minute
>> GO TO 5. EVB

With CONSULT D
VALUE” is displayed. E
NO >> Check the minimum cell voltage on the data monitor and replace a module which includes the F
G
6.PRECONDITIONING
WARNING:
Disconnect the high voltage. Refer to GI-31, "How to Disconnect High Voltage". H
2. Remove battery pack upper case. Refer to EVB-377, "Exploded View", see Step-1 to Step-3.
I
>> GO TO 2.
J
YES >> GO TO 8. K
Check connection state, damage and dust of following; L
• Module terminal fixing bolt M
YES >> GO TO 9
NO >> Repair or replace error-detected parts. N
age with “DATA MONITOR”. O
DANGER:
Is Divergence within 40mV? P
YES >> GO TO 10.
TOR

determined cell at step 3.
Resistance val-
Terminal
ue
Approx. 0 Ω
3. Check the divergence of the resistance and the resistance of other cell harness.
NO >> Repair or replace harness or connectors.

A

The A/D converter in Li-ion battery controller is malfunc- EVB
tioning.

D
With CONSULT
3. Check DTC.
G

P33EA BATTERY HEATER RELAY
DTC DETECTION LOGIC

Li-ion battery controller judges that the status of a relay control
signal transmitted from Li-ion battery controller and that of a
P33EA BATTERY HEATER RELAY • Heater relay unit
relay status signal transmitted from heater relay unit do not
match.
NOTE:
• The Li-ion battery controller transmits a relay control signal to the heater relay unit and turns ON/OFF the
relay built-in the heater relay unit.
• The heater relay unit turns ON/OFF the built-in relay, according to a relay control signal transmitted from the
Li-ion battery controller, and transmits a relay status signal (the ON/OFF status of the built-in relay) to the Li-
ion battery controller.
1.PERFORM DTC CONFIRMATION PROCEDURE-1
With CONSULT
1. Select “ACTIVE TEST” of “HV BAT.”
2. Select “HEATER RELAY UNIT.” Touch “START.”
>> GO TO 2.
With CONSULT
2. Check DTC.
Is P33EE detected?
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:

1. Remove Li-ion battery. Refer to EVB-377, "Removal and Installation". A
B
>> GO TO 2.
2.CHECK CONTINUITY LI-ION BATTERY CONTROLLER AND HEATER RELAY UNIT
EVB
1. Remove service plug switch bracket. Refer to EVB-428, "HEATER RELAY UNIT : Disassembly and
Assembly".
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. D
Lli-ion battery controller Heater relay unit

Continuity E
20 3
LB11 LB18 Existed
4 8
F
YES >> GO TO 3.
3.CHECK CONTINUITY LI-ION BATTERY AND HEATER RELAY UNIT
Check continuity li-ion battery harness connector and heater relay unit harness connector.
H
Lli-ion battery Heater relay unit

Continuity
Connector Terminal Connector Terminal I
J
YES >> GO TO 4.
4.CHECK CONTINUITY HEATER RELAY UNIT AND LI-ION BATTERY CONTROLLER K
Check continuity heater relay unit harness connector and li-ion battery controller harness connector.
Heater relay unit Li-ion battery controller L

Continuity
6 3
M
12 16
YES >> Replace to shown in the below.
• Li-ion battery controller. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly
and Assembly". O
• Heater relay unit. Refer to EVB-428, "HEATER RELAY UNIT : Disassembly and Assembly".
P

DTC DETECTION LOGIC

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

1.CHECK LI-ION BATTERY AVAILABLE CHARGE GAUGE
NOTE:
Check 12 segments for lighting status.
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.
>> GO TO 4.
With CONSULT
3. Check DTC.
Is P33ED detected?

With CONSULT

YES >> Replace corresponding Module. Refer to EVB-384, "Exploded view".
NO >> GO TO 2. A
B
>> Replace corresponding Module. Refer to EVB-384, "Exploded view".

EVB

P33EE BATTERY HEATER CONTROL SYSTEM
DTC DETECTION LOGIC

Under extremely low temperatures that Li-ion battery heater
BATTERY HEATER CON- • Heater relay unit
P33EE activates, Li-ion battery controller judges that the temperature
TROL SYSTEM • Li-ion battery heater
of Li-ion battery is still low after a lapse of specified time.
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
>> GO TO 2.
2.CHECK INSTALLATION CONDITION OF LI-ION BATTERY HEATER
Check the main body of Li-ion battery heater for installation condition.
YES >> GO TO 3.
NO >> Tighten the mounting nut of the Li-ion battery heater to the specified torque. Refer to EVB-384,
"Exploded view".
3.CHECK CONNECTION STATUS OF LI-ION BATTERY HEATER CONNECTOR
Check the connection status of the Li-ion battery heater connector.
YES >> GO TO 4.
NO >> Restore the connection status of the Li-ion battery heater connector.
4.CHECK RESISTANCE OF LI-ION BATTERY HEATER
Check resistance of Li-ion battery heater.

Li-ion battery heater A

Resistance
Item Terminal
LH 1
B
LH 2
LH 3
1 2 Less than 5,269 Ω
RH 1 EVB
RH 2
RH 3
D
RR 1
RR 2
YES >> GO TO 5.
NO >> Replace applicable Li-ion battery heater. Refer to EVB-435, "HEATER UNIT : Disassembly and
Assembly". F
5.CHECK CONTINUITY OF LI-ION BATTERY HEATER AND HEATER RELAY UNIT
1. Disconnect Li-ion battery heater and heater relay unit harness connector harness connector.
2. Check continuity Li-ion battery heater and heater relay unit harness connector harness connector. G
Li-ion battery heater Heater relay unit

Continuity H
Item Connector Terminal Connector Terminal
1 22
LH 1 LB21 LB20 Existed
2 24 I
1 22
2 24
J
1 22
2 24
1 22 K
RH 1 LB26 LB20 Existed
2 24
1 22
RH 2 LB27 LB20 Existed L
2 24
1 22
RH 3 LB28 LB20 Existed
2 24
M
1 22
RR 1 LB24 LB20 Existed
2 24
1 22 N
RR 2 LB25 LB20 Existed
2 24
O
YES >> Replace heater relay unit. Refer to EVB-435, "HEATER UNIT : Disassembly and Assembly".
P

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

When no CAN communication signal is received continu-

A
WARNING: B
EVB
maintenance.
• To prevent the removed service plug from being connected by mistake during the procedure, always D
before beginning work on the high voltage system. E
• Refer to EVB-219, "High Voltage Precautions". F
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do G
battery is judged that its insulation resistance is dropping. H
With CONSULT I
1. Power switch ON.
NOTE: J
>> GO TO 2 K
CAUTION: L
2. Remove Li-ion battery controller. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly and M
Assembly".
4. Measure voltages between positive terminal of front module stack LH and battery pack ground, and N
JSCIA0739ZZ

+
Terminal

YES >> GO TO 8.
NO >> GO TO 3.
JSCIA0739ZZ
+
Terminal

NO >> GO TO 4.
JSCIA0739ZZ

+ A
Terminal
B

YES >> GO TO 5. EVB
NO >> GO TO 6.
5.CHECK SERVICE PLUG SWITCH INSULATION RESISTANCE D
E
WARNING:
danger of damage to electronic devices. Read the insulation resistance tester instruction manual F
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting G
NOTE:
H
+ — Resistance
I
NO >> Replace service plug switch (Refer to EVB-384, "Exploded view".) and GO TO 8. J
6.CHECK MODULE-1
1. Remove front module stack LH. Refer to EVB-405, "FRONT MODULE STACK : Disassembly and Assem-
bly". K
NOTE:
2. Measure voltages between terminal / of all modules in front L
JSCIA0740ZZ O
+ P
Module − Voltage
Terminal

YES >> GO TO 7.
7.CHECK MODULE-2
WARNING:
CAUTION:
+
Terminal

GO TO 8.
JSCIA0741ZZ
+
Terminal

YES >> GO TO 14.
NO >> GO TO 9.

9.CHECK INSULATION OF FRONT MODULE STACK RH-2 A

between positive terminal of front module stack RH and battery pack ground. B
EVB
E
JSCIA0741ZZ

F
+
Front module stack RH − Voltage G
Terminal

H
NO >> GO TO 10. I
J
JSCIA0741ZZ
N
O
+
Terminal P

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

between high voltage terminal / of battery junction box and
WARNING:
applies 500 V when measuring. If used incorrectly, there is

CAUTION:

— Resistance
Terminal

NO >> Replace battery junction box (Refer to EVB-392, "BATTERY JUNCTION BOX : Disassembly and
Assembly") and GO TO 14.
12.CHECK MODULE-3
bly".
NOTE:
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 13.
13.CHECK MODULE-4

in front module stack RH and module body. A
WARNING:
CAUTION:
+ E
Terminal
F

GO TO 14.
NO >> Replace malfunctioning module (Refer to EVB-405, "FRONT MODULE STACK : Disassembly H
I
J
JSCIA0744ZZ
M
+
N
Terminal

YES-2 >> Replace or repair of malfunctioning part is complete: INSPECTION END. P
NO >> GO TO 15.

module stack.
JSCIA0146ZZ
JSCIA0744ZZ
+
Terminal

NO >> GO TO 16.
1. Remove mounting nuts / and remove high voltage harness from rear module stack.
JSCIA0743ZZ

EVB
JSCIA0744ZZ
D
+
E
Terminal

NO >> GO TO 17.
17.CHECK MODULE-5 G
NOTE:
Do not disassemble module stack. H
I
K
JSCIA0740ZZ
L
+
Module − Voltage
M
Terminal

N

YES >> GO TO 18. O
Assembly".
18.CHECK MODULE-6 P

in rear module stack and module body.
WARNING:
CAUTION:
+
Terminal

Assembly".

LI-ION BATTERY HEATER SYSTEM INSULATION RESISTANCE CHECK
A
WARNING: B
EVB
maintenance.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not E
CAUTION: F
so in the Service Manual. G
1. PRECONDITIONING
WARNING:
H
Assembly", see Step-1 to Step-3. I
>> GO TO 2.
J
2.CHECK HIGH VOLTAGE HARNESS
Check the harness shield between the heater relay unit and the Li-ion battery heater for scratches and cracks.
Is the inspection result normal? K
YES >> GO TO 3.
NO >> Repair or replace error-detected parts and Li-ion battery controller.
3.CHECK HEATER RELAY UNIT INSULATION RESISTANCE L
WARNING:
M
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
and be sure to work safely.
1. Disconnect high voltage harness connector from heater relay unit. N
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 O
the value becomes stable.
CAUTION:
higher than 500 V can result in damage to the component being inspected. P

Heater relay unit

Ground Resistance
Terminal
14
16
Battery pack lower case 1000 MΩ or more
22
24
YES >> GO TO 4.
NO >> Replace heater relay unit and Li-ion battery controller.
4.CHECK LI-ION BATTERY HEATER
WARNING:
1. Disconnect high voltage harness connector from Li-ion battery heater.
NOTE:
2. Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until
CAUTION:
Li-ion battery heater

Ground Resistance
Item Connector Terminal
1
LH1 LB21 1000 MΩ or more
2
1
2
1
2
1
RH1 LB26 1000 MΩ or more
2
Battery pack lower case
1
2
1
2
1
RR1 LB24 1000 MΩ or more
2
1
2
YES >> GO TO 5.
NO >> Replace corresponding Li-ion battery heater and Li-ion battery controller.
5.CHECK HIGH VOLTAGE HARNESS INSULATION RESISTANCE
WARNING:

incorrectly, there is the danger of electric shock. If used in the vehicle 12 V system, there is the danger A
B
CAUTION:
Be sure to set the insulation resistance tester to 500V when performing this test. Using a setting
higher than 500 V can result in damage to the component being inspected. EVB
High voltage harness

Ground Resistance D
Connector Terminal
22
LB20 Battery pack lower case 1000 MΩ or more
24
E
YES >> INSPECTION END.
NO >> Replace high voltage harness. F

WARNING:
maintenance.
CAUTION:
1.CHECK FUSE

Battery 43
55
Power switch ON
74
Is the fuse fusing?
NO >> GO TO 2.
+
Connector Terminal
6
8
YES >> GO TO 3.

+ A
Connector Terminal
B
12V battery power
B24 5 Ground
supply
YES >> GO TO 5.
NO >> GO TO 4.
E
+
No.43 fuse ter-
B24 5 Existed
minal
+
J
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4 K
21
YES >> GO TO 8.
NO >> GO TO 6.
nector.

Continuity
P
YES >> GO TO 7.

Li-ion battery
— Continuity
Connector Terminal
No.74 fuse ter-
B24 21 Existed
minal
8.PRECONDITIONING
WARNING:
>> GO TO 9.
LBC Li-ion battery

Continuity
5 21
6 4
21 5
LB11 LB1 Existed
3 8
15 7
16 6

SYMPTOM DIAGNOSIS A
B
EVB

NOTE:

YES >> GO TO 3. F
NO >> GO TO 2.

J
>> GO TO 3.
K
>> GO TO 4. M
With CONSULT N
3. Check DTC.
O
P


operation manual.

LI-ION BATTERY

LI-ION BATTERY
B
EVB
JPCIA0247GB K
1. Li-ion battery 2. Bonding plate (Stamp No.4) 3. Li-ion battery under cover (center)
4. Li-ion battery under cover (front) 5. Clip 6. Li-ion battery under cover (rear) L
7. Battery mounting bracket LH 8. Battery mounting bracket RH
M
N
WARNING:
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and O
maintenance.
CAUTION:

LI-ION BATTERY
REMOVAL
WARNING:
Perform high voltage system work preparation. Refer to GI-31, "How to Disconnect High Voltage".
1. Lift up the vehicle and remove the Li-ion battery under covers. Refer to EVB-377, "Exploded View".
2. Disconnect high voltage harness connector (A) from Li-ion bat-
tery.
WARNING:

protective gear.

• Follow the procedure below to disconnect the high voltage harness connector.
JPCIA0035ZZ
3. Disconnect the Li-ion battery vehicle communication harness

connector (A) while turning it counterclockwise.
WARNING:

protective gear.
JPCIA0063ZZ
4. Remove the bonding plates (1).
: Vehicle front
WARNING:

protective gear.
JPCIA0248ZZ

LI-ION BATTERY
5. Remove the Li-ion battery mounting bolts (A).
A
: Vehicle front
WARNING:
B
protective gear.
EVB
CAUTION: JSCIA0177ZZ
Never remove the 4 bolts (B) shown in the figure. D

6. Set the pallet onto the lifter table.
• Align center mark (A) of pallet (1) with center mark (B) of bat-
tery lift table (2). E
C. Front
D. Side F
K
JSCIA0178ZZ
7. Set the pallet (1) onto the Li-ion battery.

CAUTION: L
Set the palette and Li-ion battery with transportation fixing
bolts.
M
JSCIA0179ZZ
O
8. Remove the Li-ion battery mounting bolts (4 bolts) (A).

LI-ION BATTERY
JPCIA0206ZZ
: Vehicle front
WARNING:
9. Lower the pallet and remove the Li-ion battery (1) from the vehi-
cle.
WARNING:

protective gear.
JSCIA0181ZZ
10. Move Li-ion battery from the lift table together with the pallet.
JPCIA0196ZZ
1. Lift Li-ion battery.

2. Move lift table.
3. Lower Li-ion battery.
4. Move Li-ion battery by operating stacker.
CAUTION:
To prevent stacker from falling, never move the stacker with the Li-ion battery lifted.
INSTALLATION
1. When replacing the Li-ion battery with a new one, perform the following procedure.
b. Cut the EV battery traceability seal in two and affix each seal to the Li-ion battery and “Li-ion BATTERY

LI-ION BATTERY
2. Install 2 locating pins (1) at the positions on the vehicle body shown in the figure.
A
EVB
JSCIA0182ZZ
F
: Vehicle front

• Align the Li-ion battery (1) and the locating pin (2). G
WARNING:
To prevent electric shock hazards, be sure to wear H

protective gear.
J
JSCIA0183ZZ
4. Tighten mounting bolts (4 bolts) (A) and remove pallet from Li-ion battery.
K
JPCIA0206ZZ N
: Vehicle front
WARNING: O

P
5. Remove the locating pins from the body.

LI-ION BATTERY
• If the locating pins (1) are tight and cannot be removed, use a
spanner to remove them.
WARNING:

protective gear.
JSCIA0185ZZ
6. Install the Li-ion battery mounting bolts (A).
: Vehicle front
WARNING:

protective gear.
JPCIA0241ZZ
7. Install the bonding plate (1) at the position shown in the figure.
: Vehicle front
WARNING:

protective gear.
JPCIA0248ZZ
8. After installing the bonding plate, check the equipotential. Refer to EVB-383, "Inspection".
9. Turn the vehicle communication harness connector (A) clock-
wise to install.
WARNING:

protective gear.
JPCIA0063ZZ

LI-ION BATTERY
10. Install the high voltage harness connector (A).
WARNING: A

protective gear. B
EVB
JPCIA0062ZZ
D
• Follow the procedure below to install the high voltage harness connector.
G
JPCIA0036ZZ
11. Install the Li-ion battery under covers. Refer to EVB-377, "Exploded View".
12. Install the service plug. Refer to GI-31, "How to Disconnect High Voltage". H
I
EQUIPOTENTIAL TEST
After installing the Li-ion battery, measure the resistance between the body of the battery pack (A) and the
vehicle body (B).
J
WARNING:

K
L
If the result deviates from the standard values, perform the below inspection and correct the abnormal loca-
tion. M
• Connection conditions of bonding plates
• Corrosion on bonding plate mounting surfaces
• Paint, oil, dust, or other substance on bonding plate mounting surfaces N

LI-ION BATTERY
UNIT DISASSEMBLY AND ASSEMBLY

LI-ION BATTERY
Exploded view INFOID:0000000007634583
LI-ION BATTERY
JPCIA0251GB

LI-ION BATTERY
1. Service plug 2. Service plug switch 3. Battery pack upper case A

4. Seal 5. Bus bar 6. Front module stack RH
7. Bus bar 8. Bus bar 9. Service plug switch bracket
10. Bus bar 11. Front module stack LH 12. Battery junction box cover B
13. Battery junction box 14. Battery junction box bracket 15. Battery member pipe
16. Drain plug washer 17. Drain plug 18. Connector flange
19. Plastic plate 20. High voltage harness connector 21. Bonding plate EVB
22. Seal 23. Vehicle communication harness con- 24. Snap ring
nector
25. Battery pack lower case 26. Heater relay unit 27. Harness bracket D
28. High voltage harness 29. High voltage harness 30. Rear module stack
31. Li-ion battery heater harness 32. Seal 33. Breather
34. Vehicle communication harness 35. High voltage warning label 36. Retainer E

F
FRONT MODULE STACK

G
Removal
Left Side
H
O
JPCIA0218GB
1. Li-ion battery heater LH3 2. Bus bar cover 3. Bus bar

P
4. Front module stack LH 5. Li-ion battery heater LH1 6. Battery temperature sensor (LH front)
7. Li-ion battery heater LH2

LI-ION BATTERY
Right Side
JPCIA0217GB
1. Li-ion battery heater RH2 2. Battery temperature sensor (RH front) 3. Li-ion battery heater RH1
4. Front module stack RH 5. Bus bar 6. Bus bar cover
7. Li-ion battery heater RH3
Disassembly
NOTE:
Figure indicates front RH.

LI-ION BATTERY
EVB
JPCIA0008GB
K
1. End plate (front) 2. Module B 3. Spacer (back side)

4. Spacer (terminal side) 5. Module A 6. End plate (rear) L
7. Sub flame
M

LI-ION BATTERY
Module Layout
JPCIA0084GB
LH front module stack RH front module stack

Bus bar Layout

DANGER:

LI-ION BATTERY
Because there is a danger of electric shock and fire, never contact bus bar in a wrong terminal. A
EVB
JSCIA0875ZZ P
: Battery front
REAR MODULE STACK

Removal

LI-ION BATTERY
JPCIA0219GB
1. Li-ion battery heater RR2 2. Rear module stack 3. Bus bar

4. Bus bar cover 5. Heater harness bracket 6. Harness bracket
7. Control bracket 8. Li-ion battery controller 9. Li-ion battery heater RR1
10. Battery temperature sensor (rear)
Disassembly

LI-ION BATTERY
EVB
H
JPCIA0225GB
1. Through bolt 2. LH end plate 3. Module A

4. Mounting plate (back side) 5. Mounting plate (terminal side) 6. Module B I
7. Support plate (back side) 8. Support plate (terminal side) 9. Rear stack member
10. Front stack member 11. RH end plate
: Always replace every disassembly J
Module Layout K
P
JPCIA0084GB

LI-ION BATTERY
Rear module stack

BATTERY JUNCTION BOX

BATTERY JUNCTION BOX : Disassembly and Assembly INFOID:0000000007634584
DANGER:
maintenance.
WARNING:
CAUTION:
snowing.

LI-ION BATTERY
4. Work space
• Space approximately the size of one vehicle must be secured as the disassembly space. A
5. Standard fire fighting equipment B
guisher).
EVB
DISASSEMBLY
2. Remove service plug retainer (1). D
WARNING:
To prevent electric shock hazards, be sure to wear E

protective gear.
JSCIA0143ZZ G
H
M
JSCIA0144ZZ
: Vehicle front
N
WARNING:

O
P
Assembly".

LI-ION BATTERY
5. Disengage pawls and remove battery junction box cover (1).
: Pawl
WARNING:

JSCIA0264ZZ
6. Remove terminal mounting nut (A) of high voltage harness con-

nector.
DANGER:


harness connector (high voltage terminal) and terminals.
7. Remove mounting nut (A) and mounting bolt (B), then remove
bonding plate (1).
WARNING:

JPCIA0169ZZ
8. Remove mounting nuts (A), then disconnect high voltage har-

ness connector (1) from battery pack.
WARNING:

JPCIA0170ZZ

LI-ION BATTERY
9. Remove mounting nuts (A), then remove high voltage harness
(1) and bus bar (2) from battery junction box. A
DANGER:
• To prevent electric shock hazards, be sure to put on B

EVB

wrap insulating tape around disconnected high voltage D
10. Remove mounting nut (A) and remove battery junction box (1).
WARNING: E

F
JSCIA0268ZZ
ASSEMBLY H
1. Install battery junction box.
WARNING:
I
lated tools.
J
2. Install high voltage harness connector. K

WARNING:
L
lated tools.
M
Assembly".
4. Follow the procedure below and install battery pack upper case. N
CAUTION:
Check seal before install battery pack upper case. Refer to EVB-397, "BATTERY JUNCTION BOX :
Inspection". O
a. Tighten mounting nuts and bolts in numerical order as shown in the figure.

LI-ION BATTERY
JPCIA0140ZZ
: Vehicle front
WARNING:
JPCIA0141ZZ
: Vehicle front
WARNING:

LI-ION BATTERY
WARNING: A

protective gear. B
EVB
JSCIA0143ZZ
D
CAUTION:
• Perform the “LI-ION BATTERY JUNCTION BOX DATA CLEAR” when battery junction box is replaced.
Refer to EVC-102, "Work Procedure".
E
• Check the following items after installing battery pack: Refer to EVB-397, "BATTERY JUNCTION BOX
: Inspection".
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST F
BATTERY JUNCTION BOX : Inspection INFOID:0000000007634585
G
and cracks)
• Replace seal if its lips are damaged. H
JPCIA0376ZZ
AIR LEAK INSPECTION K

WARNING:
L
protective gear.
M
N
JPCIA0124ZZ
2. Install gauge [SST: KV99111400] (A). O

WARNING:

P
protective gear.
CAUTION:
JPCIA0125ZZ

LI-ION BATTERY
DANGER:
WARNING:

protective gear.
JPCIA0128ZZ
CAUTION:

WARNING:
CAUTION:

JPCIA0190ZZ

LI-ION BATTERY
WARNING:
A

EVB
• Paint, oil, and dust on the mounting surface of ground bolts D
LI-ION BATTERY CONTROLLER : Disassembly and Assembly INFOID:0000000007634586 E
DANGER:
F
maintenance. G
WARNING:
ing inspection or maintenance of high voltage system harnesses and parts. H
I
troller before disassembling battery pack. J
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do K
1. Must be an indoor environment. L
• The environment must prevent the entry of sweat during work, and also prevent condensation from M
N
3. The floor must be dry. O
snowing.
4. Work space P
guisher).

LI-ION BATTERY
DISASSEMBLY
WARNING:

protective gear.
JSCIA0143ZZ
JSCIA0144ZZ
: Vehicle front
WARNING:
4. Disconnect Li-ion battery controller harness connector (A).

WARNING:

protective gear.
JPCIA0222ZZ

LI-ION BATTERY
5. Remove Li-ion battery controller mounting bolts (A).
WARNING: A

insulated protective gear and use insulated tools. B
EVB
JSCIA0147ZZ
D
6. Remove harness connector (A) and harness clip, then remove
E
B : Low voltage harness connector
: Vehicle front
WARNING: F

protective gear.
G
JPCIA0204ZZ
H
NOTE:
I
Remove together with controller bracket.
ASSEMBLY
J
1. Install Li-ion battery controller.
WARNING:
K
insulated tools.
L
• There are harness connector for high voltage (A) and low M
voltage (B) to a Li-ion battery controller. When the high
voltage harness connector is inserted in the low voltage
part, it causes smoking and the part damage. Be careful
enough when install harness connector. N
: Vehicle front
O
JPCIA0204ZZ
P
CAUTION:
Check seal before install battery pack upper case. Refer to EVB-403, "LI-ION BATTERY CONTROL-
LER : Inspection".

LI-ION BATTERY
JPCIA0140ZZ
: Vehicle front
WARNING:
JPCIA0141ZZ
: Vehicle front
WARNING:

LI-ION BATTERY
WARNING: A

protective gear. B
EVB
JSCIA0143ZZ
D
CAUTION:
• Perform the “ADDITIONAL SERVICE WHEN REPLACING LI-ION BATTERY CONTROLLER” when Li-
ion battery controller is replaced. Refer to EVB-271, "Work Procedure".
E
• Check the following items after installing battery pack: Refer to EVB-403, "LI-ION BATTERY CON-
TROLLER : Inspection".
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST F
LI-ION BATTERY CONTROLLER : Inspection INFOID:0000000007634587
G
and cracks)
• Replace seal if its lips are damaged. H
JPCIA0376ZZ
AIR LEAK INSPECTION K

WARNING:
L
protective gear.
M
N
JPCIA0124ZZ
2. Install gauge [SST: KV99111400] (A). O

WARNING:

P
protective gear.
CAUTION:
JPCIA0125ZZ

LI-ION BATTERY
DANGER:
WARNING:

protective gear.
JPCIA0128ZZ
CAUTION:

WARNING:
CAUTION:

JPCIA0190ZZ

LI-ION BATTERY
WARNING:
A

EVB
• Paint, oil, and dust on the mounting surface of ground bolts D
FRONT MODULE STACK
FRONT MODULE STACK : Disassembly and Assembly INFOID:0000000007634588 E
DANGER:
F
maintenance. G
WARNING:
ing inspection or maintenance of high voltage system harnesses and parts. H
I
troller before disassembling battery pack. J
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do K
1. Must be an indoor environment. L
• The environment must prevent the entry of sweat during work, and also prevent condensation from M
N
3. The floor must be dry. O
snowing.
4. Work space P
guisher).

LI-ION BATTERY
DISASSEMBLY
1. Remove battery pack upper case. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly
and Assembly".
Assembly".
3. Remove battery junction box. Refer to EVB-392, "BATTERY JUNCTION BOX : Disassembly and Assem-
bly".
4. Remove service plug switch and heater relay unit. Refer to EVB-428, "HEATER RELAY UNIT : Disassem-
bly and Assembly".
5. Remove Li-ion battery heater (front). Refer to EVB-435, "HEATER UNIT : Disassembly and Assembly".
6. Remove bus bar (1) that connects left and right front module
stacks.
: Vehicle front
DANGER:

JSCIA0258ZZ

wrap insulating tape around disconnected high voltage harness connector and terminals.
7. Remove battery temperature sensor (1) from module (2).
JSCIA0388ZZ

: Vehicle front
WARNING:
lated tools.
8.

LI-ION BATTERY
9. Remove vehicle communication harness connector.
A
A. Front module stack LH side
B. Front module stack RH side
: Vehicle front B
WARNING:
• To prevent electric shock hazards, be sure to put on EVB

JSCIA0261ZZ
high voltage harness connector and terminals. E
10. Remove front module stack mounting bolts (A).
1. Front module stack LH F

WARNING:
G
H
JPCIA0233ZZ
11. Follow the procedure below and remove front module stack from battery pack. I
slinger belt to it.
WARNING: J

protective gear. K
L
JSCIA0439ZZ
b. Use mobile floor crane (A) to lift up front module stack (1). M
WARNING:
• To prevent electric shock hazards, be sure to wear N

protective gear.

work bench. JSCIA0440ZZ P
c. Move the battery pack and place work bench underneath front module stack.
WARNING:

LI-ION BATTERY
CAUTION:
d. Place front module stack (1) onto work bench.

WARNING:

protective gear.

NOTE:
Figure indicates front module stack RH.
12. Follow the procedure below and remove bus bar from front module stack.
a. Remove bus bar (1).
DANGER:


wrap insulating tape around disconnected high voltage JSCIA0184ZZ
b. Remove bus bar cover and remove module terminal mounting bolts (A).
JSCIA0186ZZ
DANGER:
insulated tools.

LI-ION BATTERY
c. Remove voltage detection terminal mounting screws (A) and remove bus bar (1) from front module stack.
A
EVB
JSCIA0252ZZ
DANGER: D
insulated tools.
E
F
d. Attach module terminal covers [SST: KV99111500] (A) to all module terminals.
G
JPCIA0123ZZ
J
WARNING:

K
L
13. Remove end plate and disassembly front module stack.
WARNING:
M
lated tools.
ASSEMBLY O
Note the following, assemble in the reverse order of disassembly.
DANGER:
P
minal.

LI-ION BATTERY
monly-confused with the wrong position (B), install the bus bar to the correct position (A) with
extreme caution.
JSCIA0876ZZ
A. Correct position B. Wrong position

: Battery front
WARNING:
Install Li-ion battery controller immediately before installing battery pack upper case.
CAUTION:
cedure".
• Check seal before install battery pack upper case. Refer to EVB-412, "FRONT MODULE STACK :
Inspection".
EV Battery Traceability Seal
When replacing the module with a new one, perform the following procedure.
1. Enter the date of replacement on the EV battery traceability seal packaged with the new part.
2. Cut the EV battery traceability seal in two and affix each seal to the old module and “Li-ion BATTERY
3. Fill in the “Li-ion BATTERY REPLACEMENT RECORD”.
Front Module Stack
• Check that terminal of front module stack is arranged as shown in the figure.
JSCIA0308ZZ

LI-ION BATTERY
A. Front module stack RH B. Front module stack LH A

: Vehicle front
• Tighten mounting bolts in numerical order as shown in the figure.

B
EVB
JPCIA0150ZZ
G
A. Front module stack RH B. Front module stack LH
: Vehicle front
H
DANGER:
• To prevent electric shock hazards, be sure to put on insulated protective gear and use insu-
lated tools. I

• Install end plate so that its carabiner mounting hole (A) is posi-
K
tioned as shown in the figure.

L
NOTE:
There are two kinds of end plates of which carabiner mounting
hole location is different each other. The installation of improper
end plate results in the carabiner mounting hole being placed M
inside. Accordingly, the front stack module cannot be lifted.
JSCIA0441ZZ
N
Battery Temperature Sensor
• Install battery temperature sensor (front) as shown in the figure.
O

LI-ION BATTERY
JSCIA0389ZZ

: Vehicle front
• Insert a sensor (A) into module and fix with clip (B).
NOTE:
Do not fix with grommet (C).
JSCIA0390ZZ
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-412, "FRONT MODULE STACK :
Inspection".
AIR LEAK INSPECTION
FRONT MODULE STACK : Inspection INFOID:0000000007634589

and cracks)
JPCIA0376ZZ
AIR LEAK INSPECTION

LI-ION BATTERY
WARNING: A

protective gear. B
EVB
JPCIA0124ZZ
D
WARNING:
E
protective gear.
F
CAUTION:
Handle the gauge carefully so that it will not drop. G
JPCIA0125ZZ

H
DANGER:

I
J
• Stick it so that tape is not wrinkled. K
WARNING:
To prevent electric shock hazards, be sure to wear L

protective gear.
M
JPCIA0128ZZ
5. Perform air leak inspection by applying 1.6 kPa (0.0163 kg/cm2, 0.23 psi) of pressure inside the battery N
CAUTION:
• Do not apply any pressure exceeding 2.0 kPa (0.0204 kg/cm2, 0.29 psi). O
Repair limit : 1.4 kPa (0.0143 kg/cm2, 0.20 psi) P

WARNING:

LI-ION BATTERY
CAUTION:

JPCIA0190ZZ
WARNING:

REAR MODULE STACK
DANGER:
maintenance.
WARNING:
CAUTION:

LI-ION BATTERY
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do A
1. Must be an indoor environment. B
• The environment must prevent the entry of sweat during work, and also prevent condensation from EVB
• In addition to being indoors, the environment must not permit the entry during disassembly work of D
E
snowing.
4. Work space F
than the workers do not enter the work space. G
guisher).
DISASSEMBLY
1. Remove battery pack upper case. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly I
and Assembly".
Assembly". J
3. Remove Li-ion battery heater (rear). Refer to EVB-435, "HEATER UNIT : Disassembly and Assembly".
4. Remove vehicle communication harness connector (A) on rear
module stack. K
WARNING:
• To prevent electric shock hazards, be sure to put on L


wrap insulating tape around disconnected high voltage N
5.
6. Disconnect battery temperature sensor harness connector (A) O

from bracket.
WARNING:
To prevent electric shock hazards, be sure to put on P

JPCIA0229ZZ

LI-ION BATTERY
7. Remove harness clip (A) from harness bracket and move har-
ness (1) to the position without the hindrance for work.
WARNING:

JPCIA0226ZZ
8. Remove mounting nuts (A) and remove high voltage harness from rear module stack.
JPCIA0227ZZ
DANGER:
insulated tools.
high voltage connector (high voltage terminal) and terminals.
9. Remove rear module stack (1) mounting bolts (A).
WARNING:

JPCIA0129ZZ
10. Follow the procedure below and remove rear module stack from battery pack.
lashing belt to it.
WARNING:

protective gear.
JSCIA0251ZZ

LI-ION BATTERY
b. Use mobile floor crane (A) to lift up rear module stack (1).
WARNING: A

protective gear. B
CAUTION: EVB
Do not move mobile floor crane while rear module stack is
D
c. Move the battery pack and place work bench underneath rear module stack.
WARNING:
E
F
CAUTION:
G
d. Place rear module stack onto work bench.
WARNING:
H
• Be sure to place an insulating rubber sheet on the work bench.

J
11. Remove heater harness bracket (1) from rear module stack.
WARNING:
To prevent electric shock hazards, be sure to put on K

M
JPCIA0221ZZ
12. Remove harness bracket (1) from rear module stack.

WARNING: N

insulated protective gear and use insulated tools. O
JSCIA0153ZZ
13. Follow the procedure below and remove bus bars from rear module stack.

LI-ION BATTERY
a. Remove central bus bar cover and remove module terminal
mounting bolts (A).
DANGER:

• Work alone. Failure to do this may cause shock haz- JSCIA0154ZZ

ards.
CAUTION:
Remove all bus bar covers at the same time, and do not remove module terminal mounting bolts.
b. Remove right-side bus bar cover and remove module terminal

mounting bolts (A).
DANGER:


ards.
WARNING:
This work must not be performed by more than 1 person.
c. Remove left-side bus bar cover and remove module terminal

mounting bolts (A).
DANGER:


ards.
WARNING:
This work must not be performed by more than 1 person.
d. Remove voltage detection terminal mounting screws (A), and

then remove bus bar from rear module stack.
DANGER:


ards.

LI-ION BATTERY
e. Attach module terminal covers [SST: KV99111500] (A) to all
module terminals. A
WARNING:
To prevent electric shock hazards, be sure to wear B

protective gear.
EVB
JSCIA0192ZZ
D
14. Remove battery temperature sensor (1) from rear module stack.
JPCIA0228ZZ
: Clip
H
WARNING:
I
lated tools.
J
15. Remove front stack member (1). K

WARNING:
To prevent electric shock hazards, be sure to put on L

JPCIA0126ZZ N
16. Remove rear stack member (1).

WARNING: O
P
JPCIA0230ZZ

LI-ION BATTERY
17. Use lashing belt (A) to fix rear module stack (1) in place.
WARNING:

protective gear.
JSCIA0240ZZ
18. Remove through bolt mounting nut (A) (removal side, unfixed)
and disassemble rear module stack (1), refer to following.
WARNING:

JPCIA0261ZZ
CAUTION:
• Never remove self-locking nut (fixed).
A : Self-locking nut (fixed)

B : Mounting nut (removal side, unfixed)
JPCIA0258ZZ
• Fix the tip of through bolt on the removal side to remove

mounting nut.
NOTE:
When through bolt is removed, the spacer between the mod-
ules will fall out and it will be difficult to return it to its original
position. Therefore pull the through bolt out only to the position
necessary for the module that will be removed.
JSCIA0347ZZ
ASSEMBLY
CAUTION:
cedure".
1. When replacing the module with a new one, perform the following procedure.
b. Cut the EV battery traceability seal in two and affix each seal to the old module and “Li-ion BATTERY

LI-ION BATTERY
2. Follow procedure below and assemble rear module stack.
a. Assemble rear module stack, and provisionally fasten it in place with the through bolt. A
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu- B
lated tools.
EVB
• Check that terminal of module is arranged as shown in the figure.
F
JSCIA0309ZZ
• Check that mounting plate (1) is located at position shown in the figure.
G
JPCIA0132ZZ
b. Use lashing belt (A) and apply pressure to rear module stack (1). J
WARNING:
To prevent electric shock hazards, be sure to wear K

protective gear.
JSCIA0240ZZ M
c. Inspect the module installation condition, and correct it if it is incorrectly installed or a large distortion is
found. N
JSCIA0313ZZ
WARNING:
lated tools.

LI-ION BATTERY
d. Tighten to the specified torque the mounting nuts (removal side, unfixed) for the through bolt that is
attached tentatively.
• To tighten rear module stack, fix the tip of through bolt to
tighten mounting nuts.
WARNING:

CAUTION:
Never tighten self-locking nut (fixed). If tightened, replace JSCIA0347ZZ
through bolt and nut.
3. Follow procedure below and assemble rear module member.

a. Temporarily install rear module stack member (1) to rear module
stack.
WARNING:

JPCIA0230ZZ
b. Using the scale (A), inspect the module installation condition.

WARNING:

protective gear.
• If the rear module stack is excessively distorted, loosen the

through bolt of rear module stack and correct the condition.
JPCIA0242ZZ
c. Tighten to the specified torque the mounting nuts for the rear stack member.
4. Install front stack member (1).
WARNING:

JPCIA0126ZZ

LI-ION BATTERY
5. Install battery temperature sensor (rear) (1) in the figure.
A
EVB
E
JPCIA0231ZZ
WARNING:
F
• Position module where sensor (1) will be installed so that it is

aligned with concave part (A) of rear stack member. H
: Clip
I
• Position module where clip (2) will be installed so that it is
aligned with concave part (B) of rear stack member.
J
JPCIA0238ZZ
K
• Insert a sensor (A) in a module and fix by a clip (B). Do not fix
in the grommet (C).
L
JSCIA0390ZZ
6. Remove module terminal cover [SST: KV99111500]. O

WARNING:
To prevent electric shock hazards, be sure to wear protective gear. P
7. Follow the procedure below and install bus bars onto rear module stack.
a. Install bus bars onto rear module stack.
WARNING:

LI-ION BATTERY
tion terminal mounting screws.
DANGER:

• Work alone. Failure to do this may cause shock haz- JPCIA0135ZZ

ards.
c. Tighten module terminal mounting bolts in numerical order as shown in the figure.
• When bolts 1 – 16 have been tightened, install right side bus bar cover.
• When bolts 17 – 32 have been tightened, install left side bus bar cover.
• When bolts 33 – 48 have been tightened, install center bus bar cover.
JPCIA0136ZZ
DANGER:
insulated tools.

d. Install bus bar cover (1).
JPCIA0137ZZ
WARNING:
CAUTION:
• Be sure not to install with up/down sides facing in wrong directions.

LI-ION BATTERY
• After installation, verify that the joined part does not disconnect.
A
8. Install harness bracket (1) at position of cut-out (A) in the figure.
WARNING:
B
EVB
D
JPCIA0138ZZ
9. Install heater harness bracket (1).

E
WARNING:

insulated protective gear and use insulated tools. F
JPCIA0221ZZ
H
10. Follow procedure below and install rear module stack onto battery pack.
a. Use mobile floor crane (A) to lift up rear module stack (1).
I
WARNING:

protective gear. J
K
CAUTION:
Do not move mobile floor crane while rear module stack is
L
b. Move work bench so that battery pack is underneath rear module stack.
c. Install rear module stack onto battery pack.
WARNING: M

N
CAUTION:
O
Align position of locating pin.

LI-ION BATTERY
11. Tighten rear module stack (1) mounting bolt (A).
WARNING:

JPCIA0129ZZ
12. Tighten mounting nuts (A) and connect high voltage harness to rear module stack.
JPCIA0227ZZ
DANGER:
insulated tools.
• Be sure to close terminal cover.

13. Install vehicle communication harness.
WARNING:
14. Install Li-ion battery heater (rear). Refer to EVB-435, "HEATER UNIT : Disassembly and Assembly".
Assembly".
16. Install battery pack upper case. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly and
Assembly".
CAUTION:
• Check seal before install battery pack upper case. Refer to EVB-426, "REAR MODULE STACK :
Inspection".
• Check the following items after installing battery pack: Refer to EVB-426, "REAR MODULE STACK :
Inspection".
AIR LEAK INSPECTION
REAR MODULE STACK : Inspection INFOID:0000000007634591

LI-ION BATTERY
and cracks) A
EVB
JPCIA0376ZZ
D
AIR LEAK INSPECTION
WARNING: E
protective gear.
F
JPCIA0124ZZ
H
WARNING:
To prevent electric shock hazards, be sure to wear I

protective gear.
CAUTION:
K
JPCIA0125ZZ

DANGER: L

M
4. Use vinyl tape (A) or similar means to seal the breather so that N
• Stick it so that tape is not wrinkled. O
WARNING:

protective gear.
JPCIA0128ZZ

LI-ION BATTERY
CAUTION:

WARNING:
CAUTION:

JPCIA0190ZZ
WARNING:

HEATER RELAY UNIT
HEATER RELAY UNIT : Disassembly and Assembly INFOID:0000000007634592
DANGER:
maintenance.

LI-ION BATTERY
WARNING:
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- A
B
• To prevent electric shock hazards, ignition, and damage to parts, always remove Li-ion battery con- EVB
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the D
WORK ENVIRONMENT FOR DISASSEMBLY OF LI-ION BATTERY E
vent the intrusion of rain, snow, sand, and other substances. F
• In addition to being indoors, the environment must not permit the entry during disassembly work of G
other necessary steps. H
snowing. I
4. Work space
• A sign indicating that disassembly is in progress or other measures must be taken so that persons other J
• Depending on type of fire (vehicle or battery) use standard fire fighting equipment (water or extin- K
guisher).
DISASSEMBLY L
WARNING: M

protective gear.
N
JSCIA0143ZZ
P

LI-ION BATTERY
JSCIA0144ZZ
: Vehicle front
WARNING:
Assembly".
5. Remove bus bar (1) that connects service plug switch and left
front module stack.
DANGER:

WARNING:
After removing, close bus bar cover. JSCIA0269ZZ
6. Remove mounting bolts (A) and nuts (B) of service plug switch
bracket (1).
WARNING:

JSCIA0270ZZ

LI-ION BATTERY
7. Disconnect high voltage harness (A) and connector (B) on
reverse side of service plug switch bracket, then remove service A
plug switch bracket (1).
DANGER:
B
EVB
JSCIA0271ZZ
• To prevent electric shock hazards, immediately D
wrap insulating tape around disconnected high voltage harness connector (high voltage termi-
nal) and terminals.
8. Disconnect heater relay harness connector (A) and heater har- E
ness connector (B) and than remove harness clips (C).
WARNING:
To prevent electric shock hazards, be sure to put on F

JPCIA0223ZZ
H
9. Remove mounting nuts (A) and then remove heater relay unit
(1).
WARNING: I

insulated protective gear and use insulated tools. J
K
JPCIA0224ZZ
10. Remove harness bracket (1). L

WARNING:
To prevent electric shock hazards, be sure to put on M

JPCIA0232ZZ
O
ASSEMBLY
P
1. Install heater relay unit.
WARNING:
lated tools.

LI-ION BATTERY
2. Install service plug switch bracket.

WARNING:
lated tools.
Assembly".
CAUTION:
Check seal before install battery pack upper case. Refer to EVB-433, "HEATER RELAY UNIT :
Inspection".
JPCIA0140ZZ
: Vehicle front
WARNING:

LI-ION BATTERY
EVB
JPCIA0141ZZ F
: Vehicle front
WARNING: G

H
5. Install service plug retainer (1). I

WARNING:

protective gear. J
JSCIA0143ZZ L
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-433, "HEATER RELAY UNIT :
Inspection". M
AIR LEAK INSPECTION
N
HEATER RELAY UNIT : Inspection INFOID:0000000007634593

• Visually check all lips (A) of seal (1) for damage. (e.g. scratches O
and cracks)
P
JPCIA0376ZZ

LI-ION BATTERY
AIR LEAK INSPECTION
WARNING:

protective gear.
JPCIA0124ZZ

WARNING:

protective gear.
CAUTION:
JPCIA0125ZZ

DANGER:
WARNING:

protective gear.
JPCIA0128ZZ
CAUTION:

WARNING:

LI-ION BATTERY
CAUTION:
B

EVB
H
JPCIA0190ZZ
WARNING:
I

K
L
HEATER UNIT
HEATER UNIT : Disassembly and Assembly INFOID:0000000007634594 M
DANGER:
N
maintenance. O
WARNING:

LI-ION BATTERY
CAUTION:
snowing.
4. Work space
guisher).
DISASSEMBLY
Li-Ion Battery Heater (Front)
WARNING:

protective gear.
JSCIA0143ZZ

LI-ION BATTERY
EVB
JSCIA0144ZZ F
: Vehicle front
WARNING: G

H
4. Remove Li-ion battery controller. Refer to EVB-399, "LI-ION BATTERY CONTROLLER : Disassembly and I
Assembly".
5. Remove high voltage harness connector clips and vehicle communication harness connector clips.
J
WARNING:
lated tools. K
L
6. Remove battery member pipe (1).
WARNING:
M
N
O
JSCIA0260ZZ

LI-ION BATTERY
7. Disconnect Li-ion battery heater (front) harness connectors (A).
WARNING:

JPCIA0237ZZ
8. Remove mounting nuts (A) and then remove Li-ion battery

heater (front).

WARNING: JPCIA0236ZZ

Li-Ion Battery Heater (Rear)

WARNING:

protective gear.
JSCIA0143ZZ

LI-ION BATTERY
EVB
JSCIA0144ZZ F
: Vehicle front
WARNING: G

H
4. Disconnect rear module stack heater harness connectors (A). I

1. Li-ion battery heater RR2
J
WARNING:

insulated protective gear and use insulated tools. K
JPCIA0234ZZ L
5. Remove mounting nuts (A) and then remove Li-ion battery

heater (rear).
M
N
WARNING:

insulated protective gear and use insulated tools. O
JPCIA0235ZZ
P
ASSEMBLY
Li-Ion Battery Heater (Front & Rear)
1. Install Li-ion battery heater (front & rear)
WARNING:

LI-ION BATTERY
lated tools.
Assembly".
CAUTION:
Check seal before install battery pack upper case. Refer to EVB-441, "HEATER UNIT : Inspection".
JPCIA0140ZZ
: Vehicle front
WARNING:
JPCIA0141ZZ

LI-ION BATTERY
: Vehicle front A
WARNING:
To prevent electric shock hazards, be sure to wear protective gear. B
EVB
WARNING:
D
protective gear.
E
F
JSCIA0143ZZ
WARNING:
G
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated
tools.
H
CAUTION: I
• Check the following items after installing battery pack: Refer to EVB-441, "HEATER UNIT : Inspec-
tion".
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST J
HEATER UNIT : Inspection INFOID:0000000007634595
K
and cracks)
L
JPCIA0376ZZ
AIR LEAK INSPECTION O

LI-ION BATTERY
WARNING:

protective gear.
JPCIA0124ZZ

WARNING:

protective gear.
CAUTION:
JPCIA0125ZZ

DANGER:
WARNING:

protective gear.
JPCIA0128ZZ
CAUTION:

WARNING:

LI-ION BATTERY
CAUTION:
Never allow soapy water to contact the service plug and each connector terminals. A

After installing the battery pack, measure the resistance between the ground bolt mating surface (A) and the B
EVB
JPCIA0190ZZ
WARNING: H
Standard : Less than 0.1 Ω J

• Rust on the mounting surface of ground bolts K


Items Specification
Type Li-ion battery
Rated voltage (V) Approx. 360
Weight [kg (lb)] Approx. 300 (661.5)
JPCIA0065ZZ
External dimension “a” [mm (in)] 1188.0 (46.77)

“b” [mm (in)] 1007.0 (39.65)
“c” [mm (in)] 264.9 (10.43)
“d” [mm (in)] 1570.5 (61.83)

APPLICATION NOTICE
HOW TO USE THIS MANUAL A

APPLICATION NOTICE
B
EVB
D
E
Type A
JSCIA0277ZZ
Type 3 Without Li-ion battery heater Type B

I
JSCIA0706ZZ
J

PRECAUTIONS
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an
WARNING:
the implantable cardioverter defibrillator (ICD), when using the service, etc.
device. The possible effects on the devices must be checked with the device manufacturer before
TCU use.
WARNING:
facturer before Intelligent Key use.
The high voltage system may starts automatically. It is required to check that the timer air conditioner
NOTE:

PRECAUTIONS
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. A
Service Manual.
WARNING: B
an authorized NISSAN/INFINITI dealer. EVB
Module, see “SRS AIR BAG”. D
connectors.
E
WARNING:
Always observe the following items for preventing accidental activation. F
injury. G
H
INFOID:0000000011103818
For vehicle with steering lock unit, if the 12V battery is disconnected or discharged, the steering wheel will lock I
J
OPERATION PROCEDURE
NOTE: K
(At this time, the steering lock will be released.) L
4. Perform the necessary repair operation. M
N
NOTE:
tion. O

PRECAUTIONS
windshield.
PIIB3706J
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:
DANGER:

PRECAUTIONS
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 EVB
• Never allow workers other than the responsible person to touch the vehicle containing high voltage D
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise E
F
HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS G
WARNING: H
nets. Such persons must not perform work on the vehicle. I
metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage J
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT” K

PRECAUTIONS
workers.
JSAIA1600GB

PREPARATION
PREPARATION A
PREPARATION
B
The actual shape of the tools may differ from those illustrated here.
(TechMate No.) EVB
Tool name
(J-50583) D
Palette
JPCIA0239ZZ
F
KV99111300 When installing Li-ion battery.
(J-50306) 2 piece/set
G
H
JPCIA0023ZZ
KV99111400 When checking air leaks after disassem-

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

(—) 24 pieces/set
JPCIA0069ZZ
M
(J-50346)
N
O
JPCIA0070ZZ

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

PREPARATION

300A]
JMCIA0149ZZ

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

nents
electric line
[ANSI Z87.1]
JPCIA0012ZZ

nents
Face shield
electric line
JPCIA0167ZZ
Insulated helmet Removing and installing high voltage components
JPCIA0013ZZ

PREPARATION
A
B
EVB
JPCIA0019ZZ
JPCIA0018ZZ
Battery lift table Removing and installing Li-ion battery G
JPCIA0024ZZ
H
I
J
JPCIA0015ZZ

L
JPCIA0014ZZ
Insulated hand tools Removing and installing high voltage components N
JPCIA0067ZZ
O
P
JPCIA0068ZZ

PREPARATION
• Removing and installing battery module stack

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

NOTE:
• D: 14.0 mm (0.55 in)
Carabineer [large]
• L: 204.0 mm (8.03 in)
• S: 47.0 mm (1.85 in)
• W: 105.0 mm (4.13 in)
JPCIA0017ZZ

Belt slinger NOTE:
Length: 2.0 m (6.562 ft)
JPCIA0021ZZ
Mobile floor crane Removing and installing battery module stack
JPCIA0020ZZ
JPCIA0022ZZ

(Cut the adhesive)
JSCIA0640ZZ

(Cut the adhesive)
NOTE:
JSCIA0641ZZ

PREPARATION
A
Installing battery pack upper case B

Scraper
EVB
JSCIA0643ZZ
D
E
JSCIA0639ZZ

NOTE:
Metal bar G
• D: φ 7 mm (0.28 in)
• L: 1 m (3.28 ft)
JSCIA0735ZZ
H
Sealant or/and Lubricant INFOID:0000000011400388
I
Tool name
Description
Tool number
Adhesive J
999MP-57302NP
Dam rubber
KA390-0059U K
Primer (Adhesive primer)
999MP-43533PP
Primer sufacer (anti-corrosion praimer) L
—

COMPONENT PARTS
SYSTEM DESCRIPTION
COMPONENT PARTS
JSCIA1306ZZ

COMPONENT PARTS
A. Front of battery pack B. Back of battery pack A

: Vehicle front
No. Component Function B

EVB
5. Battery current sensor EVB-459, "Battery Current Sensor" D
E
9. Battery temperature sensor 1 EVB-460, "Battery Temperature Sensor"
10. Battery temperature sensor 3 EVB-460, "Battery Temperature Sensor" F
G
• A Li-ion battery with flat construction is placed under floor. H

I
JSCIA0701ZZ K
L
JSCIA0702ZZ

COMPONENT PARTS

JSCIA0071ZZ
• State of charge
• Temperature


JSCIA0703ZZ

NOTE:
JPCIA0197GB

COMPONENT PARTS
MODULE LAYOUT
A
EVB
JSCIA1411GB F
NOTE:
G
CELL
H
JSCIA0274ZZ
The Features of Laminated Cell K

tery life.
• Light and thin structure increases flexibility in layout. L
Battery Current Sensor INFOID:0000000011198524
M
• The battery current sensor is installed to bus bar between battery
junction box and rear module stack.
• This sensor measures charge/discharge current sent to Li-ion bat-
tery and transmits a current signal to Li-ion battery controller N
(LBC).
• Li-ion Battery controller (LBC) measures remaining battery level
according to charge/discharge current and sends the data to VCM. O
P
JSCIA0507ZZ

COMPONENT PARTS

JSCIA0705ZZ

JPCIA0295GB
pack.
Pre-charge relay to protect the high voltage circuit from a high cur-
rent immediately after power switch ON.
- System main relay to provide/interrupt DC current sent from Li-ion
battery.
- Pre-charge relay to protect the high voltage circuit from a high cur-
JSCIA0276ZZ

maintenance.
• Always use insulating protective equipment when removing and
JSCIA0706ZZ

COMPONENT PARTS
A
label in the original position. B
Li-ion Battery
EVB
JPCIA0207ZZ
F
• The label (A) is affixed to the body panel near the high voltage har- G
ness connector.
: Vehicle front H
JPCIA0208ZZ
J
K
JSCIA0111ZZ
N
Service Plug
O
JPCIA0209ZZ

SYSTEM
SYSTEM
System Description INFOID:0000000011103832
SYSTEM DIAGRAM
JSCIA0413GB

Input Signal Item

Output Signal Item

SYSTEM
Received unit Signal name A

B
Li-ion battery current signal EVB
VCM EV system CAN
D
Li-ion battery capacity signal E
F
DESCRIPTION
information, such as the charging status of Li-ion battery and possible power, to VCM (vehicle control module) G
as overvoltage, over discharge or excessive temperature rise in the battery. H
charge/charge line. I
transfers the detected state to VCM so that the vehicle does not start with an unsteady state. J
• Estimates a battery charge state and low battery state, based on the data obtained with the battery state K
BATTERY PROTECTION
The Li-ion battery has a voltage range capable of charge/discharge. If charged/discharged exceeding the L
voltage stays within the voltage range. M
Charging energy control N
O
System main relay cut P
control

SYSTEM
During cell capacity adjustment, the capacity of each cell is estimated based on the no-load voltage when the
that have excess capacity. In this way, capacity adjustment by the Li-ion battery controller allows the capacity
JPCIA0094GB

resistance of each high voltage part and sends the measurement results to VCM via EV system CAN commu-
nication.
tance value.
JSCIA0415GB

SYSTEM
EVB
JSCIA1310GB
P

SYSTEM
JSCIA1311GB
HARNESS LAYOUT

SYSTEM
EVB
JSCIA1313GB
P
: Vehicle front

HANDLING PRECAUTION
HANDLING PRECAUTION
• To improve the Li-ion battery life, never perform quick charge heavily.
• Lay an anti-static rubber sheet underneath the battery.
• Prevent other objects from falling onto the battery.

A
APPLICATION ITEM B
Item Function EVB

Data Monitor Input/Output data in LBC can be read. D
Work Support
E
itor
F
G
ECU IDENTIFICATION
SELF-DIAGNOSTIC RESULTS H

Regarding items of DTC, refer to EVB-481, "DTC Index". I
How to Erase DTC
2. “SELF-DIAGNOSTIC RESULTS”. J
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT. K

DTC Displays the DTC which caused FFD memory L
M
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug N
CLOSE
O
ature 1
BATTERY TEMPERATURE 2 °C P
ature 2
ature 3
ature 4
DATA MONITOR

Monitored item Unit Remark

OPEN /
CLOSE
ature 1
ature 2
ature 3
ature 4
WORK SUPPORT

DATA replaced.
TION DATA replaced.
CLEAR BATTERY GRADUAL When all modules of Li-ion bat-
CHARGE INFORMATION DATA erased. tery are replaced.
TION cells.
an abnormal cell, unless it is replaced.

EV BATTERY SYSTEM
ECU DIAGNOSIS INFORMATION A

EV BATTERY SYSTEM
B

NOTE: EVB

D
IR SEN SHORT PULSE READY Approx. 4,100 – 4,300 mV E
F
CELL VOLTAGE 03 READY H
I
Total battery voltage 317 V Approx. 3,200 - 3,400 mV J
CELL VOLTAGE 07 READY K
M
CELL VOLTAGE 12 READY O
P

EV BATTERY SYSTEM

EV BATTERY SYSTEM
A
D
H
K
O

EV BATTERY SYSTEM

EV BATTERY SYSTEM
A
D
H
K
M
20°C - 30°C (68°F - 86°F)
READY (Stop the vehi- O
cle)
20°C - 30°C (68°F - 86°F)
BATTERY TEMPERATURE 2 Ambient temperature: 25°C (77°F) [Equivalent to air temperature P
cle)
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
cle)

EV BATTERY SYSTEM
The fail-safe mode differs depending on the contents of the detected malfunction.
FAIL-SAFE PATTERN
• Pattern B: Driving output power limit, and Charge stop
FAIL-SAFE LIST
Pattern
A B C D
P303A CELL CONT ASIC10 ×
P303F CELL CONT ASIC15 ×

EV BATTERY SYSTEM
Pattern
A B C D
P3050 CELL CONT ASIC8 VOLT × B
P3053 CELL CONT ASIC11 VOLT × EVB
D
P3058 CELL CONT ASIC16 VOLT × E
F
P305D CELL CONT ASIC21 VOLT × G
H
P3062 BYPASS SW × I
J

K
P3092 CELL CONT ASIC8 OPEN × L
M
P3097 CELL CONT ASIC13 OPEN × N
O
P309C CELL CONT ASIC18 OPEN × P

EV BATTERY SYSTEM
Pattern
A B C D
P30FC OVER CURRENT ×
P31A7 CAN ERROR INV/MC No fail-safe

EV BATTERY SYSTEM
Pattern
A B C D
P331E CELL OVER VOLTAGE MODULE29 × B
P3321 CELL OVER VOLTAGE MODULE32 × EVB
D
P3326 CELL OVER VOLTAGE MODULE37 × E
F
P332B CELL OVER VOLTAGE MODULE42 × G
H
J

K
P337A CELL OVER DISCHARGE MODULE6 × L
M
P337F CELL OVER DISCHARGE MODULE11 × N
O
P3384 CELL OVER DISCHARGE MODULE16 × P

EV BATTERY SYSTEM
Pattern
A B C D
P33D4 BATT GADUAL CAPA LOSS DIAG ×
P33DB TEMPERATURE SENSOR No fail-safe
P33E2 BATT PACK OVER TEMP ×

EV BATTERY SYSTEM
Pattern
A B C D
U1000 CAN COMM CIRCUIT × B
×: Applicable —: Not applicable EVB

EV system
lamp D
E
P3032 CELL CONT ASIC2 × 1 EVB-500 F
P3035 CELL CONT ASIC5 × 1 EVB-500 G
H
P303A CELL CONT ASIC10 × 1 EVB-500 I
J
P303F CELL CONT ASIC15 × 1 EVB-501 K
L
P3044 CELL CONT ASIC20 × 1 EVB-501 M
P3047 CELL CONT ASIC23 × 1 EVB-501 N
O
P304C CELL CONT ASIC4 VOLT × 1 EVB-502 P

EV BATTERY SYSTEM
EV system
lamp

EV BATTERY SYSTEM
EV system
lamp
P30FC OVER CURRENT × 1 EVB-518 B
EVB
P3191 COMMUNICATION ERROR — 1 EVB-524 D
E
P31A7 CAN ERROR INV/MC — 1 EVB-529 F
G

P3308 CELL OVER VOLTAGE MODULE7 × 1 EVB-531 I
J
P330D CELL OVER VOLTAGE MODULE12 × 1 EVB-531 K
L
P3312 CELL OVER VOLTAGE MODULE17 × 1 EVB-535 M
N
P3317 CELL OVER VOLTAGE MODULE22 × 1 EVB-535 O
P331A CELL OVER VOLTAGE MODULE25 × 1 EVB-539 P

EV BATTERY SYSTEM
EV system
lamp

EV BATTERY SYSTEM
EV system
lamp
P338E CELL OVER DISCHARGE MODULE26 × 1 EVB-554 B
EVB
P3393 CELL OVER DISCHARGE MODULE31 × 1 EVB-554 D
E
P3398 CELL OVER DISCHARGE MODULE36 × 1 EVB-554 F
G

P339D CELL OVER DISCHARGE MODULE41 × 1 EVB-557 H
P33A0 CELL OVER DISCHARGE MODULE44 × 1 EVB-557 I
J
P33D4 BATT GRADUAL CAPA LOSS DIAG × 1 EVB-560 K
L
P33DB TEMPERATURE SENSOR — 1 EVB-565 M
N
P33E2 BATT PACK OVER TEMP × 1 EVB-570 O
P33E6 CELL VOLTAGE DEVIATION DIAG × 2 EVB-573 P

VCM
WIRING DIAGRAM
VCM
described in wiring diagram), refer to GI-12, "Connector Information".
JRCWC0089GB

VCM
EVB
JRCWC0090GB

VCM
JRCWC0091GB

VCM
EVB
JRCWC0092GB

BASIC INSPECTION
DETAILED FLOW
1.GET INFORMATION FOR SYMPTOM
>> GO TO 2.
2.CHECK DTC IN VCM
Are any DTCs detected?
NO >> GO TO 3.
3.CHECK DTC
1. Check DTC.
- Erase DTC.
(Symptom Matrix Chart is useful. Refer to EVC-347, "Symptom Index".)
Symptom is described, DTC is detected>>GO TO 4.
>> GO TO 6.
>> GO TO 7.
again.
NOTE:

Manual. This simplified check procedure is an effective alternative though DTC cannot be detected during A
this check.
MATION PROCEDURE.
B
Is DTC detected?
YES >> GO TO 8.
EVB
7. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
step 4, and determine the trouble diagnosis order based on possible causes and symptoms. D
YES >> GO TO 8.
NO >> Monitor input data from related sensors using CONSULT. E
Inspect according to Diagnosis Procedure of the system. F
YES >> GO TO 9.
NO >> Monitor input data from related sensors using CONSULT. G
2. Reconnect parts or connectors disconnected during Diagnosis Procedure again after repair and replace- H
ment.
I
>> GO TO 10.
10.FINAL CHECK J
the symptom is not detected. K
L
M
DESCRIPTION
There are many operating conditions that lead to the malfunction of N
important to fully understand the symptoms or conditions for a cus- O
tomer complaint.
tion for troubleshooting. P
NOTE:
JSCIA0412GB
WORKSHEET SAMPLE

Question Sheet
Incident Date VIN
Customer name
MR/MS
lamp is on
Does not charge Other* *: If applied, enter in detail
Detailed symptom
Onomatopoeia

Weather
Not affected
conditions
Temp. [Approx. °C
( °F)]
road
Other
Driving conditions Not affected
D position (stop the vehicle)
Does not disappear
Other
Other

A
LER
B
When only Li-ion Battery Controller (LBC) is replaced, it is necessary to save the battery information stored in
LBC to the new LBC.
EVB

D
With CONSULT
E
>> GO TO 2.
2.REPLACE LI-ION BATTERY OR LBC F
Replace LBC. Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal and Installation".
G
>> GO TO 3.
With CONSULT H
I
>> GO TO 4.
4.WRITE THE LBC INTERNAL INFORMATION TO VCM J
>> END K

If a malfunction (e.g. abnormal voltage) occurs in a Li-ion battery cell, the module which includes the malfunc-
NOTE:
it is advisable to adjust voltage under room temperature conditions [20°C ± 10°C (68°F ±18°F)].
With CONSULT
1. Power switch ON.
3. Check “MAXIMUM CELL VOLTAGE”.

>> GO TO 2.
CAUTION:

3.DISCAHRGE OF MODULE VOLTAGE
CAUTION:
>> 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.


Standard : Adjustment voltage value ± 10 mV A
>> GO TO 6.
B
With CONSULT
1. After adjusting the voltage, install the module to the vehicle. EVB
range. D

E
>> WORK END

F

DTC/CIRCUIT DIAGNOSIS
DTC DETECTION LOGIC


With CONSULT
3. Check DTC.
Is P0A1F detected?
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
2. Remove battery pack upper case. Refer to EVB-606, "BATTERY PACK UPPER CASE : Removal and
Installation", see Step-1 to Step-3.
>> GO TO 2.

LBC A
— Continuity
Connector Terminal
B
YES >> GO TO 3.
NO >> Replace Li-ion battery vehicle communication harness. EVB
2. Check the continuity between Li-ion battery controller harness connector and ground. D
LBC
— Continuity E
Connector Terminal
YES >> GO TO 4.
4.CHECK LI-ION BATTERY INTERLOCK DETECTIONG CIRCUIT FOR SHORT-3 G
H
Connector Terminal
I
YES >> Replace Li-ion battery controller. Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal J
and Installation".
K

DTC DETECTION LOGIC

BATTERY ENERGY CON- Self diagnosis program of Li-ion battery controller de-

With CONSULT
3. Check DTC.
Is P0A1F detected?
LER : Removal and Installation".

A


With CONSULT E
3. Check DTC. F
Is P3030 detected?
With CONSULT
2. Check to see if “P30F3” is detected simultaneously with “P3030”. I
Is P30F3 detected?
J
NO >> Replace Li-ion battery controller. Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal
and Installation".

DTC DETECTION LOGIC


P303B CELL CONT ASIC11

With CONSULT
3. Check DTC.

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P3031 -P303C”.
Is P3030 detected?
and Installation".

A

P303D CELL CONT ASIC13 EVB
D

F
P3047 CELL CONT ASIC23 G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P303D” -“P3048”. M
Is P3030 detected?
NO >> Replace Li-ion battery controller. Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal N
and Installation".

DTC DETECTION LOGIC

P304E CELL CONT ASIC6 VOLT • Li-ion battery controller
• Module

With CONSULT
3. Check DTC.

With CONSULT
2. Check DTC.

"LI-ION BATTERY CONTROLLER : Removal and Installation".
B
EVB

DTC DETECTION LOGIC

P305A CELL CONT ASIC18 VOLT • Li-ion battery controller
• Module
P305F CELL CONT ASIC23 VOLT

With CONSULT
3. Check DTC.

With CONSULT
2. Check DTC.

B
EVB

DTC DETECTION LOGIC

An open circuit diagnosis detection circuit in Li-ion battery

With CONSULT
3. Check DTC.
Is P3061 detected?

P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
A

DTC DETECTION LOGIC D

With CONSULT E
3. Check DTC. F
Is P3062 detected?
With CONSULT
2. Check to see if “P3375”-“P33A4” is detected simultaneously with “P3062”. I
J
• When “P338D” - “P3398” are detected simultaneously, perform the diagnosis procedure of K
“P3399” - “P33A4”. Refer to EVB-557, "Diagnosis Procedure". L
and Installation".

DTC DETECTION LOGIC

P3090 CELL CONT ASIC6 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller

DTC DETECTION LOGIC

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

OVER DISCHARGE related codes) is detected simultaneously with “P308B”-“P3096”. A
EVB
“P338D”-“P3398”. Refer to EVB-554, "Diagnosis Procedure" E
NO >> GO TO 2.
F
2.PRECONDITIONING
WARNING:
Installation". H
>> GO TO 3.
YES >> GO TO 4.
K
1. Disconnect Li-ion battery controller harness connector and voltage detection terminal of bus bar.
2. Refer to below table and continuity between Li-ion battery controller and voltage detection terminal L
of bus bar, according to detected DTC.
JSCIA0813ZZ

Module Li-ion battery controller

DTC Continuity
No. Connector Terminal
1 50
P308B LB13 Existed
2 51
3 52
P308C LB13 Existed
4 53
5 54
P308D LB13 Existed
6 55
7 56
P308E LB13 Existed
8 57
9 58
P308F LB13 Existed
10 59
11 Voltage detection terminal of bus 60
P3090 LB13 Existed
12 bar 61
13 62
P3091 LB13 Existed
14 63
15 77
P3092 LB14 Existed
16 78
17 80
P3093 LB14 Existed
18 81
19 82
P3094 LB14 Existed
20 83
21 84
P3095 LB14 Existed
22 85
23 86
P3096 LB14 Existed
24 87
YES >> Replace Li-ion battery controller. Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal
and Installation".

A

P3097 CELL CONT ASIC13 OPEN EVB
D
P309C CELL CONT ASIC18 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller E

F
P30A1 CELL CONT ASIC23 OPEN G

With CONSULT
3. Check DTC.
K
WARNING:
L
maintenance. M
N
P
CAUTION:
With CONSULT

OVER DISCHARGE related codes) is detected simultaneously with “P3097”-“P30A2”.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
YES >> GO TO 4.
DTC.

DTC Continuity
25 73 110
26 74 111
27 60 112
28 77 113
29 78 114
30 64 115
31 81 116
32 82 117
33 68 118
34 85 119
35 86 120
36 72 121


DTC Continuity A
37 89 122
38 90 123 B
39 91 124
40 92 125
41 93 127 EVB
42 94 128
43 95 130
P30A0 LB7 LB15 Existed D
44 96 138
45 97 140
46 98 141 E
47 99 142
48 100 143
F
and Installation". G

DTC DETECTION LOGIC


With CONSULT
3. Check DTC.
Is P30F3 detected?

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P30F3”.
and Installation".

A

• Module
D
With CONSULT
3. Check DTC.
Is P30F4 detected?
H
WARNING:
maintenance.
CAUTION:
1.PERFORM THE SELF-DIAGNOSIS OF LI-ION BATTERY CONTROLLER N
With CONSULT
2. Check if any DTC is detected in “Self Diagnostic Result”. O
Just “P30F4” is detected>>GO TO 2. P
2.CHECK FUSE

3.PRECONDITIONING
WARNING:
Installation".
>> GO TO 4.
Check connection status between each stack and connection status of each bus bar.
YES >> GO TO 5.
Check the voltage of all modules.
and Installation".
NO >> Replace corresponding module. Refer to EVB-636, "FRONT MODULE STACK : Disassembly and
Assembly" (Front module) or EVB-651, "REAR MODULE STACK : Disassembly and Assembly"
(Rear module).


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

A

• Module
D
With CONSULT
3. Check DTC.
Is P30F5 detected?
H
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. I
YES >> Perform diagnosis on the detected “P30F4”. Refer to EVB-515, "Diagnosis Procedure". J
and Installation".
K

P30FC OVER CURRENT
P30FC OVER CURRENT
DTC DETECTION LOGIC

When the temperature of the entire battery pack estimat- • Battery current sensor
P30FC OVER CURRENT

With CONSULT
3. Check DTC.
Is P30FC detected?

With CONSULT
NO >> GO TO 2.
With CONSULT
Using FFD, check the values of four temperature sensors when DTC is detected.

Temperature increase is not seen>>Replace battery junction box. Refer to EVB-616, "LI-ION BATTERY
CONTROLLER : Removal and Installation".

A

• Total voltage detection switch in Li-ion battery control- EVB
D
With CONSULT
3. Check DTC. F
Is P30FC detected?
G
H
I

DTC DETECTION LOGIC

• 12V battery
• Harness

With CONSULT
3. Check DTC.
Is P30FE detected?
WARNING:
maintenance.
CAUTION:
Check the voltage of 12 V battery using circuit tester.
YES >> GO TO 2.
NO >> Replace 12 V battery. Refer to PG-101, "Removal and Installation".
2.CHECK FUSE
2. Check 20A fuse [No.43].
NOTE:
YES >> GO TO 3.
2. Check voltage between Li-ion battery harness connector and ground. A
+
Li-ion battery − Voltage B
Connector Terminal
Battery
B24 5 Ground
voltage
EVB

YES >> GO TO 4. D
4.PRECONDITIONING
E
WARNING:
2. Remove battery pack upper case. Refer to EVB-606, "BATTERY PACK UPPER CASE : Removal and F
Installation".
>> GO TO 5. G
1. Disconnect Li-ion battery harness connector and Li-ion battery controller harness connector. H
tor.
I
Continuity
LB1 5 LB11 12 Existed J
and Installation". K

DTC DETECTION LOGIC

ROR uously.
• VCM

With CONSULT
3. Check DTC.
Is P318D detected?

A

NOTE:

• VCM D
ROR continuously.

With CONSULT
F
7. Check DTC.
Is P318E detected?
J
With CONSULT
Is P318E detected?
YES >> Replace VCM. Refer to EVC-369, "Removal and Installation". L
NO >> GO TO 2.
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P318E”. N
Is U1000 detected?
and Installation". O

DTC DETECTION LOGIC

NOTE:


With CONSULT
7. Check DTC.
Is P3191 detected?

With CONSULT
Is P3191 detected?
YES >> Replace traction motor inverter. Refer to TMS-115, "Removal and Installation"
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".

A

NOTE:

• On board charger D

With CONSULT
F
7. Check DTC.
Is P3196 detected?
J
With CONSULT
Is P3196 detected?
YES >> Replace on board charger. Refer to VC-105, "Removal and Installation" L
NO >> GO TO 2.
With CONSULT
Is U1000 detected?

DTC DETECTION LOGIC

COMMUNICATION ER- • VCM

With CONSULT
3. Check DTC.
Is P3199 detected?

A

COMMUNICATION ER- • Traction motor inverter EVB

D
With CONSULT
3. Check DTC.
Is P319C detected? F
G
H

P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
DTC DETECTION LOGIC

If the CAN data from VCM has not change from the value

With CONSULT
3. Check DTC.
Is P31A4 detected?

A

If the CAN data from traction motor inverter has not EVB

D
With CONSULT
3. Check DTC.
G
H

DTC DETECTION LOGIC

• Li-ion battery
range. • VCM

With CONSULT
3. Check DTC.
Is P3300 detected?

With CONSULT
NO >> GO TO 2.
With CONSULT
and Installation".

A

D
• Module
P330C CELL OVER VOLTAGE MODULE11 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
1. Disconnect voltage detection terminal of bus bar and Li-ion battery controller harness connector.
2. Refer to below table and check the continuity between Li-ion battery controller and corresponding bus
bar .
JSCIA0812GB

Module Li-ion battery controller A

DTC Continuity
33
B
P3302 1 LB13 50 Existed
34
34 EVB
35
D
35
36 E
36
37
F
37
G
38
38
P3307 6 LB13 55 Existed H
Bus bar
39
39
I
40
40 J
42
K
42
P330A 9 LB13 58 Existed
43 L
43
P330B 10 LB13 59 Existed
M
44
44
P330C 11 LB13 60 Existed N
45
45
P330D 12 LB13 61 Existed O
46
Is the inspection result normal? P
YES >> GO TO 4.

and Installation".
NO >> Replace corresponding module. Refer to EVB-651, "REAR MODULE STACK : Disassembly and
Assembly".


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

A

P330E CELL OVER VOLTAGE MODULE13 EVB
D
• Module

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
bar .
JSCIA0812GB


DTC Continuity
46
B
P330E 13 LB13 62 Existed
47
47 EVB
P330F 14 LB13 63 Existed
48
D
LB13 48
P3310 15 77 Existed
LB14
65 E
65
66
F
66
G
69
69
Bus bar
70
70
I
71
71 J
72
K
72
73 L
73
M
74
74
P3318 23 LB14 86 Existed N
75
75
P3319 24 LB14 87 Existed O
76
YES >> GO TO 4.

and Installation".
NO >> Replace corresponding module. Refer to EVB-631, "FRONT MODULE STACK : Removal and
Installation".


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

A

P331A CELL OVER VOLTAGE MODULE25 EVB
D
P331F CELL OVER VOLTAGE MODULE30 tion E
• Module

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT

DTC Continuity
57 89
58 90
58 90
75 91
75 91
76 92
76 92
62 93
62 93
79 94
79 94
80 95
80 95
P3320 31 LB8 81 LB15 116 Existed
66 96
66 96
P3321 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity A
83 97
P3322 33 LB8 68 LB15 118 Existed B
84 99
84 99
70 100
70 100
D
P3324 35 LB8 86 LB15 120 Existed
87 101
87 101 E
P3325 36 LB8 72 LB15 121 Existed
88 102
F
YES >> GO TO 4.
H
and Installation".
NO >> Replace corresponding module. Refer to EVB-636, "FRONT MODULE STACK : Disassembly and I
Assembly".
J
Check voltage of module. K

B : Negative terminal (Black) L
Terminals
Voltage M
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V N
NO >> Replace module. Refer to EVB-636, "FRONT MODULE O
P
JSCIA0338ZZ

DTC DETECTION LOGIC

P332B CELL OVER VOLTAGE MODULE42 When cell voltage exceeds the allowable • Module
• Bus bar

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
With CONSULT
G
DTC Continuity
LB8 88 102 H
P3326 37 89 LB15 122 Existed
LB7
101 103
I
101 103
P3327 38 LB7 90 LB15 123 Existed
102 104 J
102 104
P3328 39 LB7 91 LB15 124 Existed
K
103 105
103 105
P3329 40 LB7 92 LB15 125 Existed L
104 106
104 106
M
105 107
105 107 N
106 108
106 LB15 108 O
LB16
107 130
P
107 130
108 131


DTC Continuity
108 131
109 132
109 132
110 133
110 133
P3330 47 LB7 99 LB16 142 Existed
111 134
111 134
P3331 48 LB7 100 LB16 143 Existed
112 135
YES >> GO TO 4.
and Installation".
Assembly".


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

A

"DTC Logic".
EVB
• Module
D
• Bus bar
motor inverter/VCM malfunction E

1.CHECK SELF-DIAGNOSIS RESULTS F
With CONSULT
3. Check DTC.
Is P3373 detected? H
Diagnosis Procedure INFOID:0000000011103914 I

With CONSULT J
Is any DTC detected? K
NO >> GO TO 2.
2.PERFORM THE SELF-DIAGNOSISS OF LI-ION BATTERY CONTROLLER L
With CONSULT
1. Select “Self Diagnostic Result” of “HV BAT”. M
YES >> • When “P3375”-“P3380” are detected simultaneously, perform the diagnosis procedure of N
• When “P338D”-“P3398” are detected simultaneously, perform the diagnosis procedure of O
“P3399”-“P33A4”. Refer to EVB-557, "Diagnosis Procedure". P
and Installation".

DTC DETECTION LOGIC

P337A CELL OVER DISCHARGE MODULE6 When cell voltage lowers below the • Module
• Bus bar

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
bar . F
M
JSCIA0812GB


DTC Continuity
33
34
34
35
35
36
36
37
37
38
38
Bus bar
39
39
40
40
P337C 8 LB13 57 Existed
42
42
P337D 9 LB13 58 Existed
43
43
44
44
45
45
46
YES >> GO TO 4.

and Installation". A
Assembly".
Component Inspection INFOID:0000000011103917 B

Check voltage of module. EVB

B : Negative terminal (Black) D
Terminals E
Voltage
(+) (-)
(Approx.)
Module
Positive terminal (Red) Negative terminal (Black) 5.0 - 8.5 V F

YES >> INSPECTION END G
Assembly" (Rear module). H
JSCIA0338ZZ

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Disconnect high voltage circuit. Refer to GI-31, "How to Disconnect High Voltage". EVB
Installation".
D
>> GO TO 3.
bar . F
M
JSCIA0812GB


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

Assembly".


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

JSCIA0338ZZ

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
With CONSULT
G
DTC Continuity
57 89 H
58 90
I
58 90
75 91 J
75 91
K
76 92
76 92
P3390 28 LB8 77 LB15 113 Existed L
62 93
62 93
M
P3391 29 LB8 78 LB15 114 Existed
79 94
79 94 N
P3392 30 LB8 64 LB15 115 Existed
80 95
80 95 O
P3393 31 LB8 81 LB15 116 Existed
66 96
P
66 96
P3394 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity
83 97
P3395 33 LB8 68 LB15 118 Existed
84 99
84 99
P3396 34 LB8 85 LB15 119 Existed
70 100
70 100
P3397 35 LB8 86 LB15 120 Existed
87 101
87 101
P3398 36 LB8 72 LB15 121 Existed
88 102
YES >> GO TO 4.
and Installation".
Assembly".


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

A

D
P339E CELL OVER DISCHARGE MODULE42 function E
• Module
P33A3 CELL OVER DISCHARGE MODULE47 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT

DTC Continuity
LB8 88 102
P3399 37 89 LB15 122 Existed
LB7
101 103
101 103
102 104
102 104
103 105
103 105
104 106
104 106
105 107
105 107
106 108
106 LB15 108
LB16
107 130
107 130
108 131


DTC Continuity A
108 131
P33A1 45 LB7 97 LB16 140 Existed B
109 132
109 132
P33A2 46 LB7 98 LB16 141 Existed EVB
110 133
110 133
D
111 134
111 134 E
P33A4 48 LB7 100 LB16 143 Existed
112 135
F
YES >> GO TO 4.
H
and Installation".
Assembly".
J

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

DTC DETECTION LOGIC

BATT GRADUAL CAPA LOSS When the battery charge lowers.

With CONSULT
3. Check DTC.
Is P33D4 detected?

A

Deviation in characteristics of battery current sensor sig- • Li-ion battery controller EVB
D
With CONSULT
3. Check DTC.
Is P33D5 detected?
H
WARNING:
maintenance.
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS OF VCM N
With CONSULT
2. Check to see if “P0AA0”, “P0AA1” or “P0AA4” is detected. O
NO >> GO TO 2. P
2.PRECONDITIONING
WARNING:
Installation".

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

Continuity
S 10
LB5 V LB11 9 Exited
G 17
YES >> GO TO 5.
Current sensor Resistance val-

S G
V G
YES >> GO TO 6.


YES >> Replace current sensor. Refer to EVB-619, "BATTERY JUNCTION BOX AND BATTERY HAR-
NESS : Exploded View".
and Installation".

A

Deviation from the specified voltage characteristics of EVB

D
With CONSULT
3. Check DTC.
G
WARNING:
maintenance. I
L
CAUTION:
1.PRECONDITIONING
WARNING: N
Installation". O
>> GO TO 2.
P

Resistance value
Connector Terminal

10 9
9 17
and Installation".
NO >> GO TO 3.
3.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND CURRENT 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
LB11 9 LB5 V Existed
17 G

A

Battery temperature sensor 1 signal voltage is too high EVB
P33D7
or too low.
Battery temperature sensor 2 signal voltage is too high
or too low. D
Battery temperature sensor 3 signal voltage is too high • Harness or connector
P33DB
or too low.
Battery temperature sensor 4 signal voltage is too high E
P33DD
or too low.

F
With CONSULT
3. Check DTC.
Is any DTC detected? H
I
WARNING:
• Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of elec- J
maintenance.
K
carry it in your pocket or put it in the tool box. L
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not M
CAUTION: N
1.PRECONDITIONING
WARNING:
P
Installation".
>> GO TO 2.

2.CHECK HARNESS
YES >> GO TO 3.
YES >> GO TO 4.
4.CHECK HARNESS BETWEEN BATTERY TEMPERATURE SENSOR AND GROUND
Battery tem-
sor
1 LB9 1
2 LB10 4
Ground No existed
3 LB9 3
4 LB10 2
and Installation".

1. Remove battery temperature sensor. Refer to EVB-636, "FRONT MODULE STACK : Disassembly and
Assembly" (Front module) or EVB-651, "REAR MODULE STACK : Disassembly and Assembly" (Rear
module).

1 1 and 5
10 (50) Approx. 7.4
2 3 and 4
Temperature °C (°F)
3 3 and 7 25 (77) Approx. 4.0
4 1 and 2 40 (104) Approx. 2.3

A

BAT VOLTAGE ISOLA- Signal voltage of the on-board isolation resistance moni- EVB

D
With CONSULT
3. Check DTC.
Is P33DF detected? F
G
LER : Removal and Installation". H

DTC DETECTION LOGIC

BATTERY VOLTAGE ISO- Signal Voltage of the on-board isolation resistance mon-

With CONSULT
3. Check DTC.
Is P33E0 detected?

A

BATTERY VOLTAGE ISO- Signal voltage of the on-board isolation resistance moni- EVB

D
With CONSULT
3. Check DTC.
G
ponent Inspection". H

DTC DETECTION LOGIC

BATTERY PACK OVER When the battery (battery pack) temperature is excessively Overcharge caused by traction
P33E2

With CONSULT
3. Check DTC.
Is P33E2 detected?

With CONSULT
dure".
NO >> GO TO 2.
With CONSULT

Temperature increase is seen>>Replace Li-ion battery. Refer to EVB-616, "LI-ION BATTERY CONTROL-
Temperature increase is not seen>>Replace battery temperature sensors. Refer to EVB-605, "BATTERY
PACK UPPER CASE : Exploded View".

A

Deviation in characteristics of Battery temperature sensor EVB
P33E4
P33E5
rear RH or front LH. D
With CONSULT
3. Check DTC.
H
WARNING:
maintenance.
• Be sure to remove the service plug in order to disconnect the high voltage circuits before perform- J
touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or sim- L
CAUTION:
1.PRECONDITIONING N
WARNING:
Disconnect high voltage. Refer to GI-31, "How to Disconnect High Voltage". O
Installation".
P
>> GO TO 2.


module).

1 1 and 5
10 (50) Approx. 7.4
2 3 and 4
3 3 and 7 25 (77) Approx. 4.0
4 1 and 2 40 (104) Approx. 2.3

A

With the power switch ON and no load condition, the dif- EVB

With CONSULT E
3. Check DTC. F
Is P33E6 detected?
WARNING: H
dled incorrectly. Be sure to follow the correct work procedures when performing inspection and I
maintenance.
• To prevent the removed service plug from being connected by mistake during the procedure, always J
L
CAUTION:
With CONSULT N
O
EVB-597, "Removal and Installation".
EVB-806, "Diagnosis Procedure". P
NO >> GO TO 2.
With CONSULT
of cells).

Average cell voltage = “TOTAL BETTER VOLTAGE” ÷ 96 (the number of cells)


ULE STACK : Exploded View" (Front module stack) or EVB-642, "REAR MODULE STACK :
Exploded View" (Rear module stack). After replacing module, GO TO 3.
ULE STACK : Exploded View" (Front module stack) or EVB-642, "REAR MODULE STACK :
Exploded View" (Rear module stack). After replacing module, GO TO 3.
With CONSULT
Is “MINIMUM CELL VOLTAGE” 3,712 mV or less?
YES >> GO TO 5.
NO >> GO TO 4.
With CONSULT

3. Check “DATA MONITOR” and let the Li-ion battery discharge until the “MINIMUM CELL VOLTAGE”
NOTE:

ing segments of Li-
Time to 2 segments
charge gauge
6 Approx. 90 minute
5 Approx. 70 minute

ing segments of Li- A
Time to 2 segments
charge gauge
4 Approx. 40 minute B
3 Approx. 20 minute
>> GO TO 5. EVB

With CONSULT D
VALUE” is displayed. E
NO >> Check the minimum cell voltage on the data monitor and replace a module which includes the F
minimum cell voltage. Refer to EVB-628, "FRONT MODULE STACK : Exploded View" (Front
module stack) or EVB-642, "REAR MODULE STACK : Exploded View" (Rear module stack).
6.PRECONDITIONING G
WARNING:
1. Remove Li-ion battery. Refer to EVB-597, "Removal and Installation". H
2. Remove battery pack upper case. Refer to EVB-605, "BATTERY PACK UPPER CASE : Exploded View".
>> GO TO 7. I
Check condensation in battery pack. J
YES >> GO TO 8.
NO >> Replace Li-ion battery. Refer to EVB-597, "Removal and Installation". K
• Li-ion battery controller (LBC) harness connector L
YES >> GO TO 9
9.CHECK MODULE VOLTAGE N
O
DANGER:
P
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.
and Installation".
TOR

Resistance val-
Terminal
ue
Approx. 0 Ω
YES >> GO TO 11
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.
JSCIA0811GB
Resistance val-
Terminal
ue
Module harness con-
Bus bar Approx. 0 Ω
nector
12.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND BUS BAR

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

DTC DETECTION LOGIC

tioning.

With CONSULT
3. Check DTC.
Is P33E7 detected?

A

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

NOTE:
YES >> GO TO 3.
NO >> GO TO 2. F

Headlamp : High beam ON I
3. Let the Li-ion battery discharge until the Li-ion battery available charge gauge shows segment 1 or below. J
>> GO TO 3.
3.CHARGE OF LI-ION BATTERY K
gauge shows 12 segments. L
>> GO TO 4.
M
With CONSULT
1. Power switch ON and wait for 10 seconds or more. N
3. Check DTC.
Is P33ED detected? O
P

With CONSULT

YES >> Replace corresponding Module. Refer to EVB-628, "FRONT MODULE STACK : Exploded View".
NO >> GO TO 2.
>> Replace corresponding Module. Refer to EVB-628, "FRONT MODULE STACK : Exploded View".

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 E

When no CAN communication signal is received continu- F
Diagnosis Procedure INFOID:0000000011103955 G
H

WARNING:
maintenance.
CAUTION:
battery is judged that its insulation resistance is dropping.
With CONSULT
1. Power switch ON.
NOTE:
>> GO TO 2
CAUTION:
2. Remove Li-ion battery controller. Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
JSCIA0739ZZ

+ A
Terminal
B

YES >> GO TO 8. EVB
NO >> GO TO 3.
3.CHECK INSULATION OF FRONT MODULE STACK LH-2 D
E
JSCIA0739ZZ
H

I
+
Front module stack LH − Voltage J
Terminal

K
NO >> GO TO 4. L
2. Measure voltages between positive terminal of front module stack LH and battery pack ground, and M
JSCIA0739ZZ

+
Terminal

YES >> GO TO 5.
NO >> GO TO 6.
5.CHECK SERVICE PLUG SWITCH INSULATION RESISTANCE
WARNING:
danger of damage to electronic devices. Read the insulation resistance tester instruction manual
CAUTION:
NOTE:
+ — Resistance
NO >> Replace service plug switch (Refer to EVB-619, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Exploded View".) and GO TO 8.
6.CHECK MODULE-1
1. Remove front module stack LH. Refer to EVB-631, "FRONT MODULE STACK : Removal and Installa-
tion".
NOTE:
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 7. A
7.CHECK MODULE-2 B

EVB
WARNING:
danger of electric shock. If used in the vehicle 12V system, D
sure to work safely. E
CAUTION:
result in damage to the component being inspected. F
+
G
Terminal
H
Is the inspection result normal? I

GO TO 8.
and Assembly".) and GO TO 8. J

1. Measure voltages between positive terminal of front module stack RH and battery pack ground, and K
JSCIA0741ZZ
O
+ P
Terminal

YES >> GO TO 14.

NO >> GO TO 9.
JSCIA0741ZZ
+
Terminal

NO >> GO TO 10.
JSCIA0741ZZ
+
Terminal

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

11.CHECK BATTERY JUNCTION BOX INSULATION RESISTANCE A

B
WARNING: EVB
tem, there is the danger of damage to electronic devices. D

CAUTION: E
F
— Resistance
Terminal
G
Is the inspection result normal? H

NO >> Replace battery junction box (Refer to EVB-621, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Disassembly and Assembly") and GO TO 14. I
12.CHECK MODULE-3
1. Remove front module stack RH. Refer to EVB-631, "FRONT MODULE STACK : Removal and Installa-
tion". J
NOTE:
2. Measure voltages between terminal / of all modules in front K
JSCIA0740ZZ N
+ O
Module − Voltage
Terminal
P

YES >> GO TO 13.

13.CHECK MODULE-4
WARNING:
CAUTION:
+
Terminal

GO TO 14.
JSCIA0744ZZ
+
Terminal

Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal and Installation".
NO >> GO TO 15.

module stack. A
EVB
JSCIA0146ZZ
D
E
JSCIA0744ZZ H
+
Front module stack RH − Voltage I
Terminal
, Battery pack ground Approx. 0 V J

NO >> GO TO 16. K
1. Remove mounting nuts / and remove high voltage harness from rear module stack. L
JSCIA0743ZZ
O

JSCIA0744ZZ
+
Terminal

NO >> GO TO 17.
17.CHECK MODULE-5
NOTE:
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 18.
Assembly".
18.CHECK MODULE-6

in rear module stack and module body. A
WARNING:
CAUTION:
+ E
Terminal
F

YES-2 >> Replace or repair of malfunctioning part is complete: INSPECTION END. H
Assembly".
I

WARNING:
maintenance.
CAUTION:
1.CHECK FUSE

Battery 43
55
Power switch ON
74
Is the fuse fusing?
NO >> GO TO 2.
+
Connector Terminal
6
8
YES >> GO TO 3.

+ A
Connector Terminal
B
12V battery power
B24 5 Ground
supply
YES >> GO TO 5.
NO >> GO TO 4.
E
+
No.43 fuse ter-
B24 5 Existed
minal
+
J
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4 K
21
YES >> GO TO 8.
NO >> GO TO 6.
nector.

Continuity
P
YES >> GO TO 7.

Li-ion battery
— Continuity
Connector Terminal
No.74 fuse ter-
B24 21 Existed
minal
8.PRECONDITIONING
WARNING:
Installation".
>> GO TO 9.
LBC Li-ion battery

Continuity
5 21
6 4
21 5
LB11 LB1 Existed
3 8
15 7
16 6

SYMPTOM DIAGNOSIS A
B
EVB

NOTE:

YES >> GO TO 3. F
NO >> GO TO 2.

J
>> GO TO 3.
K
>> GO TO 4. M
With CONSULT N
3. Check DTC.
O
P


operation manual.

LI-ION BATTERY

LI-ION BATTERY
B
EVB
N
JSCIA1373GB
Li-ion battery Bonding plate (stamped No. 4.) Li-ion battery undercover (front)
O
Li-ion battery undercover (center) Li-ion battery undercover (rear) Clip
Battery mounting bracket (left) Battery mounting bracket (right)
: N-m (kg-m ft-lb) P
DANGER:

LI-ION BATTERY
Because hybrid vehicles and electric vehicles contain a high voltage battery, there is a risk of
electric shock, electric leakage, or similar accidents if the vehicle is handled incorrectly. Be sure to fol-
low the correct work procedures when performing inspection and maintenance.
WARNING:
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con-
tainer so that another person does not accidentally connect it while work is in progress.
• Be sure to put on insulating protective gear before beginning work on the high voltage system.
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet
or similar item to prevent contact with other persons.
CAUTION:
REMOVAL
WARNING:
Prepare for work on the high-voltage system. Refer to GI-31, "How to Disconnect High Voltage".
1. Lift up the vehicle and remove the Li-ion battery undercover. Refer to EVB-597, "Exploded View".
2. Remove the harness clamp and disconnect the Li-ion battery
high-voltage harness connector .
DANGER:
• There is the danger of electric shock caused by

contact with the terminals. Be sure to wear insulated pro-
tective gear.
JSCIA1374GB
• Because there is the danger of electric shock, imme-

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

while rotating it in the counterclockwise direction.
WARNING:
To prevent electric shock, wear insulated protective

gear.
JSCIA1375GB

LI-ION BATTERY
4. Remove bonding plate .

A
WARNING:

gear. B
EVB
JSCIA0559ZZ
D
5. Remove Li-ion battery mounting bolts .
WARNING:
E
gear.
F
CAUTION:
Do not remove the 4 bolts shown by in the figure. G
JSCIA0560ZZ
6. Set the pallet [SST: — (J-50583)] onto the lift table. H

• Align the pallet center mark and the lift table center
mark .
I
Front
Side
J
JSCIA0178ZZ
O
7. Set the pallet onto the Li-ion battery.
CAUTION:
For preventing the battery from falling, fasten the pallet and
P
battery with transport fastening bolts.
JSCIA0179ZZ

LI-ION BATTERY
8. Remove the Li-ion battery mounting bolts (4 bolts) .
JSCIA0561ZZ
WARNING:
To prevent electric shock, wear insulated protective gear.
9. Lower the pallet, and remove the Li-ion battery from the vehi-
cle.
WARNING:

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

2. Move the lift table.
3. Lower the Li-ion battery.
4. Operate the stacker and move the Li-ion battery.
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.
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
(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”.

LI-ION BATTERY
2. Install the locating pin [SST: KV99111300 (J-50306)] in the position on the body as shown in the figure.
A
EVB
JSCIA0182ZZ
F
: Vehicle front

G
• Align the Li-ion battery and the locating pin .
WARNING:
To prevent electric shock, wear insulated protective H

gear.
J
JSCIA0183ZZ
4. Tighten the Li-ion battery mounting bolts (4 bolts) , then remove the pallet.
K
JSCIA0561ZZ
WARNING: N

O
5. Remove the locating pin from the body. P

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

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

WARNING:

gear.
JSCIA0560ZZ
7. Install the bonding plate .

WARNING:

gear.
JSCIA0559ZZ
8. After installing the bonding plate, perform an electric equipotential test. EVB-603, "Inspection".
9. Rotate the vehicle communications connector clockwise to
connect it.
WARNING:

gear.
JSCIA1376GB

LI-ION BATTERY
10. Install the high-voltage harness connector and install the har-
ness clamp . A
WARNING:
To prevent electric shock, wear insulated protective B

gear.
EVB
JSCIA1374GB
D
• Connect the high-voltage harness connector by the following procedure.
G
JPCIA0036ZZ
11. Install the Li-ion battery undercover.

12. Install the service plug Refer to GI-31, "How to Disconnect High Voltage". H
I
After installing the Li-ion battery, measure the resistance between the battery pack ground bolt and the body
ground. J
O
JSCIA1377GB
WARNING:
To prevent electric shock, wear insulated protective gear. P
Standard : Less than 0.1Ω

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

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

LI-ION BATTERY
UNIT DISASSEMBLY AND ASSEMBLY A

LI-ION BATTERY
BATTERY PACK UPPER CASE
B
BATTERY PACK UPPER CASE : Exploded View INFOID:0000000011400392
EVB
JSCIA0565GB

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

Seal Plug Plug washer
Breather
Battery pack case side
: Always replace after every disas-
sembly.
BATTERY PACK UPPER CASE : Removal and Installation INFOID:0000000011400393
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
• 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.
• 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.
guisher).
REMOVAL
LI-ION BATTERY
1. Clean any dust or dirt adhered to the battery pack.
2. Remove the service plug retainer . A
WARNING:

gear and use insulated tools.
EVB
JSCIA0143ZZ
D
3. Remove the battery pack upper case mounting bolts and ground bolts .
E
JSCIA0571GB 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

LI-ION BATTERY
b. Use the windshield cutter and cut the adhesive in the order from 1 to 4 as shown in the figure.
JSCIA0655ZZ
JSCIA0699ZZ
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: 999MP-
43533PP).
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.

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.

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: 999MP-43533PP).

- If the paint sealant damage on a corner is damaged, repair by applying primer (adhesive primer:
999MP-43533PP).
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

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
JSCIA0634ZZ
D
4. Apply dam rubber (KA390-0059U) on the inside of the old adhesive on the battery pack lower case.
G
JSCIA0578ZZ
C : 10 mm (0.39 in)
H
WARNING:

I
CAUTION: J
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,
K
then the next time the battery pack is disassembled, the windshield cutter may not be able to reach the
adhesive and removing the battery pack upper case may be difficult.
5. Apply adhesive (999MP-57302NP) to the battery pack lower case as shown in the figure. L
WARNING:
To prevent electric shock, wear insulated protective gear. M

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

: Old adhesive : Dam rubber
E : 50 mm (1.97 in) or more
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 12 minutes. [Humidity: 80%, Temperature: 35°C (95°F)]
• Before installing the battery pack upper case, check that there are no locations of insufficient
adhesive. If there is insufficient adhesive, correct the location. (If the adhesive height is lower
than the height of the dam rubber, then the amount of adhesive is insufficient.)
• Do not apply too much adhesive as doing so may make work difficult the next time the battery
pack upper case is removed.
NOTE:

LI-ION BATTERY
• For applying the adhesive in a triangle, cut the end of the nozzle as shown in the figure.
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
JSCIA0680ZZ
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
JSCIA0581ZZ

LI-ION BATTERY
7. Tighten the mounting bolts in the order from 1 to 6 as shown in the figure.
JSCIA0582ZZ
WARNING:
8. Install the ground bolt .
JSCIA0583ZZ
WARNING:

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

gear and use insulated tools. B
EVB
JSCIA0143ZZ
D
10. Perform a battery pack air leak inspection. Refer to EVB-603, "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
WARNING:

gear. G
JSCIA0584ZZ
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-603, "Inspection". K
AIR LEAK INSPECTION
L

LI-ION BATTERY
LI-ION BATTERY CONTROLLER : Exploded View INFOID:0000000011400394
JSCIA0760GB
Li-ion battery controller Controller bracket
LI-ION BATTERY CONTROLLER : Removal and Installation INFOID:0000000011400395
DANGER:
maintenance.
WARNING:
CAUTION:

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-606, "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.
JSCIA0145ZZ
K
3. Remove the Li-ion battery controller mounting nuts , then
remove the mounting bolts .
WARNING: L

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

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

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

gear.
JPCIA0204ZZ

LI-ION BATTERY
• Because there is a risk of electric shock, immediately protect the terminals of the discon-
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
JPCIA0204ZZ
2. Install the battery pack upper case. Refer to EVB-606, "BATTERY PACK UPPER CASE : Removal and
Installation".
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-658, "Inspection".
AIR LEAK INSPECTION
BATTERY JUNCTION BOX AND BATTERY HARNESS

LI-ION BATTERY
BATTERY JUNCTION BOX AND BATTERY HARNESS : Exploded View INFOID:0000000011400396
EVB
P
JSCIA1378GB
Service plug switch Service plug switch bracket High-voltage battery harness
Bus bar nut cap Bus bar Bus bar nut cap
Bus bar (integrated with noise filter) Battery junction box Harness bracket
Vehicle communications harness Snap ring High-voltage harness connector

LI-ION BATTERY
Connector flange Seal Voltage detection harness
Bus bar Battery current sensor (integrated High-voltage battery harness
with bus bar)
sembly.
Bus bar Layout

DANGER:

LI-ION BATTERY
EVB
JSCIA1379ZZ P
: Battery front
BATTERY JUNCTION BOX AND BATTERY HARNESS : Disassembly and Assembly

INFOID:0000000011400397
DANGER:

LI-ION BATTERY
WARNING:
CAUTION:
4. Work space
guisher).
DISASSEMBLY
1. Remove the battery pack upper case. EVB-606, "BATTERY PACK UPPER CASE : Removal and Installa-
tion".
Installation".
3. Disconnect the high-voltage harness engagement detection
switch harness connector .
WARNING:

gear.
JSCIA1380ZZ

LI-ION BATTERY
4. Open the bus bar cover and remove the high-voltage harness
connector terminal mounting bolt . A
DANGER:
• There is the danger of electric shock caused by B

tective gear and use insulated tools.
EVB
JSCIA1381ZZ
• Because of the danger of electric shock, be sure to D
close the bus bar cover after removing the bus bar.
5. Remove the mounting bolt and disconnect the high-voltage E

harness connector from the connector flange.
WARNING:
To prevent electric shock, wear insulated protective F

JSCIA1382ZZ
H
6.
7.
8. Disconnect the vehicle communications harness connector

from the junction box, and remove the connector clips . I
WARNING:
To prevent electric shock, wear insulated protective J

JSCIA0711ZZ
L
9. Remove the bus bar nut caps .
WARNING:
M
O
JSCIA0727ZZ

LI-ION BATTERY
10. Remove the bus bar mounting nuts and , and remove the
bus bar (integrated with noise filter) .
WARNING:

JSCIA0728ZZ
11. Remove the harness clips, then remove the battery member
pipe .
WARNING:

NOTE:
The right-side mounting hole is larger for facilitating removal of JSCIA0715ZZ
the battery member pipe. Lifting up the left side first makes
removal easier.
12. Remove the bus bar nut cap and remove the high-voltage
harness nut cap , then open the bus bar cover .
WARNING:

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

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

ately protect the terminals of the disconnected high-voltage harness connector (high-voltage
terminals) with insulating tape so that they are not exposed.
• Because of the danger of electric shock, be sure to close the bus bar cover after removing
the bus bar.

LI-ION BATTERY
14. Remove the mounting nuts and remove the junction box .
WARNING: A

EVB
JSCIA0595ZZ
D
15. Disconnect the current sensor harness connector .
WARNING:
E
F
G
JSCIA0657ZZ
16. Remove the bus bar mounting nut which connects the current
H
sensor and left front module stack .
DANGER:
• There is the danger of electric shock caused by I

J
JSCIA0596ZZ
• Because of the danger of electric shock, be sure to K
17. Remove the service plug switch bracket mounting bolts L

and mounting nuts .
WARNING:
M
N
JSCIA1410ZZ O

LI-ION BATTERY
18. Invert the service plug switch bracket and remove the high-volt-
age harness mounting bolt , current sensor mounting bolt ,
and the connector , then remove the service plug switch
bracket .
DANGER:

JSCIA0598ZZ
nected high-voltage harness connector (high-voltage terminals) with insulating tape so that they
are not exposed.
19. Remove the mounting nuts , then remove high-voltage harness and .
JSCIA0599ZZ
: Harness clip
DANGER:
the bus bar.
20. Remove the vehicle communications harness and voltage detection harness.

LI-ION BATTERY
EVB
JSCIA0600ZZ F
Vehicle communications harness Voltage detection harness Snap ring

: Harness clip G
WARNING:
To prevent electric shock, wear insulated protective gear and use insulated tools. H
ASSEMBLY
Note the following items, and disassembly in the reverse order of disassembly. J
DANGER:
K
minal. M
monly-confused with the wrong position , install the bus bar to the correct position with extreme N
caution.

LI-ION BATTERY
JSCIA0873ZZ
Correct position Wrong position

: Battery front
WARNING:
Install the Li-ion battery controller immediately before installing the battery pack upper case. Refer to
EVB-606, "BATTERY PACK UPPER CASE : Removal and Installation".
CAUTION:
AIR LEAK INSPECTION
FRONT MODULE STACK
FRONT MODULE STACK : Exploded View INFOID:0000000011400398
REMOVAL AND INSTALLATION

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

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

(front)
Sub frame Bus bar cover Bus bar module

LI-ION BATTERY
NOTE:
The figure shows the right front. A
Module layout
EVB
JSCIA1411GB
G
Left front module stack Right front module stack
H
MD27 Module A 53 & 54 MD39 Module A 77 & 78 I
J

K
MD35 Module A 69 & 70 MD47 Module A 93 & 94 L
FRONT MODULE STACK : Removal and Installation INFOID:0000000011400399 M
DANGER:
N
O
WARNING:
• Be sure to put the removed service plug in pocket and carry it or store it in a tool box or other con- P

LI-ION BATTERY
CAUTION:
4. Work space
guisher).
REMOVAL
tion".
Installation".
3. Remove the following. EVB-621, "BATTERY JUNCTION BOX AND BATTERY HARNESS : Disassembly
and Assembly".
• Battery junction box
• Service plug switch bracket
• All high-voltage battery harnesses
• Vehicle communications harness
• Voltage detection harness
4. Remove the mounting nuts , then remove the bus bar
which connects the left and right front module stacks.
: Battery front
DANGER:

JSCIA0714ZZ
• Because there is a danger of electric shock, be sure to close the bus bar cover after remov-
ing the bus bar.

LI-ION BATTERY
5. Disconnect the harness connector between the battery tem-
perature sensor harness (front) and the battery temperature A
sensor harness (rear).
WARNING:
B
gear.
EVB
JSCIA0658ZZ
D
6. Remove the battery temperature sensor harness (front) from the right front module stack.
JSCIA0631ZZ
H
: Harness clip
WARNING:
I
7. Remove the battery member pipe .

WARNING: K

gear and use insulated tools. L
M
NOTE:
The right-side mounting hole is larger for facilitating removal of
the battery member pipe. Lifting up the left side first makes JSCIA0715ZZ
removal easier. N

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

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

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

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

WARNING: D

gear.
E
F
• Because there is a risk of electric shock, lay an anti-
static rubber sheet on the workbench. JSCIA0719ZZ
NOTE: G
The figure shows the front module stack RH.
INSTALLATION
H
Note the following items, and disassembly in the reverse order of disassembly.
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear I
minal. K
- Since the correct installation position for the bus bar connected to both front module stacks is com- L
monly-confused with the wrong position , install the bus bar to the correct position with extreme
caution.
M
JSCIA0873ZZ

LI-ION BATTERY

: Battery front
WARNING:
EV Battery Tracking Identification Seal
When replacing the Li-ion battery with a new battery, perform the following operation.
1. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
2. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
(old) LI-ion battery and to the “Li-ion battery replacement history record”.
3. Enter the necessary information in the “Li-ion battery replacement history record”.
Battery Temperature Sensor Harness (Front)

Install the battery temperature sensor harness (front) onto the front module stack RH.
JSCIA0659ZZ
CAUTION:
AIR LEAK INSPECTION
NOTE:
Install the battery temperature sensor onto module No. MD39 and MD46.
DANGER:
maintenance.
WARNING:

LI-ION BATTERY
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet A
B
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do EVB
D
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur E
• The indoor environment must also prevent metal powder, grease, and other foreign substances from F
G
4. Work space
H
5. Standard fire fighting equipment I
guisher). J
DISASSEMBLY
1. Follow the procedure below and remove the bus bar module from the front module stack.
K
a. Remove the bus bar cover, then remove the module terminal mounting bolts .
N
JSCIA0720ZZ
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear O
• This work must not be performed by multiple operators because there is a risk of electric
shock if the operators contact one another.

LI-ION BATTERY
b. Remove the voltage detection terminal mounting screws , then remove the bus bar module from the
front module stack.
JSCIA0721ZZ
DANGER:
c. Install a module terminal cover [SST: KV99111500 ( — )] onto all module terminals.
JPCIA0123ZZ
WARNING:
2. 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.
DANGER:

LI-ION BATTERY
There is the danger of electric shock caused by contact with the terminals. Be sure to wear A
B
a. Assemble the module so that the module terminals are arranged as shown in the figure.
EVB
J
JSCIA0681ZZ
Right module stack Left module stack

K
: Battery front
WARNING:
L
Be careful of the directions of the + terminal and – terminal when assembling the module. If
the polarity is incorrect, there is a risk of electric shock, fire, and component damage.
NOTE: M
• To identify the module + terminal and − terminal, refer to the
figure.
: Red N
+ terminal identification color
− terminal identification color : Black
P
JSCIA0682ZZ

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.
JSCIA0722ZZ
NOTE:
There are 2 end plates, each with different carabiner installation hole positions. If they are installed
reversed, the carabiner installation hole is positioned on the inside and lifting up is not possible.
c. Install the mounting bolts at opposite corners for each module, then insert φ7 mm (0.28 in) metal bars
(B) into the empty bolt holes and perform centering of the module collar position.
JSCIA0734ZZ
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.

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
JSCIA0721ZZ 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. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
H
L
JPCIA0150ZZ
Right module stack Left module stack M

: Battery front
DANGER: N
O
P
c. Install the bus bar cover.
REAR MODULE STACK

LI-ION BATTERY
REAR MODULE STACK : Exploded View INFOID:0000000011400401
JSCIA0568GB


LI-ION BATTERY

A
DISASSEMBLY AND ASSEMBLY B
EVB
JSCIA1383GB N
Battery temperature sensor harness Right end plate Harness bracket

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

LI-ION BATTERY
Module layout
JSCIA1411GB
Rear module stack

NOTE:
• Module A: No bracket
• Module B: With bracket
REAR MODULE STACK : Removal and Installation INFOID:0000000011400402
DANGER:
WARNING:

LI-ION BATTERY
ing electric shock, fire, and damage to parts. A
CAUTION:
B
1. Must be an indoor environment. EVB
D
entering due to maintenance performed on other vehicles and other sources during disassembly work. E
3. The floor must be dry. F
4. Work space
• The work space must be approximately the size of one entire vehicle. G
5. Standard fire fighting equipment H
guisher).
I
REMOVAL
1. Remove the battery pack upper case. Refer to EVB-606, "BATTERY PACK UPPER CASE : Removal and
Installation". J
Installation".
3. Disconnect the harness connector between the battery tem- K
perature sensor harness (front) and the battery temperature
WARNING: L

gear.
M
JSCIA0658ZZ N

LI-ION BATTERY
4. Disconnect the connector, and then remove the battery temperature sensor harness (rear).
JSCIA1384ZZ
WARNING:
5. Remove the harness clips of the voltage detection harness from the harness bracket, and move them
to a location where they do not inhibit with work.
JSCIA0633ZZ
: Harness clip
WARNING:
6. Remove the mounting nuts and remove the high-voltage harness , from the rear module stack.

LI-ION BATTERY
EVB
JSCIA0599ZZ
D
: Harness clip
DANGER:
E
F
• Because there is a risk of electric shock, immediately protect the disconnected high-volt- G
age terminals with insulating tape so that they are not exposed.
7. Remove the rear module stack mounting bolts .
H
WARNING:

gear and use insulated tools. I
JPCIA0129ZZ
K
8. Follow the procedure below and remove the rear module stack from the battery pack.
a. Attach a carabiner to position (A) as shown in the figure and
connect a lashing belt to it. L
WARNING:
To prevent electric shock, wear insulated protective M

gear.
JSCIA0251ZZ

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
is lifted up. JPCIA0130ZZ
c. Move the battery pack and place the workbench below the rear module stack.
WARNING:
CAUTION:
Place the removed battery pack upper case onto the battery pack for storage.
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
2. Follow the following procedure and install the rear module stack onto the battery pack.
a. Use the engine frame (A) and lift up the rear module stack .
WARNING:

gear.
CAUTION:
b. Move the workbench and place the battery pack below the rear module stack.
c. Mount the rear module stack onto the battery pack.
WARNING:

LI-ION BATTERY
CAUTION:
Be sure to align the locating pin position.
B
3. Tighten the rear module stack mounting bolts .
WARNING:
EVB
D
E
JPCIA0129ZZ
4. Tighten the mounting nuts , and then install the high-voltage harness , onto the rear module stack. F
I
JSCIA0599ZZ
: Harness clip
J
DANGER:
• There is the danger of electric shock caused by contact with the terminals. Be sure to wear K
• Because there is a risk of electric shock, immediately protect the disconnected high-volt-
age terminals with insulating tape so that they are not exposed. M
5. Install the voltage detection harness .

LI-ION BATTERY
JSCIA0633ZZ
: Harness clip
WARNING:
6. Install the battery temperature sensor harness (rear).
JSCIA1384ZZ
WARNING:
NOTE:

LI-ION BATTERY
7. Connect the harness connector between the battery tempera-
ture sensor harness (front) and battery temperature sensor har- A
ness (rear).
WARNING:
B
gear.
EVB
JSCIA0658ZZ
D
8. Install the Li-ion battery controller. Refer to EVB-616, "LI-ION BATTERY CONTROLLER : Removal and
Installation".
9. Install the battery pack upper case. Refer to EVB-606, "BATTERY PACK UPPER CASE : Removal and E
Installation".
CAUTION:
F
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST G
H
DANGER:
electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are I
maintenance.
WARNING: J
• 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.
tainer so that another person does not accidentally connect it while work is in progress. K
touch the vehicle. When not working, cover high voltage components with an anti-static cover sheet L
M
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do N
O
• The environment must not cause the intrusion of sweat during work, or cause condensation to occur P

LI-ION BATTERY
4. Work space
guisher).
DISASSEMBLY
1. Remove harness bracket , and from the rear module stack.
JSCIA0635ZZ
WARNING:
2. Follow the following procedure and remove the bus bar from the rear module stack.
a. Remove the center bus bar cover, then remove the module ter-
minal mounting bolts .
DANGER:

JSCIA0154ZZ
• This work must not be performed by multiple opera-
tors because there is a risk of electric shock if the operators contact one another.
CAUTION:
Do not remove all bus bar covers and all module terminal mounting bolts at the same time.
b. Remove the left-side bus bar cover, then remove the module ter-
DANGER:

JSCIA0148ZZ

LI-ION BATTERY
c. Remove the right-side bus bar cover, then remove the module
terminal mounting bolts . A
DANGER:

EVB
JSCIA0155ZZ
• This work must not be performed by multiple opera- D
d. Remove the voltage detection terminal mounting screws , E

then remove the bus bar from the rear module stack.
DANGER:
• There is the danger of electric shock caused by F

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

onto all module terminals.
WARNING:
J
gear.
K
NOTE:
• Because “module B” interferes with the bracket and cover, cut JSCIA0192ZZ L
the module terminal cover at the position shown in the figure.
JSCIA0729ZZ
A : 7 mm (0.28 in) B : 5 mm (0.20 in) P

LI-ION BATTERY
3. Remove the front stack member .
WARNING:

JPCIA0126ZZ
4. Remove the rear stack member .

WARNING:

JSCIA0723ZZ
5. Fasten the rear module stack with a lashing belt .

WARNING:

gear.
JSCIA0240ZZ
6. Remove the through bolt mounting nut, then disassemble the

rear module stack .
WARNING:

JPCIA0131ZZ
ASSEMBLY
2. Follow the procedure below to assemble the rear module.
WARNING:

LI-ION BATTERY
To prevent electric shock, wear insulated protective gear and use insulated tools. A
B
a. Assemble the rear module so that the module terminals are arranged as shown in the figure.
EVB
E
JSCIA0683ZZ
WARNING:
Be careful of the directions of the + terminal and − terminal when assembling the module. If F
NOTE:
• To identify the module + terminal and − terminal, refer to the G
figure.
+ terminal identification color : Red

H
JSCIA0682ZZ J
b. Use a lashing belt and apply pressure to the rear module
stack .
K
WARNING:

gear. L
JSCIA0240ZZ
c. Inspect the module installation condition, and correct it if it is skewed or a large distortion is found. N
JSCIA0313ZZ
WARNING:

LI-ION BATTERY
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.
JSCIA0717ZZ
CAUTION:
e. Install the remaining 2 through-bolts, and tighten the mounting nuts to the prescribed torque.
• When installing, hold the end of the through bolt stationary and
tighten the installation nut.
JSCIA0347ZZ
3. Install the rear stack member .

WARNING:

JSCIA0723ZZ

LI-ION BATTERY
4. Install the front stack member .
WARNING: A

EVB
JPCIA0126ZZ
D
5. Remove the module terminal cover [SST: KV99111500 ( — )]
(A).
WARNING: E
gear.
F
6. Follow the procedure below and install the bus bar module onto G
the rear module stack. JSCIA0192ZZ
a. Install the bus bar module onto the rear module stack.
WARNING: H

I
J
tion terminal mounting screws to the prescribed torque.
DANGER:
• There is the danger of electric shock caused by K

L
JPCIA0135ZZ
• This work must not be performed by multiple opera- M
c. Tighten the module terminal mounting bolts in numerical order as shown in the figure. N
• When tightening of 1 – 16 is completed, install the left-side bus bar cover.
• When tightening of 17 – 32 is completed, install the right-side bus bar cover.
• When tightening of 33 – 48 is completed, install the center bus bar cover.
O
JPCIA0136ZZ
DANGER:

LI-ION BATTERY
d. Install the bus bar cover .
JPCIA0137ZZ
WARNING:
CAUTION:
• Be careful not to install with the top and bottom facing in the wrong directions.
• After installation, check that the mating is not skewed.
7. Install the harness bracket , and to the rear module stack.
JSCIA0635ZZ
WARNING:
CAUTION:
AIR LEAK INSPECTION
AIR LEAK INSPECTION

LI-ION BATTERY
1. Use vinyl tape or similar means (A) for preventing air leakage
from the harness connectors. A
• 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.
B
WARNING:

gear. EVB
JSCIA1385ZZ
2. Use vinyl tape or similar means (A) to prevent air leakage from
the breather.
• Use wide vinyl tape that is capable of covering all of the E
breather with one strip.
WARNING: F

gear. G
JPCIA0128ZZ
H
3. Remove the plug and install the adapter (A) of the air leak tester
[SST: KV99111400 ( — )].
WARNING: I

gear.
J
K
JSCIA1386ZZ
4. Install the gauge (A) of the air leak tester [SST: KV99111400 L
( — )].
WARNING:
M
gear.
CAUTION:
The gauge is a precision instrument. Be careful not to drop JSCIA0646ZZ O
it when handling it.
5. Install the service plug.

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

LI-ION BATTERY
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:
a. Open the cock on the air leak tester.

CAUTION:
Do not operate the pump before opening the cock on the air
leak tester. Doing so may damage the gauge. If the pump is
operated before the cock 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 battery pack. If the
gauge pressure does not rise, or if the gauge reading fluctuates, check for the location of air leakage.
Specified inspection pressure : 1.6 kPa (0.016 bar, 0.0163 kg/cm2, 0.232 psi)
CAUTION:
• Operate the air pump carefully when applying pressure. If pressure is applied suddenly to the
gauge, the gauge may be damaged.
• Do not apply pressure of 2.0 kPa (0.0204 kg/cm2) or more to the battery case or air leak tester.
c. Close the cock and wait for 1 minute.
d. Check that the air leak tester reading remains at or above the limit value.
Repair limit : 1.4 kPa (0.014 bar, 0.0142 kg/cm2, 0.203 psi)
e. If the pressure is below the limit value, check for the locations of air leakage.
NOTE:
Check for air leakage from the sound of air escaping when pressure is applied.

LI-ION BATTERY
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 A
(location of coating peeling) .
EVB
JSCIA1387ZZ
WARNING: G

H
Standard : Less than 0.1Ω I

• Ground bolt connection condition
• Corrosion on ground bolt mounting surface J
• Presence of paint, oil, dirt, or other substance on ground bolt mounting surface


Items Specification
Type Li-ion battery
Weight [kg (lb)] Approx. 273 (602)
JSCIA1388ZZ
External dimension “a” [mm (in)] 1188 (46.77)

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

APPLICATION NOTICE
HOW TO USE THIS MANUAL A

APPLICATION NOTICE
B
EVB
D
E
Type A
JSCIA0277ZZ
Type 3 Without Li-ion battery heater Type B

I
JSCIA0706ZZ
J

PRECAUTIONS
PRECAUTION
PRECAUTIONS
WARNING:
WARNING:
• If a technician uses a medical electric device such as an implantable cardiac pacemaker or an
WARNING:
the implantable cardioverter defibrillator (ICD), when using the service, etc.
device. The possible effects on the devices must be checked with the device manufacturer before
TCU use.
WARNING:
facturer before Intelligent Key use.
The high voltage system may starts automatically. It is required to check that the timer air conditioner
NOTE:

PRECAUTIONS
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. A
Service Manual.
WARNING: B
an authorized NISSAN/INFINITI dealer. EVB
Module, see “SRS AIR BAG”. D
connectors.
E
WARNING:
Always observe the following items for preventing accidental activation. F
injury. G
H
INFOID:0000000011103980
For vehicle with steering lock unit, if the 12V battery is disconnected or discharged, the steering wheel will lock I
J
OPERATION PROCEDURE
NOTE: K
(At this time, the steering lock will be released.) L
4. Perform the necessary repair operation. M
N
NOTE:
tion. O

PRECAUTIONS
windshield.
PIIB3706J
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:
DANGER:

PRECAUTIONS
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 EVB
• Never allow workers other than the responsible person to touch the vehicle containing high voltage D
CAUTION:
Never bring the vehicle into the READY status with the service plug removed unless otherwise E
F
HANDLING OF HIGH VOLTAGE HARNESS AND TERMINALS G
WARNING: H
nets. Such persons must not perform work on the vehicle. I
metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage J
POSTING A SIGN OF “DANGER! HIGH VOLTAGE AREA. KEEP OUT” K

PRECAUTIONS
workers.
JSAIA0091GB

PREPARATION
PREPARATION A
PREPARATION
B
The actual shape of the tools may differ from those illustrated here.
(TechMate No.) EVB
Tool name
(J-50583) D
Palette
JPCIA0239ZZ
F
KV99111300 When installing Li-ion battery.
(J-50306) 2 piece/set
G
H
JPCIA0023ZZ
KV99111400 When checking air leaks after disassem-

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

(—) 24 pieces/set
JPCIA0069ZZ
M
(J-50346)
N
O
JPCIA0070ZZ

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

PREPARATION

300A]
JMCIA0149ZZ

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

nents
electric line
[ANSI Z87.1]
JPCIA0012ZZ

nents
Face shield
electric line
JPCIA0167ZZ
Insulated helmet Removing and installing high voltage components
JPCIA0013ZZ

PREPARATION
A
B
EVB
JPCIA0019ZZ
JPCIA0018ZZ
Battery lift table Removing and installing Li-ion battery G
JPCIA0024ZZ
H
I
J
JPCIA0015ZZ

L
JPCIA0014ZZ
Insulated hand tools Removing and installing high voltage components N
JPCIA0067ZZ
O
P
JPCIA0068ZZ

PREPARATION
• Removing and installing battery module stack

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

NOTE:
• D: 14.0 mm (0.55 in)
Carabineer [large]
• L: 204.0 mm (8.03 in)
• S: 47.0 mm (1.85 in)
• W: 105.0 mm (4.13 in)
JPCIA0017ZZ

Belt slinger NOTE:
Length: 2.0 m (6.562 ft)
JPCIA0021ZZ
Mobile floor crane Removing and installing battery module stack
JPCIA0020ZZ
JPCIA0022ZZ

(Cut the adhesive)
JSCIA0640ZZ

(Cut the adhesive)
NOTE:
JSCIA0641ZZ

PREPARATION
A
Installing battery pack upper case B

Scraper
EVB
JSCIA0643ZZ
D
E
JSCIA0639ZZ

NOTE:
Metal bar G
• D: φ 7 mm (0.28 in)
• L: 1 m (3.28 ft)
JSCIA0735ZZ
H
Sealant or/and Lubricant INFOID:0000000011400534
I
Tool name
Description
Tool number
Adhesive J
999MP-57302NP
Dam rubber
KA390-0059U K
Primer (Adhesive primer)
999MP-43533PP
Primer sufacer (anti-corrosion praimer) L
—

COMPONENT PARTS
SYSTEM DESCRIPTION
COMPONENT PARTS
JSCIA1306ZZ

COMPONENT PARTS
A. Front of battery pack B. Back of battery pack A

: Vehicle front
No. Component Function B

EVB
5. Battery current sensor EVB-679, "Battery Current Sensor" D
E
10. Battery temperature sensor 3 EVB-679, "Battery Temperature Sensor" F
G
JSCIA0771ZZ
O
: Vehicle front
No. Component Function P


COMPONENT PARTS
6. Heater relay unit EVB-678, "Heater Relay Unit"

JSCIA0701ZZ
JSCIA0702ZZ

JSCIA0071ZZ
• State of charge
• Temperature

COMPONENT PARTS
5. Detection of decrease in insulation resistance of high-voltage circuit A
B
• There are two kinds of modules, according to the location of posi- EVB
Positive terminal : Red D

JSCIA0703ZZ
MODULE INTERNAL CIRCUIT F

G
NOTE:
the parallel circuit. H
I
JPCIA0197GB
MODULE LAYOUT
J
JSCIA1411GB
O
NOTE:
P
CELL

COMPONENT PARTS
JSCIA0274ZZ

tery life.
• Light and thin structure increases flexibility in layout.
Heater Relay Unit INFOID:0000000011103990
• The heater relay unit is installed in the battery pack (under the ser-
vice plug).
• When receiving a relay control signal from LBC (Li-ion battery con-
troller), the heater relay unit turns ON the built-in relay and sup-
plies high-voltage power to each Li-ion battery heater.
JSCIA0772ZZ
Li-ion Battery Heater INFOID:0000000011103991
• Li-ion battery heater is installed in the battery pack.

• High voltage power is supplied from the heater relay unit.
• Each Li-ion battery heater is connected in parallel.
FRONT LI-ION BATTERY HEATER
• Two front Li-ion battery heaters are installed to each front module
stack.
JPCIA0212ZZ
REAR LI-ION BATTERY HEATER

COMPONENT PARTS
• Two rear Li-ion battery heaters are installed to the rear module
stack. A
EVB
JPCIA0213ZZ
D
Battery Current Sensor INFOID:0000000011110688
• The battery current sensor is installed to bus bar between battery

junction box and rear module stack. E
• This sensor measures charge/discharge current sent to Li-ion bat-
tery and transmits a current signal to Li-ion battery controller
(LBC). F
• Li-ion Battery controller (LBC) measures remaining battery level
according to charge/discharge current and sends the data to VCM.
G
JSCIA0507ZZ
H

measure the temperature. I
J
JSCIA0705ZZ
L

the thermistor decreases as the temperature increases. M
JPCIA0295GB

COMPONENT PARTS
pack.
- System main relay to provide/interrupt DC current sent from Li-ion
battery.
- Pre-charge relay to protect the high voltage circuit from a high cur-
JSCIA0276ZZ
• When an error occurs in the system, the system main relay is
turned OFF and the Li-ion battery is interrupted for ensuring safety, based on a command from VCM (Vehi-
cle control module).

maintenance.
• Always use insulating protective equipment when removing and
JSCIA0706ZZ
label in the original position.
Li-ion Battery
JPCIA0207ZZ

COMPONENT PARTS
• The label (A) is affixed to the body panel near the high voltage har-
ness connector. A
: Vehicle front
: Direction of the label B
EVB
JPCIA0208ZZ
D
G
JSCIA0111ZZ
Service Plug H

I
K
JPCIA0209ZZ

SYSTEM
SYSTEM
LI-ION BATTERY CONTROL SYSTEM
LI-ION BATTERY CONTROL SYSTEM : System Description INFOID:0000000011103996
SYSTEM DIAGRAM
JSCIA0413GB

Input Signal Item

Output Signal Item

SYSTEM
Received unit Signal name A

B
Li-ion battery current signal EVB
VCM EV system CAN
D
Li-ion battery capacity signal E
F
DESCRIPTION
information, such as the charging status of Li-ion battery and possible power, to VCM (vehicle control module) G
as overvoltage, over discharge or excessive temperature rise in the battery. H
charge/charge line. I
transfers the detected state to VCM so that the vehicle does not start with an unsteady state. J
• Estimates a battery charge state and low battery state, based on the data obtained with the battery state K
BATTERY PROTECTION
The Li-ion battery has a voltage range capable of charge/discharge. If charged/discharged exceeding the L
voltage stays within the voltage range. M
Charging energy control N
O
System main relay cut P
control

SYSTEM
During cell capacity adjustment, the capacity of each cell is estimated based on the no-load voltage when the
that have excess capacity. In this way, capacity adjustment by the Li-ion battery controller allows the capacity
JPCIA0094GB

resistance of each high voltage part and sends the measurement results to VCM via EV system CAN commu-
nication.
tance value.
JSCIA0415GB
LI-ION BATTERY HEATER CONTROL SYSTEM

SYSTEM
LI-ION BATTERY HEATER CONTROL SYSTEM : System Description INFOID:0000000011103997
A
SYSTEM DIAGRAM
EVB
JSCIA1307GB J
Input Signal Item K

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

M
Receive unit Signal name
VCM EV system CAN communication Next start time signal
N
DESCRIPTION
• When the temperature decreases [approximately −20°C (−4°F)] extremely in the battery pack, the Li-ion bat-
tery heater control system automatically activates the Li-ion battery heater to warm the inside of the battery
pack for protecting Li-ion battery from freezing and preventing the decline in battery output. In addition, when O
the temperature in the battery pack is restored [approximately −10°C (14°F)], the Li-ion battery heater stops.
• The Li-ion battery controller (LBC) detects a temperature in the battery pack, according to a signal transmit-
ted from the battery temperature sensor installed to the battery pack and judges the activation of the Li-ion P
battery heater.
• When the relay built in the heater relay unit turns ON, high voltage power is supplied to each Li-ion battery
heater.
• 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.

SYSTEM
• When the temperature in Li-ion battery pack is low with no necessity of Li-ion battery heater operation, LBC
estimates the time that Li-ion battery may freeze and transmits a next start time signal to VCM via EV sys-
tem CAN communication to prepare for starting the Li-ion battery heater next time.
• When receiving a next start time signal via EV system CAN communication, VCM transmits a start request
signal (CHG-IGN) to LBC after a lapse of the set time. When receiving a start request signal (CHG-IGN),
LBC activates the Li-ion battery heater.
When EVSE is connected (normal charge)
JSCIA0430ZZ
• When the temperature in the battery pack is low outside the timer charge set time, VCM transmits a keep
SOC request signal to LBC via EV system CAN communication. In this case Li-ion battery is not charged,
and only Li-ion battery heater is activated.
• When timer charge starts at the set time, Li-ion batter is charged, and the Li-ion battery heater is activated.
When EVSE is not connected (normal charge)
JSCIA0431ZZ
• 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.

SYSTEM
EVB
JSCIA1308GB
P

SYSTEM
JSCIA0795GB

SYSTEM
EVB
JSCIA1309GB H
HARNESS LAYOUT

SYSTEM
JSCIA1312GB
: Vehicle front

SYSTEM
EVB
JSCIA0797GB
P
: Vehicle front

HANDLING PRECAUTION
HANDLING PRECAUTION
• To improve the Li-ion battery life, never perform quick charge heavily.
• Lay an anti-static rubber sheet underneath the battery.
• Prevent other objects from falling onto the battery.

A
APPLICATION ITEM B
Item Function EVB

Data Monitor Input/Output data in LBC can be read. D
Work Support
E
itor
F
G
ECU IDENTIFICATION
SELF-DIAGNOSTIC RESULTS H

Regarding items of DTC, refer to EVB-705, "DTC Index". I
How to Erase DTC
2. “SELF-DIAGNOSTIC RESULTS”. J
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT. K

DTC Displays the DTC which caused FFD memory L
M
OPEN /
SERVICE PLUG INTERLOCK Displays the OPEN/CLOSE state of the service plug N
CLOSE
O
ature 1
BATTERY TEMPERATURE 2 °C P
ature 2
ature 3
ature 4
DATA MONITOR

Monitored item Unit Remark

OPEN /
CLOSE
ature 1
ature 2
ature 3
ature 4
WORK SUPPORT

DATA replaced.
TION DATA replaced.
CLEAR BATTERY GRADUAL When all modules of Li-ion bat-
CHARGE INFORMATION DATA erased. tery are replaced.
TION cells.
an abnormal cell, unless it is replaced.

EV BATTERY SYSTEM
ECU DIAGNOSIS INFORMATION A

EV BATTERY SYSTEM
B

NOTE: EVB

D
IR SEN SHORT PULSE READY Approx. 4,100 – 4,300 mV E
F
CELL VOLTAGE 03 READY H
I
Total battery voltage 317 V Approx. 3,200 - 3,400 mV J
CELL VOLTAGE 07 READY K
M
CELL VOLTAGE 12 READY O
P

EV BATTERY SYSTEM

EV BATTERY SYSTEM
A
D
H
K
O

EV BATTERY SYSTEM

EV BATTERY SYSTEM
A
D
H
K
M
20°C - 30°C (68°F - 86°F)
READY (Stop the vehi- O
cle)
20°C - 30°C (68°F - 86°F)
BATTERY TEMPERATURE 2 Ambient temperature: 25°C (77°F) [Equivalent to air temperature P
cle)
20°C - 30°C (68°F - 86°F)
cle)
20°C - 30°C (68°F - 86°F)
cle)

EV BATTERY SYSTEM
The fail-safe mode differs depending on the contents of the detected malfunction.
FAIL-SAFE PATTERN
• Pattern B: Driving output power limit, and Charge stop
FAIL-SAFE LIST
Pattern
A B C D
P303A CELL CONT ASIC10 ×
P303F CELL CONT ASIC15 ×

EV BATTERY SYSTEM
Pattern
A B C D
P3050 CELL CONT ASIC8 VOLT × B
P3053 CELL CONT ASIC11 VOLT × EVB
D
P3058 CELL CONT ASIC16 VOLT × E
F
P305D CELL CONT ASIC21 VOLT × G
H
P3062 BYPASS SW × I
J

K
P3092 CELL CONT ASIC8 OPEN × L
M
P3097 CELL CONT ASIC13 OPEN × N
O
P309C CELL CONT ASIC18 OPEN × P

EV BATTERY SYSTEM
Pattern
A B C D
P30FC OVER CURRENT ×
P31A7 CAN ERROR INV/MC No fail-safe

EV BATTERY SYSTEM
Pattern
A B C D
P331E CELL OVER VOLTAGE MODULE29 × B
P3321 CELL OVER VOLTAGE MODULE32 × EVB
D
P3326 CELL OVER VOLTAGE MODULE37 × E
F
P332B CELL OVER VOLTAGE MODULE42 × G
H
J

K
P337A CELL OVER DISCHARGE MODULE6 × L
M
P337F CELL OVER DISCHARGE MODULE11 × N
O
P3384 CELL OVER DISCHARGE MODULE16 × P

EV BATTERY SYSTEM
Pattern
A B C D
P33D4 BATT GRADUAL CAPA LOSS DIAG ×
P33DB TEMPERATURE SENSOR No fail-safe
P33E2 BATT PACK OVER TEMP ×
P33EA BATTERY HEATER RELAY ×

EV BATTERY SYSTEM
Pattern
A B C D
P33EE BATTERY HEATER CONTROL SYSTEM × B

EVB
EV system
DTC CONSULT screen items warning Trip Reference D
lamp
E
P3031 CELL CONT ASIC1 × 1 EVB-725 F
P3034 CELL CONT ASIC4 × 1 EVB-725 G
H
P3039 CELL CONT ASIC9 × 1 EVB-725 I
J
P303E CELL CONT ASIC14 × 1 EVB-726 K
L
P3043 CELL CONT ASIC19 × 1 EVB-726 M
P3046 CELL CONT ASIC22 × 1 EVB-726 N
O
P304B CELL CONT ASIC3 VOLT × 1 EVB-727 P

EV BATTERY SYSTEM
EV system
lamp

EV BATTERY SYSTEM
EV system
lamp
P30F5 TOTAL VOLT SENSOR × 1 EVB-742 B
EVB
P318E COMMUNICATION ERROR × 1 EVB-748 D
E
P31A4 CAN ERROR VCM × 1 EVB-753 F
G

P3307 CELL OVER VOLTAGE MODULE6 × 1 EVB-756 I
J
P330C CELL OVER VOLTAGE MODULE11 × 1 EVB-756 K
L
P3311 CELL OVER VOLTAGE MODULE16 × 1 EVB-760 M
N
P3316 CELL OVER VOLTAGE MODULE21 × 1 EVB-760 O
P3319 CELL OVER VOLTAGE MODULE24 × 1 EVB-760 P

EV BATTERY SYSTEM
EV system
lamp

EV BATTERY SYSTEM
EV system
lamp
P338D CELL OVER DISCHARGE MODULE25 × 1 EVB-779 B
EVB
P3392 CELL OVER DISCHARGE MODULE30 × 1 EVB-779 D
E
P3397 CELL OVER DISCHARGE MODULE35 × 1 EVB-779 F
G

P339C CELL OVER DISCHARGE MODULE40 × 1 EVB-782 H
P339F CELL OVER DISCHARGE MODULE43 × 1 EVB-782 I
J
P33A4 CELL OVER DISCHARGE MODULE48 × 1 EVB-782 K
L
P33D9 TEMPERATURE SENSOR — 1 EVB-790 M
N
P33E1 BATT VOLTAGE ISOLATION SEN × 1 EVB-794 O
P33E5 TEMPERATURE SENSOR — 1 EVB-796 P
P33EA BATTERY HEATER RELAY × 1 EVB-804

EV BATTERY SYSTEM
EV system
lamp
P33EE BATTERY HEATER CONTROL SYSTEM × 1 EVB-808

VCM
WIRING DIAGRAM A
VCM
B
described in wiring diagram), refer to GI-12, "Connector Information". EVB
JRCWC0089GB

VCM
JRCWC0090GB

VCM
EVB
JRCWC0091GB

VCM
JRCWC0092GB

BASIC INSPECTION A
B
DETAILED FLOW
1.GET INFORMATION FOR SYMPTOM EVB
D
>> GO TO 2.
2.CHECK DTC IN VCM E
Are any DTCs detected? F
NO >> GO TO 3.
3.CHECK DTC G
1. Check DTC.
H
- Erase DTC.
(Symptom Matrix Chart is useful. Refer to EVC-347, "Symptom Index".) I
Symptom is described, DTC is detected>>GO TO 4. J
4.CONFIRM THE SYMPTOM K
and EVB-700, "Fail-safe". L
M
>> GO TO 6.
N
Diagnosis Work Sheet is useful to verify the incident. O
>> GO TO 7. P
again.
NOTE:

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 8.
7.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
step 4, and determine the trouble diagnosis order based on possible causes and symptoms.
YES >> GO TO 8.
Inspect according to Diagnosis Procedure of the system.
YES >> GO TO 9.
2. Reconnect parts or connectors disconnected during Diagnosis Procedure again after repair and replace-
ment.
>> GO TO 10.
10.FINAL CHECK
the symptom is not detected.
DESCRIPTION
There are many operating conditions that lead to the malfunction of
important to fully understand the symptoms or conditions for a cus-
tomer complaint.
tion for troubleshooting.
NOTE:
JSCIA0412GB
WORKSHEET SAMPLE

Question Sheet A
Incident Date VIN
Customer name
MR/MS
B

lamp is on
EVB
Does not charge Other* *: If applied, enter in detail D
Detailed symptom
E
Onomatopoeia

F
Weather
Not affected
conditions G
Temp. [Approx. °C
( °F)] H
road I
Other
J
Driving conditions Not affected K
D position (stop the vehicle) L
M
N
Does not disappear
Other
O
Other

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.

With CONSULT
>> GO TO 2.
Replace LBC. Refer to EVB-848, "LI-ION BATTERY CONTROLLER : Removal and Installation".
>> GO TO 3.
With CONSULT
>> GO TO 4.
4.WRITE THE LBC INTERNAL INFORMATION TO VCM
>> END

A
If a malfunction (e.g. abnormal voltage) occurs in a Li-ion battery cell, the module which includes the malfunc- B
Work Procedure INFOID:0000000011104010 EVB
NOTE:
it is advisable to adjust voltage under room temperature conditions [20°C ± 10°C (68°F ±18°F)]. D

With CONSULT E
1. Power switch ON.
3. Check “MAXIMUM CELL VOLTAGE”. F

G
>> GO TO 2. H
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual. I
J
3.DISCAHRGE OF MODULE VOLTAGE K
CAUTION:
For details on the module charge balancer operation, refer to the adjuster operation manual. L

M
>> GO TO 4.
4.ADJUST VOLTAGE WITH A MODULE CHARGE BALANCER N
CAUTION:
1. Enter “adjustment voltage value” into module charge balancer. O

2. Start the voltage adjustment. P


Standard : Adjustment voltage value ± 10 mV
>> GO TO 6.
With CONSULT
1. After adjusting the voltage, install the module to the vehicle.
range.
>> WORK END

DTC/CIRCUIT DIAGNOSIS A
B
DTC DETECTION LOGIC

EVB
D
With CONSULT
3. Check DTC.
Is P0A1F detected?
H
WARNING:
maintenance.
L
CAUTION:
1.PRECONDITIONING N
WARNING:
1. Remove Li-ion battery. Refer to EVB-829, "Removal and Installation". O
Installation".
P
>> GO TO 2.

LBC
— Continuity
Connector Terminal
YES >> GO TO 3.
LBC
— Continuity
Connector Terminal
YES >> GO TO 4.

Connector Terminal
and Installation".

A

BATTERY ENERGY CON- Self diagnosis program of Li-ion battery controller de- EVB

D
With CONSULT
3. Check DTC.
Is P0A1F detected? F
G

DTC DETECTION LOGIC


With CONSULT
3. Check DTC.
Is P3030 detected?

With CONSULT
2. Check to see if “P30F3” is detected simultaneously with “P3030”.
Is P30F3 detected?
and Installation".

A

P3031 CELL CONT ASIC1 EVB
D

F
P303B CELL CONT ASIC11 G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P3031 -P303C”. M
Is P3030 detected?
NO >> Replace Li-ion battery controller. Refer to EVB-848, "LI-ION BATTERY CONTROLLER : Removal N
and Installation".

DTC DETECTION LOGIC

P303D CELL CONT ASIC13


With CONSULT
3. Check DTC.

With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P303D” -“P3048”.
Is P3030 detected?
and Installation".

A

D
P304E CELL CONT ASIC6 VOLT • Li-ion battery controller E
• Module
F
P3053 CELL CONT ASIC11 VOLT G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check DTC. M


A

D
P305A CELL CONT ASIC18 VOLT • Li-ion battery controller E
• Module
F
P305F CELL CONT ASIC23 VOLT G

With CONSULT
3. Check DTC.
K

With CONSULT
2. Check DTC. M


A

An open circuit diagnosis detection circuit in Li-ion battery EVB

D
With CONSULT
3. Check DTC.
G

P3062 BYPASS SWITCH
P3062 BYPASS SWITCH
DTC DETECTION LOGIC

DTC DETECTION LOGIC

With CONSULT
3. Check DTC.
Is P3062 detected?

With CONSULT
and Installation".

A

P308B CELL CONT ASIC1 OPEN EVB
D
P3090 CELL CONT ASIC6 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller E

F
P3095 CELL CONT ASIC11 OPEN G

With CONSULT
3. Check DTC.
K
WARNING:
L
maintenance. M
N
P
CAUTION:
With CONSULT

OVER DISCHARGE related codes) is detected simultaneously with “P308B”-“P3096”.
“P338D”-“P3398”. Refer to EVB-779, "Diagnosis Procedure"
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
YES >> GO TO 4.
1. Disconnect Li-ion battery controller harness connector and voltage detection terminal of bus bar.
2. Refer to below table and continuity between Li-ion battery controller and voltage detection terminal
of bus bar, according to detected DTC.
JSCIA0813ZZ


DTC Continuity
1 50
P308B LB13 Existed B
2 51
3 52
P308C LB13 Existed
4 53 EVB
5 54
P308D LB13 Existed
6 55
D
7 56
P308E LB13 Existed
8 57
9 58 E
P308F LB13 Existed
10 59
11 Voltage detection terminal of bus 60
P3090 LB13 Existed F
12 bar 61
13 62
P3091 LB13 Existed
14 63
G
15 77
P3092 LB14 Existed
16 78
17 80 H
P3093 LB14 Existed
18 81
19 82
P3094 LB14 Existed I
20 83
21 84
P3095 LB14 Existed
22 85 J
23 86
P3096 LB14 Existed
24 87
K
and Installation". L

DTC DETECTION LOGIC

P309C CELL CONT ASIC18 OPEN Self diagnosis program of Li-ion battery controller de- • Li-ion battery controller

DTC DETECTION LOGIC

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

OVER DISCHARGE related codes) is detected simultaneously with “P3097”-“P30A2”. A
EVB
“P338D”-“P3398”. Refer to EVB-779, "Diagnosis Procedure". E
NO >> GO TO 2.
F
2.PRECONDITIONING
WARNING:
Installation". H
>> GO TO 3.
YES >> GO TO 4.
K
DTC.

DTC Continuity
25 73 110
26 74 111 N
27 60 112
28 77 113
O
29 78 114
30 64 115
31 81 116 P
32 82 117
33 68 118
34 85 119
35 86 120
36 72 121


DTC Continuity
37 89 122
38 90 123
39 91 124
40 92 125
41 93 127
42 94 128
43 95 130
44 96 138
45 97 140
46 98 141
47 99 142
48 100 143
and Installation".

A


With CONSULT E
3. Check DTC. F
Is P30F3 detected?
With CONSULT
2. Check to see if “P3030” is detected simultaneously with “P30F3”. I
J
and Installation".

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
Is P30F4 detected?
WARNING:
maintenance.
CAUTION:
With CONSULT
2. Check if any DTC is detected in “Self Diagnostic Result”.
Just “P30F4” is detected>>GO TO 2.
2.CHECK FUSE

3.PRECONDITIONING A
WARNING:
1. Remove Li-ion battery. Refer to EVB-829, "Removal and Installation". B
Installation".
EVB
>> GO TO 4.
Check connection status between each stack and connection status of each bus bar. D
YES >> GO TO 5.
NO >> Recover the connection status. E

Check the voltage of all modules. F
and Installation". G
(Rear module). H


K
Terminals
Voltage
(+) (-)
(Approx.)
Module L
M
JSCIA0338ZZ P

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
Is P30F5 detected?

With CONSULT
YES >> Perform diagnosis on the detected “P30F4”. Refer to EVB-740, "Diagnosis Procedure".
and Installation".

P30FC OVER CURRENT
P30FC OVER CURRENT
A

When the temperature of the entire battery pack estimat- • Battery current sensor EVB
P30FC OVER CURRENT

D
With CONSULT
3. Check DTC.
Is P30FC detected? F
G
1.PERFORM THE SELF-DIAGNOSIS H

With CONSULT
I
NO >> GO TO 2. J
With CONSULT
Using FFD, check the values of four temperature sensors when DTC is detected. K

L
Battery temperature sensor 3 M
Temperature increase is seen>>Replace Li-ion battery. Refer to EVB-829, "Removal and Installation". N
Temperature increase is not seen>>Replace battery junction box. Refer to EVB-853, "BATTERY JUNCTION
BOX AND BATTERY HARNESS : Disassembly and Assembly".
O

DTC DETECTION LOGIC

• Total voltage detection switch in Li-ion battery control-

With CONSULT
3. Check DTC.
Is P30FC detected?

A

• 12V battery EVB
• Harness

D
With CONSULT
3. Check DTC.
Is P30FE detected? F
G
WARNING:
maintenance. I
L
CAUTION:
Check the voltage of 12 V battery using circuit tester. N
YES >> GO TO 2.
NO >> Replace 12 V battery. Refer to PG-101, "Removal and Installation". O
2.CHECK FUSE
2. Check 20A fuse [No.43]. P
NOTE:
YES >> GO TO 3.
2. Check voltage between Li-ion battery harness connector and ground.
+
Connector Terminal
Battery
B24 5 Ground
voltage
YES >> GO TO 4.
4.PRECONDITIONING
WARNING:
Installation".
>> GO TO 5.
1. Disconnect Li-ion battery harness connector and Li-ion battery controller harness connector.
tor.

Continuity
and Installation".

A

• CAN communication line EVB
ROR uously.
• VCM

With CONSULT E
3. Check DTC. F
Is P318D detected?
For the diagnosis procedure, refer to LAN-15, "Trouble Diagnosis Flow Chart". H

DTC DETECTION LOGIC

NOTE:

• VCM
ROR continuously.

With CONSULT
7. Check DTC.
Is P318E detected?

With CONSULT
Is P318E detected?
YES >> Replace VCM. Refer to EVC-369, "Removal and Installation".
NO >> GO TO 2.
With CONSULT
2. Check to see if “U1000” is detected simultaneously with “P318E”.
Is U1000 detected?
and Installation".

A

NOTE:

• Traction motor inverter D

With CONSULT
F
7. Check DTC.
Is P3191 detected?
J
With CONSULT
Is P3191 detected?
YES >> Replace traction motor inverter. Refer to TMS-115, "Removal and Installation" L
NO >> GO TO 2.
With CONSULT
Is U1000 detected?

DTC DETECTION LOGIC

NOTE:

• On board charger

With CONSULT
7. Check DTC.
Is P3196 detected?

With CONSULT
Is P3196 detected?
YES >> Replace on board charger. Refer to VC-105, "Removal and Installation"
NO >> GO TO 2.
With CONSULT
Is U1000 detected?
and Installation".

A

COMMUNICATION ER- • VCM EVB

D
With CONSULT
3. Check DTC.
G
H

DTC DETECTION LOGIC

COMMUNICATION ER- • Traction motor inverter

With CONSULT
3. Check DTC.
Is P319C detected?

P31A4 CAN ERROR VCM
P31A4 CAN ERROR VCM
A

If the CAN data from VCM has not change from the value EVB

D
With CONSULT
3. Check DTC.
G
H

DTC DETECTION LOGIC

If the CAN data from traction motor inverter has not

With CONSULT
3. Check DTC.
Is P31A7 detected?

A

• Li-ion battery EVB
range. • VCM
D
With CONSULT
3. Check DTC. F
Is P3300 detected?
G
H
With CONSULT
1. Perform "All DTC Reading". I
YES >> After performing trouble diagnosis of detected DTC, GO TO 2. J
NO >> GO TO 2.
K
With CONSULT
L
M
• When “P331A” - “P3325” are detected simultaneously, perform the diagnosis procedure of N
“P3326” - “P3331”. Refer to EVB-767, "Diagnosis Procedure". O
and Installation".

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
bar . F
M
JSCIA0812GB


DTC Continuity
33
34
34
35
35
36
36
37
37
38
38
Bus bar
39
39
40
40
42
42
43
43
44
44
45
45
46
YES >> GO TO 4.

Assembly".


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

JSCIA0338ZZ

DTC DETECTION LOGIC

• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
bar . F
M
JSCIA0812GB


DTC Continuity
46
47
47
48
LB13 48
P3310 15 77 Existed
LB14
65
65
66
66
69
69
Bus bar
70
70
71
71
72
72
73
73
74
74
75
75
76
YES >> GO TO 4.

Assembly".


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

JSCIA0338ZZ

DTC DETECTION LOGIC

P331F CELL OVER VOLTAGE MODULE30 tion
• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
With CONSULT
G
DTC Continuity
57 89 H
58 90
I
58 90
75 91 J
75 91
K
76 92
76 92
P331D 28 LB8 77 LB15 113 Existed L
62 93
62 93
M
79 94
79 94 N
80 95
80 95 O
P3320 31 LB8 81 LB15 116 Existed
66 96
P
66 96
P3321 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity
83 97
P3322 33 LB8 68 LB15 118 Existed
84 99
84 99
P3323 34 LB8 85 LB15 119 Existed
70 100
70 100
P3324 35 LB8 86 LB15 120 Existed
87 101
87 101
P3325 36 LB8 72 LB15 121 Existed
88 102
YES >> GO TO 4.
and Installation".
Assembly".


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

A

D
P332B CELL OVER VOLTAGE MODULE42 When cell voltage exceeds the allowable • Module E
• Bus bar
F

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT

DTC Continuity
LB8 88 102
P3326 37 89 LB15 122 Existed
LB7
101 103
101 103
P3327 38 LB7 90 LB15 123 Existed
102 104
102 104
P3328 39 LB7 91 LB15 124 Existed
103 105
103 105
P3329 40 LB7 92 LB15 125 Existed
104 106
104 106
105 107
105 107
106 108
106 LB15 108
LB16
107 130
107 130
108 131


DTC Continuity A
108 131
109 132
109 132
110 133
110 133
D
P3330 47 LB7 99 LB16 142 Existed
111 134
111 134 E
P3331 48 LB7 100 LB16 143 Existed
112 135
F
YES >> GO TO 4.
H
and Installation".
Assembly".
J

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

DTC DETECTION LOGIC

"DTC Logic".

• Module
• Bus bar

With CONSULT
3. Check DTC.
Is P3373 detected?

With CONSULT
NO >> GO TO 2.
2.PERFORM THE SELF-DIAGNOSISS OF LI-ION BATTERY CONTROLLER
With CONSULT
YES >> • When “P3375”-“P3380” are detected simultaneously, perform the diagnosis procedure of
and Installation".

A

D
P337A CELL OVER DISCHARGE MODULE6 When cell voltage lowers below the • Module E
• Bus bar
F
P337F CELL OVER DISCHARGE MODULE11 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
bar .
JSCIA0812GB


DTC Continuity
33
B
34
34 EVB
35
D
35
36 E
36
37
F
37
G
38
38
P337A 6 LB13 55 Existed H
Bus bar
39
39
I
40
40 J
42
K
42
43 L
43
M
44
44
P330F 11 LB13 60 Existed N
45
45
P3380 12 LB13 61 Existed O
46
YES >> GO TO 4.

and Installation".
Assembly".


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

A

D
• Module
P338B CELL OVER DISCHARGE MODULE23 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
bar .
JSCIA0812GB


DTC Continuity
46
B
47
47 EVB
48
D
LB13 48
P3383 15 77 Existed
LB14
65 E
65
66
F
66
G
69
69
Bus bar
70
70
I
71
71 J
72
K
72
73 L
73
M
74
74
P338B 23 LB14 86 Existed N
75
75
P338C 24 LB14 87 Existed O
76
YES >> GO TO 4.

and Installation".
Assembly".


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

A

P338D CELL OVER DISCHARGE MODULE25 EVB
D
• Module
P3397 CELL OVER DISCHARGE MODULE35 G

H
With CONSULT
3. Check DTC.
K
WARNING:
maintenance. M
CAUTION: P
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".
>> GO TO 3.
With CONSULT

DTC Continuity
57 89
58 90
58 90
75 91
75 91
76 92
76 92
P3390 28 LB8 77 LB15 113 Existed
62 93
62 93
P3391 29 LB8 78 LB15 114 Existed
79 94
79 94
P3392 30 LB8 64 LB15 115 Existed
80 95
80 95
P3393 31 LB8 81 LB15 116 Existed
66 96
66 96
P3394 32 LB8 82 LB15 117 Existed
83 97


DTC Continuity A
83 97
P3395 33 LB8 68 LB15 118 Existed B
84 99
84 99
70 100
70 100
D
P3397 35 LB8 86 LB15 120 Existed
87 101
87 101 E
P3398 36 LB8 72 LB15 121 Existed
88 102
F
YES >> GO TO 4.
H
and Installation".
Assembly".
J

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

DTC DETECTION LOGIC

P339E CELL OVER DISCHARGE MODULE42 function
• Module

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
With CONSULT

NO >> GO TO 2.
2.PRECONDITIONING B
WARNING:
Installation".
D
>> GO TO 3.
With CONSULT
G
DTC Continuity
LB8 88 102 H
P3399 37 89 LB15 122 Existed
LB7
101 103
I
101 103
102 104 J
102 104
K
103 105
103 105
P339C 40 LB7 92 LB15 125 Existed L
104 106
104 106
M
105 107
105 107 N
106 108
106 LB15 108 O
LB16
107 130
P
107 130
108 131


DTC Continuity
108 131
109 132
109 132
110 133
110 133
111 134
111 134
P33A4 48 LB7 100 LB16 143 Existed
112 135
YES >> GO TO 4.
and Installation".
Assembly".


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

A

BATT GRADUAL CAPA LOSS When the battery charge lowers. EVB

D
With CONSULT
3. Check DTC.
G
H

DTC DETECTION LOGIC

Deviation in characteristics of battery current sensor sig- • Li-ion battery controller

With CONSULT
3. Check DTC.
Is P33D5 detected?
WARNING:
maintenance.
CAUTION:
1.CHECK SELF-DIAGNOSIS RESULTS OF VCM
With CONSULT
2. Check to see if “P0AA0”, “P0AA1” or “P0AA4” is detected.
NO >> GO TO 2.
2.PRECONDITIONING
WARNING:
Installation".

>> GO TO 3. A
Check connection status of Li-ion battery controller harness connector and current sensor harness connector. B
YES >> GO TO 4.
NO >> Recover the connection status. EVB
4. CHECK HARNESS BETWEEN CURRENT SENSOR AND LI-ION BATTERY CONTROLLER
Check continuity between current sensor harness connector and Li-ion battery controller harness connector.
D
Current sensor Li-ion battery controller

Continuity
Connector Terminal Connector Terminal E
S 10
LB5 V LB11 9 Exited
G 17 F
YES >> GO TO 5.
G
Check resistance of current sensor. H
Current sensor Resistance val-

Connector Terminal Terminal ue I
S G
V G J
YES >> GO TO 6.
NO >> Replace current sensor. K
L

M
YES >> Replace current sensor. Refer to EVB-851, "BATTERY JUNCTION BOX AND BATTERY HAR- N

DTC DETECTION LOGIC

Deviation from the specified voltage characteristics of

With CONSULT
3. Check DTC.
Is P33D6 detected?
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.

Resistance value
Connector Terminal

10 9
LB11 1 kΩ–10 MΩ A
9 17
YES >> Replace Li-ion battery controller. Refer to EVB-848, "LI-ION BATTERY CONTROLLER : Removal B
and Installation".
NO >> GO TO 3.
3.CHECK HARNESS BETWEEN LI-ION BATTERY CONTROLLER AND CURRENT SENSOR EVB
1. Disconnect current sensor harness connector.
2. Check continuity between Li-ion battery controller and current sensor.
D
Li-ion battery controller Current sensor
Continuity
E
10 S
LB11 9 LB5 V Existed
17 G F
NESS : Exploded View". G

DTC DETECTION LOGIC

P33D7
or too low.
or too low.
Battery temperature sensor 3 signal voltage is too high • Harness or connector
P33DB
or too low.
P33DD
or too low.

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.

2.CHECK HARNESS A
Is the inspection result normal? B
YES >> GO TO 3.
3.CHECK BATTERY TEMPERATURE SENSOR EVB
D
YES >> GO TO 4.
4.CHECK HARNESS BETWEEN BATTERY TEMPERATURE SENSOR AND GROUND E
F
Battery tem-
sor
G
1 LB9 1
2 LB10 4
Ground No existed
3 LB9 3 H
4 LB10 2
I
and Installation".
J
1.CHECK BATTERY TEMPERATURE SENSOR K

module). L
Battery temperature sensor Terminals Condition Resistance (kΩ) M

1 1 and 5
10 (50) Approx. 7.4
2 3 and 4
3 3 and 7 25 (77) Approx. 4.0 N
4 1 and 2 40 (104) Approx. 2.3
P

DTC DETECTION LOGIC

BAT VOLTAGE ISOLA- Signal voltage of the on-board isolation resistance moni-

With CONSULT
3. Check DTC.
Is P33DF detected?

A

BATTERY VOLTAGE ISO- Signal Voltage of the on-board isolation resistance mon- EVB

D
With CONSULT
3. Check DTC.
G

DTC DETECTION LOGIC

BATTERY VOLTAGE ISO- Signal voltage of the on-board isolation resistance moni-

With CONSULT
3. Check DTC.
Is P33E1 detected?
ponent Inspection".

A

BATTERY PACK OVER When the battery (battery pack) temperature is excessively Overcharge caused by traction EVB
P33E2

D
With CONSULT
3. Check DTC.
G

H
With CONSULT
I
dure".
NO >> GO TO 2. J

With CONSULT K
Monitor item Condition Limit L

Power switch ON 55°C (131°F) or less M
Is there temperature increase? N
Temperature increase is not seen>>Replace battery temperature sensors. Refer to EVB-878, "FRONT
MODULE STACK : Disassembly and Assembly" (Front module) or EVB-893, "REAR MODULE O
STACK : Disassembly and Assembly" (Rear module).

DTC DETECTION LOGIC

P33E4
P33E5
rear RH or front LH.

With CONSULT
3. Check DTC.
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.

A
1.CHECK BATTERY TEMPERATURE SENSOR B

module).
2. Check resistance between battery temperature sensor terminals. EVB

D
1 1 and 5
10 (50) Approx. 7.4
2 3 and 4
3 3 and 7 25 (77) Approx. 4.0 E
4 1 and 2 40 (104) Approx. 2.3
F

DTC DETECTION LOGIC

With the power switch ON and no load condition, the dif-

With CONSULT
3. Check DTC.
Is P33E6 detected?
WARNING:
maintenance.
CAUTION:
With CONSULT
EVB-848, "LI-ION BATTERY CONTROLLER : Removal and Installation".
EVB-806, "Diagnosis Procedure".
NO >> GO TO 2.
With CONSULT
of cells).

Average cell voltage = “TOTAL BETTER VOLTAGE” ÷ 96 (the number of cells) A

B
EVB
STACK : Disassembly and Assembly" (Rear module stack). After replacing module, GO TO 3. D
STACK : Disassembly and Assembly" (Rear module stack). After replacing module, GO TO 3. E
With CONSULT
F
Is “MINIMUM CELL VOLTAGE” 3,712 mV or less? G
YES >> GO TO 5.
NO >> GO TO 4.
H
With CONSULT
1. Set the vehicle to READY. I
A/C set temperature : Full hot J

K
3. Check “DATA MONITOR” and let the Li-ion battery discharge until the “MINIMUM CELL VOLTAGE” L
NOTE:
M
The number of light- N

ing segments of Li-
Time to 2 segments
charge gauge
O

P
6 Approx. 90 minute
5 Approx. 70 minute

ing segments of Li-
Time to 2 segments
charge gauge
4 Approx. 40 minute
3 Approx. 20 minute
>> GO TO 5.
With CONSULT
VALUE” is displayed.
NO >> Check the minimum cell voltage on the data monitor and replace a module which includes the
6.PRECONDITIONING
WARNING:
Installation".
>> GO TO 7.
YES >> GO TO 8.
YES >> GO TO 9
DANGER:
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.
and Installation".
TOR
1. Disconnect Li-ion battery controller harness connector and module harness connector. A
B
Resistance val-
Terminal
ue
Li-ion battery control- Module harness EVB
Approx. 0 Ω
Is the inspection result normal? D
YES >> GO TO 11
11.CHECK HARNESS BETWEEN MODULE HARNESS CONNECTOR AND BUS BAR E
1. Check the resistance module harness connector and bus bar of the determined cell at step 5.
F
JSCIA0811GB
M
Resistance val-
Terminal N
ue
Module harness con-
nector
2. Check the divergence of the resistance and the resistance of other cell harness. O
NO >> Repair or replace harness or connectors. P
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.
JSCIA0812GB
Resistance val-
Terminal
ue
Li-ion battery control-
ler harness connector

A

The A/D converter in Li-ion battery controller is malfunc- EVB
tioning.

D
With CONSULT
3. Check DTC.
G

DTC DETECTION LOGIC

Li-ion battery controller judges that the status of a relay control
signal transmitted from Li-ion battery controller and that of a
P33EA BATTERY HEATER RELAY • Heater relay unit
relay status signal transmitted from heater relay unit do not
match.
NOTE:
• The Li-ion battery controller transmits a relay control signal to the heater relay unit and turns ON/OFF the
relay built-in the heater relay unit.
• The heater relay unit turns ON/OFF the built-in relay, according to a relay control signal transmitted from the
Li-ion battery controller, and transmits a relay status signal (the ON/OFF status of the built-in relay) to the Li-
ion battery controller.
With CONSULT
1. Select “ACTIVE TEST” of “HV BAT.”
2. Select “HEATER RELAY UNIT.” Touch “START.”
>> GO TO 2.
With CONSULT
2. Check DTC.
Is P33EE detected?
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:

1. Remove Li-ion battery. Refer to EVB-829, "Removal and Installation". A
Installation".
B
>> GO TO 2.
2.CHECK CONTINUITY LI-ION BATTERY CONTROLLER AND HEATER RELAY UNIT
EVB
1. Remove service plug switch bracket. Refer to EVB-851, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Exploded View".
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. D
Lli-ion battery controller Heater relay unit

Continuity E
20 3
LB11 LB17 Existed
4 6
F
YES >> GO TO 3.
3.CHECK CONTINUITY LI-ION BATTERY AND HEATER RELAY UNIT
Check continuity li-ion battery harness connector and heater relay unit harness connector.
H
Lli-ion battery Heater relay unit

Continuity
Connector Terminal Connector Terminal I
J
YES >> GO TO 4.
4.CHECK CONTINUITY HEATER RELAY UNIT AND LI-ION BATTERY CONTROLLER K
Check continuity heater relay unit harness connector and li-ion battery controller harness connector.
Heater relay unit Li-ion battery controller L

Continuity
4
3 M
8
LB17 LB11 Existed
7 15
5 16 N
YES >> Replace to shown in the below.
• Li-ion battery controller. Refer to EVB-848, "LI-ION BATTERY CONTROLLER : Removal and O
Installation".
• Heater relay unit. Refer to EVB-868, "LI-ION BATTERY HEATER RELAY UNIT : Disassembly
and Assembly".
P

DTC DETECTION LOGIC

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

1.CHECK LI-ION BATTERY AVAILABLE CHARGE GAUGE
NOTE:
Check 12 segments for lighting status.
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.
>> GO TO 4.
With CONSULT
3. Check DTC.
Is P33ED detected?

With CONSULT

YES >> Replace corresponding Module. Refer to EVB-878, "FRONT MODULE STACK : Disassembly and
Assembly" (Front module) or EVB-893, "REAR MODULE STACK : Disassembly and Assembly" A
(Rear module).
NO >> GO TO 2.
2.DTC CONFIRMATION PROCEDURE OPERATION B
EVB
>> Replace corresponding Module. Refer to EVB-878, "FRONT MODULE STACK : Disassembly and
(Rear module). D

DTC DETECTION LOGIC

Under extremely low temperatures that Li-ion battery heater
BATTERY HEATER CON- • Heater relay unit
P33EE activates, Li-ion battery controller judges that the temperature
TROL SYSTEM • Li-ion battery heater
of Li-ion battery is still low after a lapse of specified time.
WARNING:
maintenance.
CAUTION:
1.PRECONDITIONING
WARNING:
Installation".
>> GO TO 2.
2.CHECK INSTALLATION CONDITION OF LI-ION BATTERY HEATER
Check the main body of Li-ion battery heater for installation condition.
YES >> GO TO 3.
NO >> Tighten the mounting nut of the Li-ion battery heater to the specified torque. Refer to EVB-861,
"LI-ION BATTERY HEATER : Exploded view".
3.CHECK CONNECTION STATUS OF LI-ION BATTERY HEATER CONNECTOR
Check the connection status of the Li-ion battery heater connector.
YES >> GO TO 4.
NO >> Restore the connection status of the Li-ion battery heater connector.
4.CHECK RESISTANCE OF LI-ION BATTERY HEATER
Check resistance of Li-ion battery heater.

Li-ion battery heater A

Resistance
Item Terminal
LH 1
B
LH 2
RH 1
RH 2 EVB
RR 1
RR 2
D
YES >> GO TO 5.
NO >> Replace applicable Li-ion battery heater. Refer to EVB-868, "LI-ION BATTERY HEATER RELAY E
UNIT : Disassembly and Assembly".
5.CHECK CONTINUITY OF LI-ION BATTERY HEATER AND BATTERY JUNCTION BOX
1. Disconnect Li-ion battery heater and battery junction box harness connector. F
2. Check continuity Li-ion battery heater and battery junction box harness connector.
Li-ion battery heater Battery junction box G

Continuity
Item Connector Terminal Connector Terminal
LH 1 LB19 2
H
LH 2 LB20 2
RH 1 LB23 2
LB25 15 Existed
RH 2 LB24 2 I
RR 1 LB21 2
RR 2 LB22 2
J
YES >> GO TO 6
K
6.CHECK CONTINUITY OF LI-ION BATTERY HEATER AND HEATER RELAY UNIT
1. Disconnect Li-ion battery heater and heater relay unit harness connector harness connector.
2. Check continuity Li-ion battery heater and heater relay unit harness connector harness connector. L
Li-ion battery heater Heater relay unit

Continuity
Item Connector Terminal Connector Terminal M
LH 1 LB19 1
LH 2 LB20 1
N
RH 1 LB23 1
LB18 11 Existed
RH 2 LB24 1
RR 1 LB21 1 O
RR 2 LB22 1
P
YES >> Replace heater relay unit. Refer to EVB-868, "LI-ION BATTERY HEATER RELAY UNIT : Disas-

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

When no CAN communication signal is received continu-

A
WARNING: B
EVB
maintenance.
before beginning work on the high voltage system. E
• Refer to EVB-666, "High Voltage Precautions". F
CAUTION:
service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do G
battery is judged that its insulation resistance is dropping. H
With CONSULT I
1. Power switch ON.
NOTE: J
>> GO TO 2 K
CAUTION: L
2. Remove Li-ion battery controller. Refer to EVB-848, "LI-ION BATTERY CONTROLLER : Removal and M
Installation".
4. Measure voltages between positive terminal of front module stack LH and battery pack ground, and N
JSCIA0739ZZ

+
Terminal

YES >> GO TO 8.
NO >> GO TO 3.
JSCIA0739ZZ
+
Terminal

NO >> GO TO 4.
JSCIA0739ZZ

+ A
Terminal
B

YES >> GO TO 5. EVB
NO >> GO TO 6.
5.CHECK SERVICE PLUG SWITCH INSULATION RESISTANCE D
E
WARNING:
danger of damage to electronic devices. Read the insulation resistance tester instruction manual F
CAUTION:
Be sure to set the insulation resistance tester to 500 V when performing this test. Using a setting G
NOTE:
H
+ — Resistance
I
NO >> Replace service plug switch (Refer to EVB-851, "BATTERY JUNCTION BOX AND BATTERY J
HARNESS : Exploded View".) and GO TO 8.
6.CHECK MODULE-1
1. Remove front module stack LH. Refer to EVB-878, "FRONT MODULE STACK : Disassembly and Assem- K
bly".
NOTE:
Do not disassemble module stack. L
M
O
JSCIA0740ZZ
P
+
Module − Voltage
Terminal

YES >> GO TO 7.
7.CHECK MODULE-2
WARNING:
CAUTION:
+
Terminal

GO TO 8.
JSCIA0741ZZ
+
Terminal

YES >> GO TO 14.

NO >> GO TO 9.
9.CHECK INSULATION OF FRONT MODULE STACK RH-2 A

B
EVB
E
JSCIA0741ZZ
: Battery pack front F
+ G
Terminal
H

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

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


WARNING:

CAUTION:

— Resistance
Terminal

NO >> Replace battery junction box (Refer to EVB-853, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Disassembly and Assembly") and GO TO 14.
12.CHECK MODULE-3
bly".
NOTE:
JSCIA0740ZZ
+
Module − Voltage
Terminal

YES >> GO TO 13.

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

YES >> Check insulation resistance of front module stack RH, because front module stack LH is normal. H
GO TO 14.
and Assembly".) and GO TO 14. I
between positive terminal of rear module stack and battery pack ground. J
M
JSCIA0744ZZ
+ N
Terminal
O

YES-1 >> Replace or repair of malfunctioning part is not-yet performed: Replace Li-ion battery controller. P
NO >> GO TO 15.

module stack.
JSCIA0146ZZ
JSCIA0744ZZ
+
Terminal

NO >> GO TO 16.
1. Remove mounting nuts / and remove high voltage harness from rear module stack.
JSCIA0743ZZ

EVB
JSCIA0744ZZ
D
+
E
Terminal

NO >> GO TO 17.
17.CHECK MODULE-5 G
NOTE:
Do not disassemble module stack. H
I
K
JSCIA0740ZZ
L
+
Module − Voltage
M
Terminal

N

YES >> GO TO 18. O
Assembly".
18.CHECK MODULE-6 P

in rear module stack and module body.
WARNING:
CAUTION:
+
Terminal

Assembly".

A
WARNING: B
EVB
maintenance.
• Clearly identify the persons responsible for high voltage work and ensure that other persons do not E
CAUTION: F
so in the Service Manual. G
1. PRECONDITIONING
WARNING:
H
Installation". I
>> GO TO 2.
J
2.CHECK HIGH VOLTAGE HARNESS
Check the harness shield between the heater relay unit and the Li-ion battery heater for scratches and cracks.
Is the inspection result normal? K
YES >> GO TO 3.
NO >> Repair or replace error-detected parts and Li-ion battery controller.
3.CHECK HEATER RELAY UNIT INSULATION RESISTANCE L
WARNING:
M
1. Disconnect high voltage harness connector from heater relay unit. N
NOTE:
2. Use 500 V range of insulation resistance tester to measure insulation resistance. Wait for 30 seconds until O
CAUTION:
higher than 500 V can result in damage to the component being inspected. P
Heater relay unit

Ground Resistance
Terminal
10
Battery pack lower case 1000 MΩ or more
11

YES >> GO TO 4.
NO >> Replace heater relay unit and Li-ion battery controller.
4.CHECK LI-ION BATTERY HEATER
WARNING:
1. Disconnect high voltage harness connector from Li-ion battery heater.
NOTE:
CAUTION:
Li-ion battery heater

Ground Resistance
Item Connector Terminal
1
2
1
2
1
2
Battery pack lower case
1
2
1
2
1
2
YES >> GO TO 5.
NO >> Replace corresponding Li-ion battery heater and Li-ion battery controller.
5.CHECK HIGH VOLTAGE HARNESS INSULATION RESISTANCE
WARNING:
CAUTION:
Be sure to set the insulation resistance tester to 500V when performing this test. Using a setting
High voltage harness

Ground Resistance
Connector Terminal
LB18 11 Battery pack lower case 1000 MΩ or more

YES >> INSPECTION END.
NO >> Replace high voltage harness. A
EVB

WARNING:
maintenance.
CAUTION:
1.CHECK FUSE

Battery 43
55
Power switch ON
74
Is the fuse fusing?
NO >> GO TO 2.
+
Connector Terminal
6
8
YES >> GO TO 3.

+ A
Connector Terminal
B
12V battery power
B24 5 Ground
supply
YES >> GO TO 5.
NO >> GO TO 4.
E
+
No.43 fuse ter-
B24 5 Existed
minal
+
J
Voltage
Li-ion battery −
(Approx.)
Connector Terminal
4 K
21
YES >> GO TO 8.
NO >> GO TO 6.
nector.

Continuity
P
YES >> GO TO 7.

Li-ion battery
— Continuity
Connector Terminal
No.74 fuse ter-
B24 21 Existed
minal
8.PRECONDITIONING
WARNING:
Installation".
>> GO TO 9.
LBC Li-ion battery

Continuity
5 21
6 4
21 5
LB11 LB1 Existed
3 8
15 7
16 6

SYMPTOM DIAGNOSIS A
B
EVB

NOTE:

YES >> GO TO 3. F
NO >> GO TO 2.

J
>> GO TO 3.
K
>> GO TO 4. M
With CONSULT N
3. Check DTC.
O
P


operation manual.

LI-ION BATTERY

LI-ION BATTERY
B
EVB
N
JSCIA1373GB
Li-ion battery Bonding plate (stamped No. 4.) Li-ion battery undercover (front)
O
Li-ion battery undercover (center) Li-ion battery undercover (rear) Clip
Battery mounting bracket (left) Battery mounting bracket (right)
: N-m (kg-m ft-lb) P
DANGER:

LI-ION BATTERY
WARNING:
CAUTION:
REMOVAL
WARNING:
Prepare for work on the high-voltage system. Refer to GI-31, "How to Disconnect High Voltage".
1. Lift up the vehicle and remove the Li-ion battery undercover. Refer to EVB-829, "Exploded View".
2. Remove the harness clamp and disconnect the Li-ion battery
high-voltage harness connector .
DANGER:

tective gear.
JSCIA1374GB
• Because there is the danger of electric shock, imme-

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

while rotating it in the counterclockwise direction.
WARNING:

gear.
JSCIA1375GB

LI-ION BATTERY
4. Remove bonding plate .

A
WARNING:

gear. B
EVB
JSCIA0559ZZ
D
5. Remove Li-ion battery mounting bolts .
WARNING:
E
gear.
F
CAUTION:
Do not remove the 4 bolts shown by in the figure. G
JSCIA0560ZZ
6. Set the pallet [SST: — (J-50583)] onto the lift table. H

• Align the pallet center mark and the lift table center
mark .
I
Front
Side
J
JSCIA0178ZZ
O
7. Set the pallet onto the Li-ion battery.
CAUTION:
For preventing the battery from falling, fasten the pallet and
P
battery with transport fastening bolts.
JSCIA0179ZZ

LI-ION BATTERY
8. Remove the Li-ion battery mounting bolts (4 bolts) .
JSCIA0561ZZ
WARNING:
9. Lower the pallet, and remove the Li-ion battery from the vehi-
cle.
WARNING:

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

2. Move the lift table.
3. Lower the Li-ion battery.
4. Operate the stacker and move the Li-ion battery.
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
(old) Li-ion battery and to the “Li-ion battery replacement history record”.

LI-ION BATTERY
2. Install the locating pin [SST: KV99111300 (J-50306)] in the position on the body as shown in the figure.
A
EVB
JSCIA0182ZZ
F
: Vehicle front

G
• Align the Li-ion battery and the locating pin .
WARNING:
To prevent electric shock, wear insulated protective H

gear.
J
JSCIA0183ZZ
4. Tighten the Li-ion battery mounting bolts (4 bolts) , then remove the pallet.
K
JSCIA0561ZZ
WARNING: N

O
5. Remove the locating pin from the body. P

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

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

WARNING:

gear.
JSCIA0560ZZ
7. Install the bonding plate .

WARNING:

gear.
JSCIA0559ZZ
8. After installing the bonding plate, perform an electric equipotential test. EVB-835, "Inspection".
9. Rotate the vehicle communications connector clockwise to
connect it.
WARNING:

gear.
JSCIA1376GB

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

gear.
EVB
JSCIA1374GB
D
• Connect the high-voltage harness connector by the following procedure.
G
JPCIA0036ZZ
11. Install the Li-ion battery undercover.

12. Install the service plug Refer to GI-31, "How to Disconnect High Voltage". H
I
After installing the Li-ion battery, measure the resistance between the battery pack ground bolt and the body
ground. J
O
JSCIA1377GB
WARNING:
To prevent electric shock, wear insulated protective gear. P


LI-ION BATTERY
• 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

LI-ION BATTERY
UNIT DISASSEMBLY AND ASSEMBLY A

LI-ION BATTERY
BATTERY PACK UPPER CASE
B
BATTERY PACK UPPER CASE : Exploded View INFOID:0000000011400538
EVB
JSCIA0565GB

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

Seal Plug Plug washer
Breather
Battery pack case side
sembly.
BATTERY PACK UPPER CASE : Removal and Installation INFOID:0000000011400539
DANGER:
maintenance.
WARNING:
CAUTION:
4. Work space
guisher).
REMOVAL
LI-ION BATTERY
1. Clean any dust or dirt adhered to the battery pack.
2. Remove the service plug retainer . A
WARNING:

EVB
JSCIA0143ZZ
D
3. Remove the battery pack upper case mounting bolts and ground bolts .
E
JSCIA0571GB J
WARNING:
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

LI-ION BATTERY
b. Use the windshield cutter and cut the adhesive in the order from 1 to 4 as shown in the figure.
JSCIA0655ZZ
JSCIA0699ZZ
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-
• 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: 999MP-
43533PP).

NOTE:
• Because there is no clearance at the embossed part, cut the adhesive there last.

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.

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: 999MP-43533PP).

- If the paint sealant damage on a corner is damaged, repair by applying primer (adhesive primer:
999MP-43533PP).
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

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
JSCIA0634ZZ
D
4. Apply dam rubber (KA390-0059U) on the inside of the old adhesive on the battery pack lower case.
G
JSCIA0578ZZ
C : 10 mm (0.39 in)
H
WARNING:

I
CAUTION: J
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,
K
then the next time the battery pack is disassembled, the windshield cutter may not be able to reach the
adhesive and removing the battery pack upper case may be difficult.
5. Apply adhesive (999MP-57302NP) to the battery pack lower case as shown in the figure. L
WARNING:
To prevent electric shock, wear insulated protective gear. M

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

: Old adhesive : Dam rubber
E : 50 mm (1.97 in) or more
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 12 minutes. [Humidity: 80%, Temperature: 35°C (95°F)]
• Before installing the battery pack upper case, check that there are no locations of insufficient
adhesive. If there is insufficient adhesive, correct the location. (If the adhesive height is lower
than the height of the dam rubber, then the amount of adhesive is insufficient.)
• Do not apply too much adhesive as doing so may make work difficult the next time the battery
pack upper case is removed.
NOTE:

LI-ION BATTERY
• For applying the adhesive in a triangle, cut the end of the nozzle as shown in the figure.
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
JSCIA0680ZZ
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
JSCIA0581ZZ

LI-ION BATTERY
7. Tighten the mounting bolts in the order from 1 to 6 as shown in the figure.
JSCIA0582ZZ
WARNING:
8. Install the ground bolt .
JSCIA0583ZZ
WARNING:

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

EVB
JSCIA0143ZZ
D
10. Perform a battery pack air leak inspection. Refer to EVB-901, "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
WARNING:

gear. G
JSCIA0584ZZ
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
• After assembling the battery pack, perform an electric equipotential test.
• Check the following items after installing battery pack: Refer to EVB-901, "Inspection". K
AIR LEAK INSPECTION
L

LI-ION BATTERY
LI-ION BATTERY CONTROLLER : Exploded View INFOID:0000000011400540
JSCIA0760GB
Li-ion battery controller Controller bracket
LI-ION BATTERY CONTROLLER : Removal and Installation INFOID:0000000011400541
DANGER:
maintenance.
WARNING:
CAUTION:

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-838, "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.
JSCIA0145ZZ
K
3. Remove the Li-ion battery controller mounting nuts , then
remove the mounting bolts .
WARNING: L

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

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

P
: Battery front
WARNING:

gear.
JPCIA0204ZZ

LI-ION BATTERY
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
JPCIA0204ZZ
Installation".
CAUTION:
AIR LEAK INSPECTION
BATTERY JUNCTION BOX AND BATTERY HARNESS

LI-ION BATTERY
BATTERY JUNCTION BOX AND BATTERY HARNESS : Exploded View INFOID:0000000011400542
EVB
P
JSCIA1378GB
Service plug switch Service plug switch bracket High-voltage battery harness
Bus bar nut cap Bus bar Bus bar nut cap
Bus bar (integrated with noise filter) Battery junction box Harness bracket
Vehicle communications harness Snap ring High-voltage harness connector

LI-ION BATTERY
Connector flange Seal Voltage detection harness
Bus bar Battery current sensor (integrated High-voltage battery harness
with bus bar)
sembly.
Bus bar Layout

DANGER:

LI-ION BATTERY
EVB
JSCIA1379ZZ P
: Battery front
BATTERY JUNCTION BOX AND BATTERY HARNESS : Disassembly and Assembly

INFOID:0000000011400543
DANGER:

LI-ION BATTERY
maintenance.
WARNING:
CAUTION:
4. Work space
guisher).
DISASSEMBLY
Installation".
Installation".

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

gear.
EVB
JSCIA1380ZZ
D
4. Open the bus bar cover and remove the high-voltage harness
connector terminal mounting bolt .
DANGER: E

tective gear and use insulated tools. F
G
JSCIA1381ZZ
• Because of the danger of electric shock, be sure to
H
5. Remove the mounting bolt and disconnect the high-voltage
harness connector from the connector flange.
WARNING: I

gear and use insulated tools. J
K
JSCIA1382ZZ
6. Disconnect the vehicle communications harness connector , L

connector clips , and Li-ion battery heater harness connector
.
WARNING: M

N
JSCIA0762ZZ O

LI-ION BATTERY
7. Remove the bus bar nut caps .
WARNING:

JSCIA0727ZZ
8. Remove the bus bar mounting nuts and , and remove the
bus bar (integrated with noise filter) .
WARNING:

JSCIA0728ZZ
9. Remove the harness clips, then remove the battery member

pipe .
WARNING:

NOTE:
The right-side mounting hole is larger for facilitating removal of JSCIA0715ZZ
the battery member pipe. Lifting up the left side first makes
removal easier.
10. Remove the bus bar nut cap and remove the high-voltage
harness nut cap , then open the bus bar cover .
WARNING:

gear.
JSCIA0712ZZ

LI-ION BATTERY
11. Remove the mounting nuts , and remove the bus bar and
high-voltage harness . A
DANGER:

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

ately protect the terminals of the disconnected high-voltage harness connector (high-voltage
terminals) with insulating tape so that they are not exposed.
E
the bus bar.
12. Remove the mounting nuts and remove the junction box . F
WARNING:
To prevent electric shock, wear insulated protective G

JSCIA0595ZZ I
13. Disconnect the current sensor harness connector .

WARNING: J

K
JSCIA0657ZZ
M
14. Remove the bus bar mounting nut which connects the current
sensor and left front module stack .
DANGER:
N
tective gear and use insulated tools. O
P
JSCIA0596ZZ
• Because of the danger of electric shock, be sure to

LI-ION BATTERY
15. Remove the service plug switch bracket mounting bolts
and mounting nuts .
WARNING:

JSCIA1410ZZ
16. Invert the service plug switch bracket and remove the high-volt-
age harness mounting bolt , current sensor mounting bolt ,
and the connector , then remove the service plug switch
bracket .
DANGER:

JSCIA0598ZZ
nected high-voltage harness connector (high-voltage terminals) with insulating tape so that they
are not exposed.
17. Remove the mounting nuts , then remove high-voltage harness and .
JSCIA0764ZZ
: Harness clip
DANGER:

LI-ION BATTERY
• Because of the danger of electric shock, be sure to close the bus bar cover after removing A
the bus bar.
18. Remove the vehicle communications harness and voltage detection harness.
B
EVB
G
JSCIA0765ZZ
Vehicle communications harness Voltage detection harness Snap ring H

: Harness clip
WARNING: I
J
ASSEMBLY K
DANGER:
L
M
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter- N
minal.
- Always keep the bus bar cover closed until immediately before the installation of bus bar. O
caution.
P

LI-ION BATTERY
JSCIA0873ZZ

: Battery front
WARNING:
CAUTION:
AIR LEAK INSPECTION
LI-ION BATTERY HEATER

LI-ION BATTERY
LI-ION BATTERY HEATER : Exploded view INFOID:0000000011400544
EVB
P
JSCIA0750GB
Li-ion battery heater RR2 Li-ion battery heater RH2 Li-ion battery heater RH1
Li-ion battery heater LH1 Li-ion battery heater LH2 Li-ion battery heater relay unit

LI-ION BATTERY
Li-ion battery heater harness Li-ion battery heater RR1
LI-ION BATTERY HEATER : Disassembly and Assembly INFOID:0000000011400545
DANGER:
maintenance.
WARNING:
CAUTION:
snowing.
4. Work space
guisher).
REMOVAL
Li-Ion Battery Heater RR1 & RR2
Installation".
Installation".

LI-ION BATTERY
3. Disconnect the harness connectors .
A
EVB
JSCIA0751ZZ
WARNING: D
lated tools. E
F
4. Remove mounting nuts and then remove Li-ion battery heaters.
JSCIA0752ZZ L
Li-ion battery heater RR1 Li-ion battery heater RR2

: Battery front M
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu- N
lated tools.
Li-Ion Battery Heater LH1

1. Remove battery pack upper case. Refer to EVB-838, "BATTERY PACK UPPER CASE : Removal and P
Installation".
Installation".
3. Remove vehicle communication harness. Refer to EVB-853, "BATTERY JUNCTION BOX AND BATTERY
HARNESS : Disassembly and Assembly".

LI-ION BATTERY
4. Disconnect Li-ion battery heater LH1 harness connector .
: Battery front
WARNING:

JSCIA0753ZZ
5. Remove mounting nuts and then remove Li-ion battery heater
LH1 .
WARNING:
lated tools.
Li-Ion Battery Heater RH1

Installation".
Installation".
3. Disconnect Li-ion battery heater RH1 harness connector .
: Battery front
WARNING:

JSCIA0755ZZ
RH1 .
WARNING:
lated tools.
Li-Ion Battery Heater LH2

Installation".
Installation".
3. Remove the following parts; Refer to EVB-853, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
Disassembly and Assembly".
• Vehicle communication harness
• Battery current sensor (integrated with bus bar)

LI-ION BATTERY
WARNING: A

NOTE: EVB
removal easier. D
5. Disconnect Li-ion battery heater LH2 harness connector .

E
: Battery front
WARNING:
F
G
JSCIA0754ZZ
LH2 . H
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insu- I
lated tools.
Li-Ion Battery Heater RH2

1. Remove battery pack upper case. Refer to EVB-838, "BATTERY PACK UPPER CASE : Removal and K
Installation".
Installation". L
3. Remove the following parts; Refer to EVB-853, "BATTERY JUNCTION BOX AND BATTERY HARNESS :
• Vehicle communication harness M
• Bus bar [Battery junction box – Front module stack (RH)]

N
WARNING:

gear and use insulated tools. O
P
NOTE:
removal easier.

LI-ION BATTERY
5. Disconnect Li-ion battery heater RH2 harness connector .
: Battery front
WARNING:

JSCIA0756ZZ
RH2 .
WARNING:
lated tools.
Li-ion battery heater harness

Remove Li-ion battery heater harness after front module stack is removed. Refer to EVB-838, "BATTERY
PACK UPPER CASE : Removal and Installation".
INSTALLATION
Note the following, and install in the reverse order of removal.
WARNING:
tools.
CAUTION:
• Install Li-ion battery controller immediately before installing battery pack upper case. Refer to EVB-
838, "BATTERY PACK UPPER CASE : Removal and Installation".
AIR LEAK INSPECTION
LI-ION BATTERY HEATER RELAY UNIT

LI-ION BATTERY
LI-ION BATTERY HEATER RELAY UNIT : Exploded view INFOID:0000000011400546
EVB
P
JSCIA0750GB
Li-ion battery heater RR2 Li-ion battery heater RH2 Li-ion battery heater RH1
Li-ion battery heater LH1 Li-ion battery heater LH2 Li-ion battery heater relay unit

LI-ION BATTERY
Li-ion battery heater harness Li-ion battery heater RR1
LI-ION BATTERY HEATER RELAY UNIT : Disassembly and Assembly INFOID:0000000011400547
DANGER:
maintenance.
WARNING:
CAUTION:
snowing.
4. Work space
guisher).
DISASSEMBLY
Installation".
Installation".
3. Remove the following; Refer to EVB-853, "BATTERY JUNCTION BOX AND BATTERY HARNESS : Dis-
assembly and Assembly".
• Battery current sensor (integrated with bus bar)

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

. A
WARNING:

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

JSCIA0757ZZ
heater relay unit . D
ASSEMBLY
Assemble in the reverse order of disassembly. E
WARNING:
tools. F
G
CAUTION:
AIR LEAK INSPECTION
H
• Install Li-ion battery controller immediately before installing battery pack upper case.
FRONT MODULE STACK
I
FRONT MODULE STACK : Exploded View INFOID:0000000011400548
REMOVAL AND INSTALLATION J

LI-ION BATTERY
JSCIA0568GB


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

(front)
Sub frame Bus bar cover Bus bar module

LI-ION BATTERY
NOTE:
The figure shows the right front.
Module layout
JSCIA1411GB
Left front module stack Right front module stack

FRONT MODULE STACK : Removal and Installation INFOID:0000000011400549
DANGER:
maintenance.
WARNING:

LI-ION BATTERY
CAUTION:
B
D
4. Work space
guisher).
I
REMOVAL
tion". J
Installation".
3. Remove the following parts. Refer to EVB-853, "BATTERY JUNCTION BOX AND BATTERY HARNESS : K
• Battery junction box
L
• High-voltage battery harnesses
• Vehicle communications harness
• Voltage detection harness
• Harness brackets M
perature sensor harness (front) and the battery temperature
sensor harness (rear). N
WARNING:
To prevent electric shock, wear insulated protective O

gear.
P
JSCIA0658ZZ
5. Remove the battery temperature sensor harness (front) from the front module stack RH.

LI-ION BATTERY
JSCIA0631ZZ
: Harness clip
WARNING:

WARNING:

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

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

JSCIA0766ZZ
• Because there is a danger of electric shock, be sure to close the bus bar cover after remov-
ing the bus bar.
8. Remove the following parts. Refer to EVB-862, "LI-ION BATTERY HEATER : Disassembly and Assem-
bly".
• Li-ion battery heater RH1
• Li-ion battery heater RH2
• Li-ion battery heater LH1
• Li-ion battery heater LH2
9. Remove the Li-ion battery heater relay unit. Refer to EVB-868, "LI-ION BATTERY HEATER RELAY UNIT
: Disassembly and Assembly".

LI-ION BATTERY
10. Disconnect the Li-ion battery heater harness connector . And then remove the harness clips and move
them to a location where they do not inhibit with work. A
EVB
JSCIA0781ZZ
G
: Harness clip
WARNING:
H
11.
12. Remove the front module stack mounting nuts .

J
JSCIA0716ZZ
O
Front module stack LH Front module stack RH

P
WARNING:
13. Follow the procedure below and remove the front module stack from the battery pack.

LI-ION BATTERY
a. Attach a carabiner at position as shown in the figure, and attach a sling belt to it.
JSCIA0722ZZ
WARNING:
b. Use the engine frame (A) and lift up the front module stack.
WARNING:

gear.
CAUTION:
Do not move the engine crane when the front module stack
is lifted up. JSCIA0718ZZ
c. Move the battery pack and place the workbench below the front module stack.
WARNING:
CAUTION:
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. JSCIA0719ZZ
NOTE:
The figure shows the front module stack RH.
14. Remove the Li-ion battery heater harness .

LI-ION BATTERY
EVB
JSCIA0782ZZ
D
: Harness clip
WARNING:
E
INSTALLATION G
DANGER:
H
• Because there is a danger of electric shock and fire, never allow bus bar to contact a wrong ter- J
minal.
- Since the correct installation position for the bus bar connected to both front module stacks is com- K
caution.
L
JSCIA0873ZZ

: Battery front

LI-ION BATTERY
WARNING:
EV Battery Tracking Identification Seal
When replacing the Li-ion battery with a new battery, perform the following operation.
1. Enter the date of the (replacement) work on the EV battery tracking identification seal that is packaged
2. Cut the EV battery tracking identification tool into 2 pieces and apply them to the body of the replaced
3. Enter the necessary information in the “Li-ion battery replacement history record”.
Battery Temperature Sensor Harness (Front)

Install the battery temperature sensor harness (front) onto the front module stack RH.
JSCIA0659ZZ
CAUTION:
AIR LEAK INSPECTION
NOTE:
DANGER:
maintenance.
WARNING:

LI-ION BATTERY
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the A
ENVIRONMENT FOR LI-ION BATTERY DISASSEMBLY WORK B
rain, snow, dust, or other substances from entering. EVB
2. Metal powder, grease, and other foreign substances must not enter. D
vinyl curtain or an equivalent to shut out the outside environment. E
4. Work space F
such as by placing signs indicating that disassembly work is in progress. G
guisher).
DISASSEMBLY
1. Follow the procedure below and remove the bus bar module from the front module stack. I
a. Remove the bus bar cover, then remove the module terminal mounting bolts .
L
JSCIA0720ZZ
DANGER:
M
N
• This work must not be performed by multiple operators because there is a risk of electric O

LI-ION BATTERY
b. Remove the voltage detection terminal mounting screws , then remove the bus bar module from the
front module stack.
JSCIA0721ZZ
DANGER:
c. Install a module terminal cover [SST: KV99111500 ( — )] onto all module terminals.
JPCIA0123ZZ
WARNING:
2. Remove the end plate and disassemble the front module stack.
WARNING:
ASSEMBLY
2. Follow the procedure below to assemble the front module stack.
DANGER:

LI-ION BATTERY
There is the danger of electric shock caused by contact with the terminals. Be sure to wear A
B
a. Assemble the module so that the module terminals are arranged as shown in the figure.
EVB
J
JSCIA0681ZZ
Right module stack Left module stack

K
: Battery front
WARNING:
L
Be careful of the directions of the + terminal and – terminal when assembling the module. If
NOTE: M
figure.
: Red N
+ terminal identification color
P
JSCIA0682ZZ

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.
JSCIA0722ZZ
NOTE:
There are 2 end plates, each with different carabiner installation hole positions. If they are installed
reversed, the carabiner installation hole is positioned on the inside and lifting up is not possible.
c. Install the mounting bolts at opposite corners for each module, then insert φ7 mm (0.28 in) metal bars
(B) into the empty bolt holes and perform centering of the module collar position.
JSCIA0734ZZ
CAUTION:
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.

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
JSCIA0721ZZ 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. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
H
L
JPCIA0150ZZ
Right module stack Left module stack M

: Battery front
DANGER: N
O
P
c. Install the bus bar cover.
REAR MODULE STACK

LI-ION BATTERY
REAR MODULE STACK : Exploded View INFOID:0000000011400551
JSCIA0568GB


LI-ION BATTERY

A
DISASSEMBLY AND ASSEMBLY B
EVB
JSCIA1383GB N
Battery temperature sensor harness Right end plate Harness bracket

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

LI-ION BATTERY
Module layout
JSCIA1411GB
Rear module stack

NOTE:
• Module A: No bracket
• Module B: With bracket
REAR MODULE STACK : Removal and Installation INFOID:0000000011400552
DANGER:
maintenance.
WARNING:

LI-ION BATTERY
CAUTION:
B
D
4. Work space
guisher).
I
REMOVAL
Installation". J
Installation".
3. Remove Li-ion battery heater RR1 and RR2. Refer to EVB-862, "LI-ION BATTERY HEATER : Disassem- K
bly and Assembly".
perature sensor harness (front) and the battery temperature L
WARNING:
M
gear.
JSCIA0658ZZ

LI-ION BATTERY
5. Disconnect the connector, and then remove the battery temperature sensor harness (rear).
JSCIA1384ZZ
WARNING:
6. Remove the harness clips of the voltage detection harness and the Li-ion battery heater harness
from the harness bracket, and move them to a location where they do not inhibit with work.
JSCIA0769ZZ
: Harness clip
WARNING:
7. Remove the mounting nuts and remove the high-voltage harness , from the rear module stack.

LI-ION BATTERY
EVB
JSCIA0770ZZ F
: Harness clip
DANGER: G
insulated protective gear and use insulated tools. H
I
• Because there is a risk of electric shock, immediately protect the disconnected high-volt-
8. Remove the rear module stack mounting bolts . J
WARNING:
To prevent electric shock, wear insulated protective K

JPCIA0129ZZ
M
9. Follow the procedure below and remove the rear module stack from the battery pack.
a. Attach a carabiner to position (A) as shown in the figure and N
connect a lashing belt to it.
WARNING:
O
gear.
P
JSCIA0251ZZ

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

gear.
CAUTION:
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
2. Follow the following procedure and install the rear module stack onto the battery pack.
a. Use the engine frame (A) and lift up the rear module stack .
WARNING:

gear.
CAUTION:
b. Move the workbench and place the battery pack below the rear module stack.
c. Mount the rear module stack onto the battery pack.
WARNING:

LI-ION BATTERY
CAUTION:
Be sure to align the locating pin position.
B
3. Tighten the rear module stack mounting bolts .
WARNING:
EVB
D
E
JPCIA0129ZZ
4. Tighten the mounting nuts , and then install the high-voltage harness , onto the rear module stack. F
JSCIA0770ZZ
L
: Harness clip
DANGER:
M
N
• Because there is a risk of electric shock, immediately protect the disconnected high-volt- O
5. Install the voltage detection harness and the Li-ion battery heater harness .
P

LI-ION BATTERY
JSCIA0769ZZ
: Harness clip
WARNING:
6. Install the battery temperature sensor harness (rear).
JSCIA1384ZZ
WARNING:
NOTE:

LI-ION BATTERY
7. Connect the harness connector between the battery tempera-
ture sensor harness (front) and battery temperature sensor har- A
ness (rear).
WARNING:
B
gear.
EVB
JSCIA0658ZZ
D
8. Install the Li-ion battery heater RR1 and RR2. Refer to EVB-862, "LI-ION BATTERY HEATER : Disassem-
bly and Assembly".
9. Install the Li-ion battery controller. Refer to EVB-848, "LI-ION BATTERY CONTROLLER : Removal and E
Installation".
Installation".
F
CAUTION:
• Check the following items after installing battery pack: Refer to EVB-901, "Inspection". G
AIR LEAK INSPECTION
H
DANGER: I
handled incorrectly. Be sure to follow the correct work procedures when performing inspection and J
maintenance.
WARNING:
• Be sure to remove the service plug for shutting off high voltage circuits before performing inspec- K
tion or maintenance of high voltage system harnesses and parts.
L
or similar item to prevent contact with other persons. M
ing electric shock, fire, and damage to parts. N
CAUTION:
1. Must be an indoor environment. P

LI-ION BATTERY
4. Work space
guisher).
DISASSEMBLY
1. Remove harness bracket , and from the rear module stack.
JSCIA0635ZZ
WARNING:
2. Follow the following procedure and remove the bus bar from the rear module stack.
a. Remove the center bus bar cover, then remove the module ter-
DANGER:

JSCIA0154ZZ
CAUTION:
Do not remove all bus bar covers and all module terminal mounting bolts at the same time.

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

EVB
JSCIA0148ZZ
• This work must not be performed by multiple opera- D
c. Remove the right-side bus bar cover, then remove the module
E
terminal mounting bolts .
DANGER:
• There is the danger of electric shock caused by F

G
JSCIA0155ZZ
• This work must not be performed by multiple opera- H
d. Remove the voltage detection terminal mounting screws , I

then remove the bus bar from the rear module stack.
DANGER:
J
K
JSCIA0191ZZ L
e. Install a module terminal cover [SST: KV99111500 ( — )] (A) M

onto all module terminals.
WARNING:
N
gear.
O
NOTE:
• Because “module B” interferes with the bracket and cover, cut JSCIA0192ZZ
P
the module terminal cover at the position shown in the figure.

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

WARNING:

JPCIA0126ZZ
4. Remove the rear stack member .

WARNING:

JSCIA0723ZZ
5. Fasten the rear module stack with a lashing belt .

WARNING:

gear.
JSCIA0240ZZ

LI-ION BATTERY
6. Remove the through bolt mounting nut, then disassemble 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
JSCIA0683ZZ L
WARNING:
Be careful of the directions of the + terminal and − terminal when assembling the module. If
M
NOTE:
figure. N
+ terminal identification color : Red

− terminal identification color : Black O
JSCIA0682ZZ

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.
JSCIA0717ZZ
CAUTION:
e. Install the remaining 2 through-bolts, and tighten the mounting nuts to the prescribed torque.

LI-ION BATTERY
• When installing, hold the end of the through bolt stationary and
tighten the installation nut. A
EVB
JSCIA0347ZZ
D
3. Install the rear stack member .
WARNING:
E
F
G
JSCIA0723ZZ
4. Install the front stack member . H

WARNING:

gear and use insulated tools. I
JPCIA0126ZZ
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. JSCIA0192ZZ
a. Install the bus bar module onto the rear module stack.
O
WARNING:

P

LI-ION BATTERY
tion terminal mounting screws to the prescribed torque.
DANGER:

JPCIA0135ZZ
c. Tighten the module terminal mounting bolts in numerical order as shown in the figure.
• When tightening of 1 – 16 is completed, install the left-side bus bar cover.
• When tightening of 17 – 32 is completed, install the right-side bus bar cover.
• When tightening of 33 – 48 is completed, install the center bus bar cover.
JPCIA0136ZZ
DANGER:
d. Install the bus bar cover .
JPCIA0137ZZ
WARNING:
CAUTION:
• Be careful not to install with the top and bottom facing in the wrong directions.
• After installation, check that the mating is not skewed.

LI-ION BATTERY
7. Install the harness bracket , and to the rear module stack.
A
EVB
JSCIA0635ZZ
WARNING: D
E
CAUTION: F
• Check the following items after installing battery pack: Refer to EVB-901, "Inspection". G
AIR LEAK INSPECTION
H
AIR LEAK INSPECTION

I
1. Use vinyl tape or similar means (A) for preventing air leakage
from the harness connectors.
• Use wide vinyl tape that is capable of covering all of the har-
ness connector with one strip. J
WARNING:
K
gear.
L
JSCIA1385ZZ
2. Use vinyl tape or similar means (A) to prevent air leakage from M
the breather.
• Use wide vinyl tape that is capable of covering all of the
breather with one strip.
• Apply carefully so that no wrinkles in the tape occur. N
WARNING:
To prevent electric shock, wear insulated protective O

gear.
JPCIA0128ZZ P

LI-ION BATTERY
3. Remove the plug and install the adapter (A) of the air leak tester
[SST: KV99111400 ( — )].
WARNING:

gear.
JSCIA1386ZZ
4. Install the gauge (A) of the air leak tester [SST: KV99111400
( — )].
WARNING:

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

DANGER:
There is the danger of electric shock caused by contact with the terminals. Be sure to wear
insulated protective gear.
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:
a. Open the cock on the air leak tester.

CAUTION:
Do not operate the pump before opening the cock on the air
leak tester. Doing so may damage the gauge. If the pump is
operated before the cock 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 battery pack. If the
gauge pressure does not rise, or if the gauge reading fluctuates, check for the location of air leakage.
Specified inspection pressure : 1.6 kPa (0.016 bar, 0.0163 kg/cm2, 0.232 psi)

LI-ION BATTERY
CAUTION:
• Operate the air pump carefully when applying pressure. If pressure is applied suddenly to the A
gauge, the gauge may be damaged.
• Do not apply pressure of 2.0 kPa (0.0204 kg/cm2) or more to the battery case or air leak tester.
c. Close the cock and wait for 1 minute. B
d. Check that the air leak tester reading remains at or above the limit value.
Repair limit : 1.4 kPa (0.014 bar, 0.0142 kg/cm2, 0.203 psi) EVB
e. If the pressure is below the limit value, check for the locations of air leakage.
NOTE:
D
Check for air leakage from the sound of air escaping when pressure is applied.
After assembling the Li-ion battery pack, remove the battery pack upper case ground bolt , then measure E
the resistance between the high-voltage harness connector flange ground bolts and the ground bolt seat
(location of coating peeling) .
F
JSCIA1387ZZ
K
WARNING:

L
M
• Ground bolt connection condition N
• Corrosion on ground bolt mounting surface
• Presence of paint, oil, dirt, or other substance on ground bolt mounting surface
O


Items Specification
Type Li-ion battery
Weight [kg (lb)] Approx. 275 (606)
JSCIA1388ZZ
External dimension “a” [mm (in)] 1188 (46.77)

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

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ELECTRIC POWER TRAIN

HOW TO USE THIS MANUAL ..................... 14 HANDLING PRECAUTION ............................... 37

SYSTEM .............................................................31 P0A1F BATTERY ENERGY CONTROL MOD-

Revision: 2014 June EVB-1 2012 LEAF

P3031-P303C CELL CONTROLLER ASIC ....... 69 P318D COMMUNICATION ERROR .................. 91

P303D-P3048 CELL CONTROLLER ASIC ....... 70 P318E COMMUNICATION ERROR .................. 92

P3049-P3054 CELL CONTROLLER ASIC P3191 COMMUNICATION ERROR .................. 93

Revision: 2014 June EVB-2 2012 LEAF

Revision: 2014 June EVB-3 2012 LEAF

Revision: 2014 June EVB-4 2012 LEAF

Revision: 2014 June EVB-5 2012 LEAF

Revision: 2014 June EVB-6 2012 LEAF

Revision: 2014 June EVB-7 2012 LEAF

Revision: 2014 June EVB-8 2012 LEAF

Revision: 2014 June EVB-9 2012 LEAF

SERVICE DATA AND SPECIFICATIONS HANDLING PRECAUTION .............................. 692

SERVICE DATA AND SPECIFICATIONS DIAGNOSIS SYSTEM (LBC) ........................... 693

PREPARATION .......................................... 669 MODULE CHARGE BALANCE ....................... 719

Revision: 2014 June EVB-10 2012 LEAF

Revision: 2014 June EVB-11 2012 LEAF

Revision: 2014 June EVB-12 2012 LEAF

Revision: 2014 June EVB-13 2012 LEAF

HOW TO USE THIS MANUAL

Service information Vehicle type Service plug type

Type 3 Without Li-ion battery heater

Revision: 2014 June EVB-14 2012 LEAF

Revision: 2014 June EVB-15 2012 LEAF

Revision: 2014 June EVB-16 2012 LEAF

Precautions for Removing Battery Terminal INFOID:0000000007634273

Revision: 2014 June EVB-17 2012 LEAF

Revision: 2014 June EVB-18 2012 LEAF

Revision: 2014 June EVB-19 2012 LEAF

Battery location guide pin

Air leak checker

Module terminal cover

Module charge balancer

Commercial Service Tools INFOID:0000000007634276

Revision: 2014 June EVB-20 2012 LEAF

Removing and installing high voltage components

Insulated safety shoes Removing and installing high voltage components G

• Removing and installing high voltage compo-

Insulated helmet Removing and installing high voltage components N

Revision: 2014 June EVB-21 2012 LEAF

Insulated cover sheet Removing and installing high voltage components

Battery lift table Removing and installing Li-ion battery

Stacker Removing and installing Li-ion battery

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

Insulated hand tools Removing and installing high voltage components

Insulated torque wrench Removing and installing high voltage components

Removing and installing battery module stack

Revision: 2014 June EVB-22 2012 LEAF

Mobile floor crane Removing and installing battery module stack G

Removing battery pack upper case

Installing battery pack upper case

Revision: 2014 June EVB-23 2012 LEAF

Assembling battery module stack

Revision: 2014 June EVB-24 2012 LEAF

No. Component Function O

Revision: 2014 June EVB-25 2012 LEAF

Symptoms Power limitation indicator

Frequency All the time Once Sometimes ( times a day) Other