Code No. P1A46: Detection Circuit Of Traction Battery Earth Fault Detector Abnormal




TROUBLE JUDGEMENT


Check Conditions
  • The power supply mode of the electric motor switch is ON, or the drive battery starts to be charged
  • Not while earth fault is prevented from being detected (not during the quick charge).
Judgement Criterion
  • The abnormal drive battery earth fault detector circuit is detected.

FAIL-SAFE AND BACKUP FUNCTION



  • Not available

PROBABLE CAUSES



  • Earth fault of high voltage system component.
  • The quick charging contactor (+) or the quick charging contactor (-) is stuck in ON.
  • The traction battery earth fault detector failed.
  • Open circuits of traction battery earth fault detector circuit, short circuits to earth, short circuits to power supply system or damage; poor contact of connector.
  • The BMU is failed.

DIAGNOSIS PROCEDURE


danger When pulling service plugs, wear the specified protective equipment (Refer to ).

STEP 1. M.U.T.-III diagnosis code.



  • Wait 20 seconds after turning ON the power supply mode of electric motor switch.
  • Selector lever position indicator: P
  • Perform the M.U.T.-III BMU special function "Pre-check procedure of drive battery earth fault detector".
note If the diagnosis code is stored with the power supply mode of electric motor switch turned ON, an electric leak could occur inside the drive battery.

Q. Is the diagnosis code stored?

Go to Step 2.
Go to Step 18 <vehicles with quick charger>.
Go to Step 20 <vehicles without quick charger>.

STEP 2. Check service plug connector for the insulation resistance.


danger When high voltage system components are serviced, be sure to pull service plugs to shut down high voltage before serving (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect service plug, and measure at service plug box assembly side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between service plug box assembly CMU ID 05 side terminal and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 4.
Remove the battery tray cover (Refer to ). Then, go to Step 3.

STEP 3. Check contactor itself.



  • Check main contactor (+) and charging contactor itself.

Q. Is the check result normal?

Check and modify the short circuit for the harnesses and the bus bar between the main contactor (+) connector and the service plug connector. Then, assemble the drive battery assembly (Refer to ).
Replace the contactor. Then, assemble the drive battery assembly (Refer to ).

STEP 4. Check the service plug connector for the insulation resistance.


danger When high voltage system components are serviced, be sure to pull service plugs to shut down high voltage before serving (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect service plug, and measure at service plug box assembly side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between service plug box assembly CMU ID 07 side terminal and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 6.
Remove the battery tray cover (Refer to ). Then, go to Step 5.

STEP 5. Check contactor itself.



  • Check main contactor (-) itself.

Q. Is the check result normal?

Check and modify the short circuit for the harnesses and the bus bar between the main contactor (-) connector and the service plug connector. Then, assemble the drive battery assembly (Refer to ).
Replace the contactor. Then, assemble the drive battery assembly (Refer to ).

STEP 6. Voltage measurement at drive battery connector (drive battery earth fault detector power supply line).


(1)Disconnect the connector, and measure at the wiring harness side.
(2)Operate the electric motor switch without depressing the brake pedal and turn ON the power supply mode of electric motor switch.
(3)Check the voltage between the drive battery connector (drive battery earth fault detector power supply line) and body earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 7.
Repair drive battery earth fault detector in power supply line between IGCT control relay connector and drive battery connector.

STEP 7. Perform resistance measurement at drive battery connector (drive battery earth fault detector body earth line).


(1)Disconnect the connector, and measure at the wiring harness side.
(2)Check the resistance between drive battery connector (drive battery connector earth fault detector body earth line) and body earth.
OK: Continuity (2 Ω or less)

Q. Is the check result normal?

Go to Step 8.
Repair drive battery earth fault detector body earth line between drive battery connector and body earth.

STEP 8. Check of damage in drive battery earth fault detector power supply line between IGCT control relay connector and drive battery connector.


Q. Is the check result normal?

Go to Step 9.
Repair the connector(s) or wiring harness.

STEP 9. Check of short to earth, short to power supply, open circuit and damage in SENS line between BMU connector and drive battery connector.


Q. Are the check result normal?

Go to Step 10.
Repair the connector(s) or wiring harness.

STEP 10. Check of short to earth, short to power supply, open circuit and damage in PRCK line between BMU connector and drive battery connector.


Q. Are the check result normal?

Go to Step 11.
Repair the connector(s) or wiring harness.

STEP 11. Voltage measurement at BMU connector (SENS terminal).


(1)Measure BMU terminal voltage.
(2)Disconnect the drive battery connector.
(3)Operate the electric motor switch without depressing the brake pedal and turn ON the power supply mode of electric motor switch.
(4)Check the voltage between the BMU connector (SENS terminal) and body earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 13.

    Go to Step 12 .

STEP 12. M.U.T.-III diagnosis code



  • Reconfirmation of diagnosis code.

Q. Is the diagnosis code stored?

Replace the BMU.
Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).

STEP 13. Voltage measurement at BMU connector (PRCK terminal).


(1)Measure BMU terminal voltage.
(2)Operate the electric motor switch without depressing the brake pedal and turn ON the power supply mode of electric motor switch.
(3)Check the voltage between the BMU connector (PRCK terminal) and body earth.
OK: The voltage is changed.

Q. Is the check result normal?

Go to Step 14.
Go to Step 12.

STEP 14. M.U.T.-III diagnosis code


Q. Is the diagnosis code stored?

Remove the battery tray cover (Refer to ). Then, go to Step 15.
Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).

STEP 15. Check of short to earth, short to power supply, open circuit and damage in power supply line between drive battery connector and drive battery earth fault detector connector.


Q. Is the check result normal?

Go to Step 16.
Repair the connector(s) or wiring harness. Then, assemble the drive battery assembly (Refer to ).

STEP 16. Check of short to power supply, open circuit and damage in body earth line between drive battery connector and drive battery earth fault detector connector.


Q. Is the check result normal?

Go to Step 17.
Repair the connector(s) or wiring harness. Then, assemble the drive battery assembly (Refer to ).

STEP 17. Check of short to earth, short to power supply, open circuit and damage in SENS line and PRCK line between drive battery connector and drive battery earth fault detector connector.


Q. Is the check result normal?

Replace the drive battery earth fault detector. Then, assemble the drive battery assembly (Refer to ).
Repair the connector(s) or wiring harness. Then, assemble the drive battery assembly (Refer to ).

STEP 18. M.U.T.-III diagnosis code.



  • During the quick charging
note If the diagnosis code is stored during the quick charging, the quick charging contactor (+) can become stuck in the ON position or the quick charging contactor (-) can become stuck in the ON position.

Q. Is the diagnosis code stored?

Remove the battery tray cover (Refer to ). Then, go to Step 19.
Go to Step 20.

STEP 19. Check quick charging contactor itself.



  • Quick charging contactor (+) and quick charging contactor (-) check

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the quick charging contactor. Then, assemble the drive battery assembly (Refer to ).

STEP 20. M.U.T.-III diagnosis code



  • Ready indicator is illuminated
  • Selector lever position indicator: P
  • A/C switch: OFF
  • Perform the M.U.T.-III BMU special function "Pre-check procedure of drive battery earth fault detector".

Q. Is the diagnosis code stored?

Go to Step 21.
Go to Step 35.

STEP 21. Check the power drive unit connector for the insulation resistance.


danger When high voltage system components are serviced, be sure to pull service plugs to shut down high voltage before serving (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between power drive unit connector (P terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between power drive unit connector (N terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 23.
Go to Step 22.

STEP 22. Check the power drive unit (drive battery) for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Disconnect the drive battery (FPDU) connector.
(3)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(4)Check the insulation resistance between power drive unit (drive battery) connector (P terminal) and body earth.
OK: 10 MΩ or more
(5)Check the insulation resistance between power drive unit (drive battery) connector (N terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Remove the battery tray cover (Refer to ). Check and modify the harness and the bus bar between the drive battery (FPDU) connector and the main contactor (P), also between the drive battery (FPDU) connector and the main connector (N). Then, assemble the drive battery assembly (Refer to ).
Replace the wiring harness between power drive unit (drive battery) connector and drive battery (power drive unit) connector.

STEP 23. Check the power drive unit (drive battery) connector for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the equipment side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between power drive unit (drive battery) connector (N terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between power drive unit (A/C compressor) connector (N terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 28.
Go to Step 24.

STEP 24. Check the power drive unit (A/C compressor) for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between power drive unit (A/C compressor) connector (P terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between power drive unit (A/C compressor) connector (N terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 27.
After replacing the A/C refrigerant and the compressor oil, go to Step 25.

STEP 25. Check the power drive unit (A/C compressor) for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between power drive unit (A/C compressor) connector (P terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between power drive unit (A/C compressor) connector (N terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Check end
Go to Step 26.

STEP 26. Check the A/C compressor assembly for the insulation resistance.



  • Check the A/C compressor assembly for the insulation resistance (Refer to GROUP 55 - Compressor Assembly - Inspection ).

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the A/C compressor assembly.

STEP 27. Check the power drive unit for the insulation resistance.



  • Power drive unit for the insulation resistance check (Refer to ).

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the power drive unit.

STEP 28. Check the RMCU (drive battery P) connector or RMCU (drive battery N) for the insulation resistance.


danger When high voltage system components are serviced, be sure to pull service plugs to shut down high voltage before serving (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between RMCU (drive battery P) connector and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between RMCU (drive battery N) connector and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 30.
Go to Step 29.

STEP 29. Check RMCU (drive battery P) and RMCU (drive battery N) for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side connector.
(2)Disconnect connector, drive battery (normal charging P) connector and drive battery (normal charging N) connector.
(3)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(4)Check the insulation resistance between RMCU (drive battery P) connector or and body earth.
OK: 10 MΩ or more
(5)Check the insulation resistance between RMCU (drive battery N) connector and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Remove the battery tray cover (Refer to ). Check and modify the harness and the bus bar between the drive battery (FPDU) connector and the main contactor (P), also between the drive battery (FPDU) connector and the main connector (N). Then, assemble the drive battery assembly (Refer to ).
Replace the harness between RMCU (drive battery P) connector and drive battery (normal charging P) connector or RMCU (drive battery N) connector and drive battery (normal charging N) connector.

STEP 30. Check the RMCU (drive battery P) connector and RMCU (drive battery N) connector for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the equipment side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between RMCU (drive battery P) connector and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between RMCU (drive battery N) connector and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Go to Step 31.

STEP 31. Check the RMCU (On board charger/DC-DC converter) connector for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between RMCU (on board charger/DC-DC converter) connector (P terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between RMCU (on board charger/DC-DC converter) connector (N terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 32.
Replace the on board charger/DC-DC converter

STEP 32. Check the RMCU (electric heater) for the insulation resistance.


caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between RMCU (electric heater) connector (P terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between RMCU (electric heater) connector (P terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 34.
Go to Step 33.

STEP 33. Check the electric heater for the insulation resistance.



  • Check the electric heater for the insulation resistance (Refer to GROUP 55 - Heater Water Pump - Inspection ).

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the electric heater

STEP 34. Check the RMCU for the insulation resistance.



  • Check the RMCU for the insulation resistance (Refer to ).

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the RMCU

STEP 35. M.U.T.-III diagnosis code.



  • Ready indicator is illuminated
  • Selector lever position indicator: D
  • Perform the M.U.T.-III BMU special function "Pre-check procedure of drive battery earth fault detector".

Q. Is the diagnosis code stored?

Go to Step 36.
Go to Step 42.

STEP 36. Check the power drive unit connector for the insulation resistance.


danger When high voltage system components are serviced, be sure to pull service plugs to shut down high voltage before serving (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between power drive unit (front motor) connector (MU terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between power drive unit (front motor) connector (MV terminal) and body earth.
OK: 10 MΩ or more
(5)Check the insulation resistance between power drive unit (front motor) connector (MW terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 38.
Go to Step 37.

STEP 37. Check the front motor (power unit) for the insulation resistance.



  • Check the front motor (power unit) for the insulation resistance (Refer to ).

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the motor (power unit)

STEP 38. Check the power drive unit for the insulation resistance.



  • Check the power drive unit for the insulation resistance (Refer to ).

Q. Is the check result normal?

Go to Step 39.
Replace the power drive unit

STEP 39. Check the RMCU for the insulation resistance.


danger When high voltage system components are serviced, be sure to pull service plugs to shut down high voltage before serving (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between power drive unit (front motor) connector (U terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between power drive unit (front motor) connector (V terminal) and body earth.
OK: 10 MΩ or more
(5)Check the insulation resistance between power drive unit (front motor) connector (W terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 41.
Go to Step 40.

STEP 40. Check the rear motor for the insulation resistance.



  • Check the rear motor for the insulation resistance (Refer to ).

Q. Is the check result normal?

Replace the harness between FPDU (front motor) connector and rear motor (power unit) connector.
Replace the rear motor.

STEP 41. Check the RMCU for the insulation resistance



  • Check the RMCU for the insulation resistance (Refer to ).

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the RMCU.

STEP 42. M.U.T.-III diagnosis code



  • Ready indicator is illuminated
  • Selector lever position indicator: P
  • Drive battery level indicator: shows 3/4 residual amount in its entirety.
  • Battery charge: ON
  • Perform the M.U.T.-III BMU special function "Pre-check procedure of drive battery earth fault detector".

Q. Is the diagnosis code stored?

Go to Step 43.
Go to Step 45.

STEP 43. Check the power drive unit connector for the insulation resistance.


danger When high voltage system components are serviced, be sure to pull service plugs to shut down high voltage before serving (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.
(1)Disconnect the connector, and measure at the wiring harness side.
(2)Use the special tool electric insulation tester (MB992355) to set the range to 500 V.
(3)Check the insulation resistance between power drive unit (generator) connector (GU terminal) and body earth.
OK: 10 MΩ or more
(4)Check the insulation resistance between power drive unit (generator) connector (GV terminal) and body earth.
OK: 10 MΩ or more
(5)Check the insulation resistance between power drive unit (generator) connector (GW terminal) and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?

Go to Step 27.
Go to Step 44.

STEP 44. Check the generator for the insulation resistance.



  • Check the generator for the insulation resistance (Refer to ).

Q. Is the check result normal?

Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).
Replace the generator.

STEP 45. M.U.T.-III diagnosis code.



  • Reconfirmation of diagnosis code.

Q. Is the diagnosis code stored?

Go to Step 1.
Check end.