Inspection Procedure

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system.
After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:

At least 5 minutes is required to discharge the high-voltage condenser inside the inverter.

READ OUTPUT DTC (HV BATTERY)
1. Connect the hand-held tester to the DLC3.
2. Turn the power switch ON (IG).
3. Turn the hand-held tester ON.
4. On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES.
5. Read DTCs.
Result: DTCs are output

YES: GO TO RELEVANT DTC CHART (See DIAGNOSTIC TROUBLE CODE CHART )

NO

READ OUTPUT DTC (HV ECU)

Connect the hand-held tester to the DLC3.
Turn the power switch ON (IG).
Turn the hand-held tester ON.
On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
Read DTCs.

Result: DTCs listed in the table below are output

DTC P0A1F/129 DTC DETECTION

DTC No.	INF Code	Detection Item
P0AA1	226	Hybrid Battery Positive Contactor Circuit Stuck Closed
P0AA2	227	Hybrid Battery Positive Contactor Circuit Stuck Open
P0AA4	228	Hybrid Battery Negative Contactor Circuit Stuck Closed
P0AA5	229	Hybrid Battery Negative Contactor Circuit Stuck Open

YES: GO TO THE DTC TEST SHOWN IN THE TABLE ABOVE

INSPECT SERVICE PLUG GRIP
CAUTION: Wear insulated gloves before performing the following operation.
1. Turn the power switch OFF.
2. Remove the service plug grip (see SERVICE PLUG GRIP ).
  NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
3. Check the resistance between the terminals of the service plug grip.
Standard: Below1 Ω

NG: Go to step 5

Fig 1: Locating Service Plug Grip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go To Next Step

INSPECT BATTERY PLUG

CAUTION: Wear insulated gloves and goggles before performing the following operation.

Remove the HV battery assembly (see HV BATTERY ).
Remove the battery plug (see BATTERY PLUG ).

Check the resistance between the terminals of the battery plug.

RESISTANCE CHECK

Tester Connection	Specified Condition
A - C	Below1 Ω
B - D	Below1 Ω

Reinstall the battery plug (see BATTERY PLUG ).
Reinstall the HV battery assembly (see HV BATTERY ).

Fig 2: Locating Battery Plugs

NG: REPLACE BATTERY PLUG

OK: BATTERY ECU ASSY (See BATTERY ECU ASSY )

INSPECT HIGH VOLTAGE FUSE

CAUTION: Wear insulated gloves before performing the following operation.

Remove the high voltage fuse (see SERVICE PLUG GRIP ).
HINT:

The high voltage fuse is enclosed in the service plug grip.
Check the resistance between the terminals of the high voltage fuse.
Standard: Below1 Ω
Reinstall the high voltage fuse (see SERVICE PLUG GRIP ).

NG: REPLACE HIGH VOLTAGE FUSE

Fig 3: Removing High Voltage Fuse

OK: SERVICE PLUG GRIP