Inspection Procedure 9: Power supply system of on board charger




















PROBABLE CAUSES



  • The on board charger is failed.
  • The relay of the on board charger is failed.
  • Open circuits of on board charger power supply, short circuits to earth or damage; poor contact of connector
  • The EV-ECU is failed.

DIAGNOSIS PROCEDURE


STEP 1. Check auxiliary battery



  • Check auxiliary battery (Refer to GROUP 54A - Auxiliary Battery - On-vehicle Service - Battery Test ).

Q. Is the check result normal?

Go to Step 2 .
Replace the auxiliary battery.

STEP 2. Connector check: A-06X on board charger relay connector


Q. Is the check result normal?

Go to Step 3 .
Repair.

STEP 3. Check on board charger relay itself.


Check on board charger relay itself (Refer to ).

Q. Is the check result normal?

Go to Step 4 .
Replace the on board charger relay.

STEP 4. Perform voltage measurement at A-06X on board charger relay



  • Remove the relay, and measure at relay box side.
  • Voltage between terminal No. 4 and earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 5 .

    Check and repair harness between A-06X (terminal No. 4) on board charger relay connector and auxiliary battery.

    • Check power supply line for open circuit, short circuit to earth.

STEP 5. Perform voltage measurement at A-06X on board charger relay



  • Remove the relay, and measure at relay box side.
  • Electric motor switch: ON
  • Voltage between terminal No. 3 and earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 7 .
Go to Step 6 .

STEP 6. Connector check: A-08X EV control relay connector


Q. Is the check result normal?


    Check and repair harness between A-08X (terminal No. 1) EV control relay connector and A-06X (terminal No. 3) on board charger relay connector.

    • Check power supply line for open circuit, short circuit to earth.
Repair.

STEP 7. Connector check: C-108 EV-ECU connector


Q. Is the check result normal?

Go to Step 8 .
Repair.

STEP 8. Perform voltage measurement at C-108 EV-ECU connector



  • Disconnect connector, and measure at harness side.
  • Electric motor switch: ON (Do not connect the M.U.T.-III with the diagnosis connector.)
  • Voltage between terminal No. 66 and earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 9 .

    Check intermediate connector B-27, and repair if necessary. If intermediate connector is normal, check and repair harness between A-06X (terminal No. 2) on board charger relay connector and C-108 (terminal No. 66) EV-ECU connector.

    • Check power supply line for open circuit, short circuit to earth.

STEP 9. Check harness between auxiliary battery and A-06X (terminal No. 4) on board charger relay connector



  • Check power supply line for damage.

Q. Is the check result normal?

Go to Step 10 .
Repair.

STEP 10. Check harness between A-08X (terminal No. 1) EV control relay connector and A-06X (terminal No. 3) on board charger relay connector.



  • Check power supply line for damage.

Q. Is the check result normal?

Go to Step 11 .
Repair.

STEP 11. Check harness between A-06X (terminal No. 2) on board charger relay connector and C-108 (terminal No. 66) EV-ECU connector.


note Before checking harness, check intermediate connector B-27, and repair if necessary.

  • Check power supply line for damage.

Q. Is the check result normal?

Go to Step 12 .
Repair.

STEP 12. Connector check: E-03 on board charger/DC-DC converter connector


Q. Is the check result normal?

Go to Step 13 .
Repair.

STEP 13. Check harness between A-06X (terminal No. 1) on board charger relay connector and E-03 (terminal No. 2) on board charger/DC-DC converter connector


note Before checking harness, check intermediate connector A-105, and repair if necessary.

  • Check power supply line for open circuit, short circuit to earth and damage to earth.

Q. Is the check result normal?

Go to Step 14 .
Repair.

STEP 14. Perform resistance measurement at E-03 on board charger/DC-DC converter connector



  • Disconnect connector, and measure at harness side.
  • Resistance between terminal No. 10 and earth.
OK: Continuity (2 Ω or less)

Q. Is the check result normal?

Go to Step 15 .

    Check intermediate connector C-104, and repair if necessary. If intermediate connector is normal, check and repair harness between E-03 (terminal No. 10) on board charger/DC-DC converter connector and body earth.

    • Check earthing line for open circuit and damage.

STEP 15. Connector check: earth cable terminal


Q. Is the check result normal?

Go to Step 16 .
Repair.

STEP 16. Perform resistance measurement at earth cable terminal



  • Disconnect terminal, and measure at harness side.
  • Resistance between terminal and earth.
OK: Continuity (2 Ω or less)

Q. Is the check result normal?

Go to Step 17 .

    Check and repair harness between earth cable terminal and body earth.

    • Check earthing line for open circuit and damage.

STEP 17. Perform voltage measurement at E-03 on board charger/DC-DC converter connector



  • Disconnect connector, and measure at harness side.
  • Voltage between terminal No. 7 and earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 18 .

    Check intermediate connector C-107, and repair if necessary. If intermediate connector is normal, check and repair harness between E-03 (terminal No. 7) on board charger/DC-DC converter connector and auxiliary battery.

    • Check power supply line for open circuit, short circuit to earth.

STEP 18. Check harness between auxiliary battery and E-03 (terminal No. 7) on board charger/DC-DC converter connector


note Before checking harness, check intermediate connector A-107, and repair if necessary.

  • Check power supply line for damage.

Q. Is the check result normal?

Go to Step 19 .
Repair.

STEP 19. Connector check: C-106 EV-ECU connector


Q. Is the check result normal?

Go to Step 20 .
Repair.

STEP 20. Check harness between C-106 (terminal No. 11) EV-ECU connector and E-03 (terminal No. 12) on board charger/DC-DC converter connector


note Before checking harness, check intermediate connector C-102, and repair if necessary.

  • Check signal line for damage.

Q. Is the check result normal?

Go to Step 21 .
Repair.

STEP 21. Check the trouble symptom


Q. Does the trouble symptom persist?

Go to Step 22 .
Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).

STEP 22. After replacing the on board charger/DC-DC converter, check the malfunction phenomenon.



  • After replacing the on board charger/DC-DC converter, the malfunction phenomenon reoccurs or not.

Q. Does the trouble symptom persist?

Replace the EV-ECU.
Check end.




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