Inspection Procedure
1: EV-ECU power supply system
HIGH VOLTAGE POWER SUPPLY CONTRPL SYSTEM CIRCUIT
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- Malfunction of the EV control relay
- Malfunction of the EV-ECU
- Open circuit, short circuit to earth system, damage, or connector poor contact in
the EV-ECU circuit
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STEP 1. Connector check: C-106 EV-ECU connector
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Q.
Is the check result normal?
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 Go to Step 2.
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 Repair the damaged connector.
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STEP 2. Voltage measurement at C-106 EV-ECU connector
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(1)Disconnect the connector and measure at the wiring harness side.
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(2)Turn the electric motor switch to the ON position.
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(3)Measure the voltage between C-106 EV-ECU connector terminal No. 9 and the earth.
OK: Battery voltage
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(4)Measure the voltage between the C-106 EV-ECU connector terminal No. 24 and the
earth.
OK: Battery voltage
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Q.
Is the check result normal?
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Go to Step 10.
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STEP 3. Connector check: A-08X EV control relay connector
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Q.
Is the check result normal?
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Go to Step 4.
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Repair the damaged connector.
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STEP 4. EV control relay check after it has been removed
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Check the EV control relay after it has been removed. (Refer to  .)
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Q.
Is the check result normal?
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Go to Step 5.
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Replace the EV control relay.
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STEP 5. Measure the resistance at A-08X EV control relay.
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(1)Disconnect the connector and measure at the wiring harness side.
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(2)Measure the resistance between the A-08X EV control relay connector terminal No.
2 and the body earth.
OK: Continuity exists (2 Ω or less)
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Q.
Is the check result normal?
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Go to Step 7.
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Go to Step 6.
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STEP 6. Check the wiring harness between A-08X EV control relay connector
terminal No. 2 and the body earth.
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Check the earth wires for open circuit.
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Before the wiring harness check, check the B-122 earth connector, and repair if necessary.
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Q.
Is the check result normal?
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Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points - How to Cope with Intermittent Malfunction .)
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Repair the wiring harness.
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STEP 7. Measure the voltage at A-08X EV control relay connector.
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(1)Disconnect the connector and measure at the wiring harness side.
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(2)Measure the voltage between the A-08X EV control relay connector terminal No. 4
and the earth.
OK: Battery voltage
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Q.
Is the check result normal?
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Go to Step 9.
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STEP 8. Check the wiring harness between A-08X EV control relay connector
terminal No. 4 and the fusible link No. 21.
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Check the power supply line for open circuit and short circuit.
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Q.
Is the check result normal?
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Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points - How to Cope with Intermittent Malfunction .)
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Repair the wiring harness.
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STEP 9. Wiring harness check
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Check the wiring harness below for open circuit and short circuit.
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- Between the A-08X EV control relay connector terminal No. 1 and C-106 EV-ECU
connector terminal No. 9
- Between the A-08X EV control relay connector terminal No. 1 and C-106 EV-ECU connector terminal
No. 24
- Between the A-08X EV control relay connector terminal No. 3 and C-106 EV-ECU connector terminal
No. 2
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Prior to the wiring harness inspection, check B-27 intermediate connectors, and repair
if necessary.
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Q.
Is the check result normal?
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Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points - How to Cope with Intermittent Malfunction .)
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Repair the wiring harness.
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STEP 10. Voltage measurement at C-106 EV-ECU connector
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(1)Disconnect the connector and measure at the wiring harness side.
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(2)Measure the voltage between the C-106 EV-ECU connector terminal No. 1 and the earth.
OK: Battery voltage
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Q.
Is the check result normal?
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Go to Step 12.
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STEP 11. Check the wiring harness between C-106 EV-ECU connector terminal
No. 1 and the fusible link No. 25.
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Check the power supply line for open circuit and short circuit.
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Before the wiring harness check, check B-301 and B-310 junction block connector, and repair
if necessary.
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Q.
Is the check result normal?
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Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points - How to Cope with Intermittent Malfunction .)
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Repair the wiring harness.
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STEP 12. Measure the resistance at C-106 EV-ECU connector.
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(1)Disconnect the connector and measure at the wiring harness side.
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(2)Measure the resistance between the C-106 EV-ECU connector terminal No. 10 and the
body earth.
OK: Continuity exists (2 Ω or less)
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(3)Measure the resistance between the C-106 EV-ECU connector terminal No. 25 and the
body earth.
OK: Continuity exists (2 Ω or less)
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Q.
Is the check result normal?
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Go to Step 14.
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Go to Step 13.
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STEP 13. Check the wiring harness between C-106 EV-ECU connector terminal
No. 10 or 25 and the body earth.
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Check the earth wires for open circuit.
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Before the wiring harness check, check the C-32 earth connector, and repair if necessary.
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Q.
Is the check result normal?
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Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points - How to Cope with Intermittent Malfunction .)
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Repair the wiring harness.
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STEP 14. Check the trouble symptom.
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Check that the EV-ECU functions work normally.
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Q.
Is the check result normal?
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Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points - How to Cope with Intermittent Malfunction .)
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Replace the EV-ECU.
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