Inspection Procedure 6: Although READY indicator (green lamp) and CHARGE indicator (orange lamp) are lit, regular charging is impossible.








COMMENTS ON TROUBLE SYMPTOM


When the regular charging starts, the CHARGE indicator (orange lamp) should be lit. When the main battery is fully charged, the CHARGE indicator (orange lamp) should be extinguished.
If charging is disabled although the READY indicator (green lamp) and the CHARGE indicator (orange lamp) are lit, the regular charging connector connection signal circuits or the regular charging high voltage system circuits may be failed.

PROBABLE CAUSES



DIAGNOSIS PROCEDURE
danger When high voltage system components are served, be sure to pull service plugs to shut down high voltage (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).

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

Q. Is diagnosis code set?
Inspection chart for diagnosis code (Refer to ).
Go to Step 2 .

STEP 2. M.U.T.-III data list

  • EV-ECU Data list reference table (Refer to ).

    1. Item 207: OBC connecting signal

Q. Is the check result normal?
Go to Step 9 .
Go to Step 3 .

STEP 3. Check the regular charging plug built-in switch itself

  • Check Charging Cable (Refer to ).

Q. Is the check result normal?
Go to Step 4 .
Replace the charging cable.

STEP 4. Connector check: G-03 regular charging connector and E-03 on board charger/DC-DC converter connector

Q. Are the check results normal?
Go to Step 5 .
Repair or replace the connector.

STEP 5. Check harness between G-03 (terminal No. 3) regular charging connector and E-03 (terminal No. 9) on board charger/DC-DC converter connector.
note Before checking harness, check intermediate connector G-12, and repair if necessary.

  • Check signal line for open circuits, short circuits to earth and damage.

Q. Is the check result normal?
Go to Step 6 .
Repair the damaged harness wire.

STEP 6. Check harness between G-03 (terminal No. 4) regular charging connector and earth.
note Before checking harness, check intermediate connector G-04, and repair if necessary.

  • Check earthing line for short circuit to earth.
note The resistor is built between the harnesses. When short circuits of the earth system occur in the upper stream, the regular charging should be disabled.

Q. Is the check result normal?
Go to Step 7 .
Repair the damaged harness wire.

STEP 7. Check harness between G-03 (terminal No. 5) regular charging connector and earth.

  • Check earthing line for open circuit and damage.

Q. Is the check result normal?
Go to Step 8 .
Repair the damaged harness wire.

STEP 8. Check the trouble symptom

Q. Does the trouble symptom persist?
Replace the EV-ECU.
Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).

STEP 9. Connector check: G-03 regular charging connector and G-11 on board charger/DC-DC converter connector
danger High voltage system components are served, be sure to pull service plugs to shut down high voltage (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).

Q. Are the check results normal?
Go to Step 10 .
Repair or replace the connector.

STEP 10. Check harness between G-03 regular charging connector and G-11 on board charger/DC-DC converter connector.

  1. Check and repair harness between G-03 (terminal No. 1) regular charging connector and G-11 (terminal No. 1) on board charger/DC-DC converter connector.
  2. Check and repair harness between G-03 (terminal No. 2) regular charging connector and G-11 (terminal No. 2) on board charger/DC-DC converter connector.

    • Check power supply line for open circuit.

Q. Are the check results normal?
Go to Step 11 .
Repair the damaged harness wire.

STEP 11. Check the trouble symptom

Q. Does the trouble symptom persist?
Replace the on board charger/DC-DC converter.
Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).




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