Hybrid Battery System: Inspection

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.

INSPECT BATTERY PLUG
1. Check the continuity.
  1. Using an ohmmeter, check the continuity between the terminals.
    Standard: 10 KΩ or higher
    
    If the standard is not met, replace the battery plug.
    
    Fig 1: Inspecting Battery Plug
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Install the service plug grip to the socket.
  3. Using an ohmmeter, check the continuity between the terminals.
    Standard: Below 1 Ω
    
    If the standard is not met, replace the battery plug.
    
    Fig 2: Checking Continuity Between The Terminals
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYSTEM MAIN RELAY NO. 1
NOTE: Connectors B and C have the same shape. Identify each connector by the wire harness length (L) and the wire harness color on the terminal 1 side.

Fig 3: Wire Harness Specifications
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 4: System Main Relay No. 1 Diagram
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Check the continuity.
  1. Using an ohmmeter, measure the resistance between the connectors.
    Standard:
    
    Fig 5: System Main Relay No. 1 Resistance Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the standards are not met, replace the system main relay No. 1.
  2. Using an ohmmeter, apply voltage between the positive and negative terminals, then measure the resistance between terminals 6 and A1 (CONT 1
    Standard: Below 1 Ω
    
    If the standard is not met, replace the system main relay No. 1.
2. Inspect the resistance.
  1. Using an ohmmeter, measure the resistance between terminals 6 and A1 (CONT 1).
    Standard: 70 to 160 Ω
    
    If the standard is not met, replace the system main relay No. 1.
INSPECT SYSTEM MAIN RELAY NO. 2
1. Install the 2 installed nuts to the negative and positive terminals.
  Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf)
2. Check the continuity.
  1. Using an ohmmeter, measure the resistance between the positive and negative terminals.
    Standard: 10 kΩ or higher
    
    If the standard is not met, replace the system main relay No. 2.
  2. Using an ohmmeter, apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals.
    Standard: Below 1 Ω
    
    Fig 6: Identifying Negative And Positive Terminals (Main Relay No. 2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the standard is not met, replace the system main relay No. 2
3. Inspect the resistance.
  1. Using an ohmmeter, measure the resistance between the connector terminals.
    Standard: 20 to 50 Ω
    
    If the standard is not met, replace the system main relay No. 2.
INSPECT SYSTEM MAIN RELAY NO. 3
1. Install the 2 installed nuts to the negative and positive terminals.
  Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf)
2. Check the continuity.
  1. Using an ohmmeter, measure the resistance between the positive and negative terminals.
    Standard: 10 kΩ or higher
    
    If the standard is not met, replace the system main relay No. 3.
  2. Using an ohmmeter, apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals.
    Standard: Below 1 Ω
    
    If the standard is not met, replace the system main relay No. 3.
3. Inspect the resistance.
  1. Using an ohmmeter, measure the resistance between the connector terminals.
    Standard: 20 to 50 Ω
    
    Fig 7: Identifying Negative And Positive Terminals (Main Relay No. 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the standard is not met, replace the system main relay No. 3.
INSPECT BATTERY CURRENT SENSOR
1. Inspect the resistance.
  
  Fig 8: Identifying Battery Current Sensor Connector Terminals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using an ohmmeter, measure the resistance between terminals 1 (VIB) and 2 (GIB).
    Standard:
    
    Fig 9: Resistance Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the standards are not met, replace the battery current sensor.
  2. Using an ohmmeter, measure the resistance between terminals 1 (VIB) and 3 (IB).
    
    Fig 10: Resistance Specifications
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard:
    
    If the standards are not met, replace the battery current sensor.
  3. Using an ohmmeter, measure the resistance between terminals 2 (GIB) and 3 (IB).
    Standard: 0.2 kΩ or less
    
    NOTE: Even if the probes are changed around, the resistance will not vary.
    
    If the standard is not met, replace the battery current sensor.
INSPECT SYSTEM MAIN RESISTOR
1. Inspect the resistance.
  1. Using an ohmmeter, measure the resistance between the terminals.
    Standard: 18 to 22 Ω
    
    Fig 11: Inspecting System Main Resistor
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the standard is not met, replace the system main resistor.
INSPECT BATTERY BLOWER RELAY NO. 1
1. Inspect the resistance.
  
  Fig 12: Inspecting Battery Blower Relay No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using an ohmmeter, measure the resistance between the terminals.
    Standard:
    
    Fig 13: Tester Connection & Specified Condition
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the standards are not met, replace the battery blower relay No. 1.