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HV Relay Assembly: Inspection

  1. INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY 
    1. SMRB inspection
      Fig 1: Locating Electric Vehicle Fuses And Bolts
      G05780892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 2: Identifying HV Battery Junction Block Assembly And Connector Location
      G05780893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below

        Standard resistance 

        RESISTANCE REFERENCE

        Tester Connection Condition Specified Condition
        g2-1 - z30-1 Battery voltage is not applied between terminals z38-3 (CON2) and z38-2 (GND) 10 kΩ or higher
        g2-1 - z30-1 Battery voltage is applied between terminals z38-3 (CON2) and z38-2 (GND) Below 1 Ω
        g2-1 - z58-1 Always Below 1 Ω
        g2-1 - z27-1 Always Below 1 Ω

        If the resistance is not as specified, replace the HV battery junction block assembly or electric vehicle fuse.

      2. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        RESISTANCE REFERENCE

        Tester Connection Condition Specified Condition
        z38-3 (CON2) - z38-2 (GND) -35 to 80°C (-31 to 176°F) 18 8 to 32 1 Ω
    2. SMRG inspection
      Fig 3: Identifying HV Battery Junction Block Assembly And Connector Location
      G05780894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        RESISTANCE REFERENCE

        Tester Connection Condition Specified Condition
        g3-1 - z34-1 Battery voltage is not applied between terminals z38-1 (CON1) and z38-2 (GND) 10 kΩ or higher
        g3-1 - z34-1 Battery voltage is applied between terminals z38-1 (CON1) and z38-2 (GND) Below 1 Ω
        g3-1 - z60-1 Always Below 1 Ω
        z34-1 - z59-1 Always Below 1 Ω
        z34-1 - z27-4 Always Below 1 Ω
      2. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        RESISTANCE REFERENCE

        Tester Connection Condition Specified Condition
        z38-1 (CON1) - z38-2 (GND) -35 to 80°C (-31 to 176°F) 18 8 to 32 1 Ω

        If the resistance is not as specified, replace the HV battery junction block assembly or electric vehicle fuse

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