HIGH VOLTAGE SYSTEM ELECTRICAL LEAKAGE INSPECTION

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Warning

<<High voltage>>

•  If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See HIGH VOLTAGE SERVICE CAUTIONS.)

High Voltage Part Inspection And Removal/Installation Notes

Warning

<<High voltage>>

•  If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See HIGH VOLTAGE SERVICE CAUTIONS.) (See HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)

Step	Inspection	Results	Action
1	VERIFY DTCs •  Inspect for BECM-related DTCs. (See DTC INSPECTION.) •  DTC P0AA7:00 is output?	Yes	Go to the next step.
		No	If any other DTC is output, perform the applicable DTC troubleshooting and repair or replace the malfunctioning location. (See DTC TABLE [BECM (e-SKYACTIV)].)
2	VERIFY DTCs AGAIN •  Clear the DTC. (See CLEARING DTC.) •  Switch the main power ON (READY off). •  Inspect for PCM-related DTCs. (See DTC INSPECTION.) •  Is an electrical leakage-related DTC output?	Yes	Wear insulating gloves and replace the high voltage battery. (Electrical leakage is present at the cells or bus bars in the high voltage battery.) (See HIGH VOLTAGE BATTERY REMOVAL/INSTALLATION.)
		No	Go to the next step.
3	CUT OFF HIGH VOLTAGE CIRCUIT Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Remove the service plug. (See SERVICE PLUG REMOVAL/INSTALLATION.) •  After 10 min have elapsed after removing the service plug, wear insulating gloves and perform a zero voltage verification at the voltage detection point of the junction box No.3 to verify that there is no electrical charge in the high voltage circuit. (See JUNCTION BOX No.3 REMOVAL/INSTALLATION.)	—	Go to the next step.
4	DETERMINE IF ELECTRICAL LEAKAGE CAUSE IS HIGH VOLTAGE BATTERY OR INVERTER Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the high voltage cable on the junction box No.3 side. (See JUNCTION BOX No.3 REMOVAL/INSTALLATION.) Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe •  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). High voltage cable terminals: ―  High voltage cable terminal 1A (Voltage application side probe)—Body ground (Ground side probe) ―  High voltage cable terminal 2A (Ground side probe)—Body ground (Voltage application side probe) a30zzw00004497 •  Is the insulation resistance more than 100 megohms?	Yes	Go to the next step.
		No	Go to Step 9.
5	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS ON ONBOARD CHARGER SIDE Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the high voltage system connector of the onboard charger. (See ONBOARD CHARGER REMOVAL/INSTALLATION.) a30jjw00000010 Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe	Yes	Wear insulating gloves and replace the onboard charger. (Electrical leakage is present in the onboard charger.) (See ONBOARD CHARGER REMOVAL/INSTALLATION.)
		No	Go to the next step.
	•  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). High voltage cable terminals: ―  High voltage cable terminal 1A (Voltage application side probe)—Body ground (Ground side probe) ―  High voltage cable terminal 2A (Ground side probe)—Body ground (Voltage application side probe) a30zzw00004497 •  Is the insulation resistance more than 100 megohms?
6	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS IN HIGH VOLTAGE CABLE (ONBOARD CHARGER CABLE) Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the connector of the onboard charging cable (onboard charger — high voltage battery) shown in the figure. (See ONBOARD CHARGER REMOVAL/INSTALLATION.) a30zzw00006986	Yes	Wear insulating gloves and replace the onboard charger cable (onboard charger — high voltage battery). (Electrical leakage is present in the onboard charger cable (onboard charger — high voltage battery) )
		No	Go to the next step.
	Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe •  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). High voltage cable terminals: ―  High voltage cable terminal 1A (Voltage application side probe)—Body ground (Ground side probe) ―  High voltage cable terminal 2A (Ground side probe)—Body ground (Voltage application side probe) a30zzw00004497 •  Is the insulation resistance more than 100 megohms?
7	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS ON PTC HEATER SIDE Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the high voltage system connector of the PTC heater. (See POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER REMOVAL/INSTALLATION.) Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe •  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). High voltage cable terminals: ―  High voltage cable terminal 1A (Voltage application side probe)—Body ground (Ground side probe) ―  High voltage cable terminal 2A (Ground side probe)—Body ground (Voltage application side probe) a30zzw00004497 •  Is the insulation resistance more than 100 megohms?	Yes	Wear insulating gloves and replace the PTC heater. (Electrical leakage is present in the PTC heater.) (See POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER REMOVAL/INSTALLATION.)
		No	Go to the next step.
8	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS IN HIGH VOLTAGE BATTERY OR HIGH VOLTAGE CABLE Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the high voltage cable connector on the high voltage battery side. (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.) a30jjw00000015 Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe	Yes	Wear insulating gloves and replace the high voltage cable. (Electrical leakage is present in the high voltage cable.) (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)
		No	Wear insulating gloves and replace the high voltage battery. (Electrical leakage is present at the cells or bus bars in the high voltage battery.) (See HIGH VOLTAGE BATTERY REMOVAL/INSTALLATION.)
	•  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). High voltage battery connector: ―  Cable terminal D (Voltage application side probe)—Body ground (Ground side probe) ―  Cable terminal A (Ground side probe)—Body ground (Voltage application side probe) a30zzw00004740 •  Is the insulation resistance more than 100 megohms?
9	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS ON ELECTRIC COMPRESSOR SIDE Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the high voltage system connector of junction box No.3. a30zzw00004741 Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester.	Yes	Go to Step 11.
		No	Go to the next step.
	Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe •  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). Cable side connector: ―  Cable terminal D (Voltage application side probe)—Body ground (Ground side probe) ―  Cable terminal A (Ground side probe)—Body ground (Voltage application side probe) a30zzw00007151 •  Is the insulation resistance more than 100 megohms?
10	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS IN HIGH VOLTAGE CABLE (ELECTRIC COMPRESSOR CABLE) Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •   Wear insulating gloves and disconnect the high voltage system connector of the electric compressor. (See ELECTRIC COMPRESSOR REMOVAL/INSTALLATION.) a30jjw00000039	Yes	Wear insulating gloves and replace the high voltage cable (electric compressor cable). (Electrical leakage is present in the high voltage cable (electric compressor cable).) (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)
		No	Wear insulating gloves and replace the electric compressor. (Electrical leakage is present in the electric compressor.) (See ELECTRIC COMPRESSOR REMOVAL/INSTALLATION.)
	Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe •  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). Electric compressor: ―  Terminal A (Voltage application side probe)—Body ground (Ground side probe) ―  Terminal D (Ground side probe)—Body ground (Voltage application side probe) a30jjw00000041 •  Is the insulation resistance more than 100 megohms?
11	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS ON DC-DC CONVERTER SIDE Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the high voltage system connector of the junction box No.3. a30zzw00004743 Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe	Yes	Go to Step 13.
		No	Go to the next step.
	•  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). Cable side connector: ―  Terminal A (Voltage application side probe)—Body ground (Ground side probe) ―  Terminal D (Ground side probe)—Body ground (Voltage application side probe) a30zzw00007152 •  Is the insulation resistance more than 100 megohms?
12	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS IN HIGH VOLTAGE CABLE (DC-DC CONVERTER CABLE) Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and disconnect the high voltage system connector of the DC-DC converter. (See DC-DC CONVERTER REMOVAL/INSTALLATION.) a30zzw00001962 Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester.	Yes	Wear insulating gloves and replace the high voltage cable (DC-DC converter cable). (Electrical leakage is present in the high voltage cable (DC-DC converter cable).) (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)
		No	Wear insulating gloves and replace the DC-DC converter. (Electrical leakage is present in the DC-DC converter.) (See DC-DC CONVERTER REMOVAL/INSTALLATION.)
	Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  The direction of the voltage applied by the insulation resistance tester when measuring the insulation resistance differs depending on the insulation resistance tester manufacturer. To prevent damage to the parts, confirm the voltage application side and ground side probes using the insulation resistance tester instruction manual, and connect the insulation resistance tester probes to the measuring terminals as follows. During high voltage (+) side circuit measurement: ―  Measuring terminal: Voltage application side probe ―  Body ground side: Ground side probe During high voltage (-) side circuit measurement: ―  Measuring terminal side: Ground side probe ―  Body ground side: Voltage application side probe •  Wear insulating gloves and measure the insulation resistance between the following terminals using the insulation resistance tester (500 V range). DC-DC converter: ―  Terminal A (Voltage application side probe)—Body ground (Ground side probe) ―  Terminal D (Ground side probe)—Body ground (Voltage application side probe) a30jjw00000044 •  Is the insulation resistance more than 100 megohms?
13	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS ON JUNCTION BOX NO.3 SIDE Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and remove the junction box No.3. (See JUNCTION BOX No.3 REMOVAL/INSTALLATION.) Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  Wear insulating gloves and measure the insulation resistance between the following terminals and each housing using the insulation resistance tester (500 V range). Junction box No.3: ―  Terminal P ―  Terminal N a30zzw00001963 •  Is the insulation resistance more than 100 megohms?	Yes	Go to the next step.
		No	Wear insulating gloves and replace the junction box No.3. (Electrical leakage is present in the junction box No.3.) (See JUNCTION BOX No.3 REMOVAL/INSTALLATION.)
14	DETERMINE IF ELECTRICAL LEAKAGE LOCATION IS IN INVERTER OR ELECTRIC MOTOR Warning <<High voltage>> •  Wear insulating gloves when working on a high voltage system. •  Verify that the service plug is removed. •  Wear insulating gloves and remove the inverter. (See INVERTER REMOVAL/INSTALLATION.) Warning <<High voltage>> •  For the insulation resistance tester usage, refer to the insulation resistance tester instruction manual. Otherwise, electrocution could result from the voltage generated by the insulation resistance tester. Caution <<High voltage>> •  Use an insulation resistance tester using a testing range of 500 V or less because the high voltage applied by the insulation resistance tester may damage the parts. •  Wear insulating gloves and measure the insulation resistance between the following terminals and each housing using the insulation resistance tester (500 V range). Electric motor: ―  Terminal U ―  Terminal V ―  Terminal W a30zzw00001966 •  Is the insulation resistance more than 100 megohms?	Yes	Wear insulating gloves and replace the inverter. (Electrical leakage is present in the inverter.) (See INVERTER REMOVAL/INSTALLATION.)
		No	Wear insulating gloves and replace the electric motor. (Electrical leakage is present in the electric motor.) (See ELECTRIC MOTOR REMOVAL/INSTALLATION.)