HIGH VOLTAGE CABLE INSPECTION [(E)]

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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.)

Visual Inspection

1.  Wear insulating gloves and remove the service plug.

(See SERVICE PLUG REMOVAL/INSTALLATION.)

2.  Wear insulating gloves and verify the conditions of the following high voltage wiring harnesses.

•  High voltage cable (high voltage battery — junction box No.3)
•  High voltage cable (DC-DC converter cable)
•  High voltage cable (electric compressor cable)
•  High voltage cable (PTC heater cable)
•  Onboard charger cable (charge port — onboard charger)
•  Onboard charger cable (onboard charger — high voltage battery)
•  Quick charging cable (charge port — intermediate connector)
•  Quick charging cable (intermediate connector — high voltage battery)

3.  If the wiring harnesses are damaged or excessively bent, wear insulating gloves and replace the wiring harnesses.


Continuity Inspection

Warning
<<High voltage>>
•  Inspections that require installation/removal of the high voltage battery cover cannot be performed because the high voltage battery cannot be disassembled. To inspect the continuity of the following high voltage cable, perform the troubleshooting on the DTCs output by the PCM, BECM, battery charge control module, and heat pump control unit. (See DTC INSPECTION.) (See DTC TABLE [PCM (e-SKYACTIV)].) (See DTC TABLE [BECM (e-SKYACTIV)].) (See DTC TABLE [BATTERY CHARGE CONTROL MODULE (e-SKYACTIV)].) (See DTC TABLE [HEAT PUMP CONTROL UNIT].)
―  High voltage cable (PTC heater cable)
―  Quick charging cable (intermediate connector — high voltage battery)

1.  Wear insulating gloves and remove the service plug.

(See SERVICE PLUG REMOVAL/INSTALLATION.)

2.  Wear insulating gloves and disconnect the terminals (both sides) of the high voltage cable between the high voltage battery and the junction box No.3.

(See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)

3.  Wear insulating gloves and remove the following high voltage wiring harnesses.

•  High voltage cable (DC-DC converter cable) (See DC-DC CONVERTER REMOVAL/INSTALLATION.)
•  High voltage cable (electric compressor cable) (See ELECTRIC COMPRESSOR REMOVAL/INSTALLATION.)
•  Onboard charger cable (charge port — onboard charger) (See ONBOARD CHARGER REMOVAL/INSTALLATION.)
•  Onboard charger cable (onboard charger — high voltage battery) (See ONBOARD CHARGER REMOVAL/INSTALLATION.) (See HIGH VOLTAGE BATTERY REMOVAL/INSTALLATION.)
•  Quick charging cable (charge port — intermediate connector) (See CHARGE PORT ASSEMBLY REMOVAL/INSTALLATION.)

4.  Wear insulating gloves and measure the insulation resistances between the following terminals.

High voltage cable resistance values

Inspection item

Terminal to be measured

Resistance (standard)
High voltage cable (high voltage battery — junction box No.3)
High voltage battery side terminal D — junction box No.3 terminal 1A
Less than 1 Ω
High voltage battery side terminal A — junction box No.3 terminal 2A
High voltage cable (DC-DC converter cable)
DC-DC converter side terminal A — junction box No.3 side terminal 3D
DC-DC converter side terminal D — junction box No.3 side terminal 3A
High voltage cable (electric compressor cable)
Junction box No.3 side terminal 4A — electric compressor side terminal A
Junction box No.3 side terminal 4D — electric compressor side terminal D
Onboard charger cable
(Charge port — onboard charger)
Charge port side terminal 2A — onboard charger side terminal 1A
Charge port side terminal 2G — onboard charger side terminal 1D
Onboard charger cable
(Onboard charger — high voltage battery)
Onboard charger side terminal 2D — high voltage battery side terminal A
Onboard charger side terminal 2A — high voltage battery side terminal D
Quick charging cable
(Charge port — intermediate connector)
Charge port side terminal 3A — intermediate connector P side terminal B
Charge port side terminal 3C — intermediate connector N side terminal B

High voltage cable (high voltage battery — junction box No.3)

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High voltage cable (DC-DC converter cable)

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High voltage cable (electric compressor cable)

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Onboard charger cable (charge port — onboard charger)

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Onboard charger cable (onboard charger — high voltage battery)

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Quick charging cable (charge port — intermediate connector)

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•  Wear insulating gloves and replace parts with values not within the standard.

Insulation Inspection


Inspection of insulation against body ground

Note
•  Perform an insulation inspection between each high voltage cable and the body ground according to the high voltage system electrical leakage inspection procedure. (See HIGH VOLTAGE SYSTEM ELECTRICAL LEAKAGE INSPECTION.)


Insulation inspection of each terminal

Warning
<<High voltage>>
•  Inspections that require installation/removal of the high voltage battery cover cannot be performed because the high voltage battery cannot be disassembled. To inspect the insulation between the terminals of the following high voltage cables, perform the troubleshooting on the DTCs output by the PCM, BECM, battery charge control module, and heat pump control unit. (See DTC INSPECTION.) (See DTC TABLE [PCM (e-SKYACTIV)].) (See DTC TABLE [BECM (e-SKYACTIV)].) (See DTC TABLE [BATTERY CHARGE CONTROL MODULE (e-SKYACTIV)].) (See DTC TABLE [HEAT PUMP CONTROL UNIT].)
―  High voltage cable (PTC heater cable)
―  Quick charging cable (intermediate connector — high voltage battery)

1.  Wear insulating gloves and remove the service plug.

(See SERVICE PLUG REMOVAL/INSTALLATION.)

2.  Wear insulating gloves and disconnect the terminals (both sides) of the high voltage cable between the high voltage battery and the junction box No.3.

(See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)

3.  Wear insulating gloves and remove the following high voltage wiring harnesses.

•  High voltage cable (DC-DC converter cable) (See DC-DC CONVERTER REMOVAL/INSTALLATION.)
•  High voltage cable (electric compressor cable) (See ELECTRIC COMPRESSOR REMOVAL/INSTALLATION.)
•  Onboard charger cable (charge port — onboard charger) (See ONBOARD CHARGER REMOVAL/INSTALLATION.)
•  Onboard charger cable (onboard charger — high voltage battery) (See ONBOARD CHARGER REMOVAL/INSTALLATION.) (See HIGH VOLTAGE BATTERY REMOVAL/INSTALLATION.)
•  Quick charging cable (charge port — intermediate connector) (See CHARGE PORT ASSEMBLY REMOVAL/INSTALLATION.)

4.  Wear insulating gloves and insulate the following terminals using electrical tape.

•  High voltage cable high voltage battery side terminal
•  High voltage cable (DC-DC converter cable) DC-DC converter side terminal
•  High voltage cable (electric compressor cable) electric compressor side terminal
•  Onboard charger cable (charge port — onboard charger) charging connector side terminal
•  Onboard charger cable (onboard charger — high voltage battery) high voltage battery side terminal
•  Quick charging cable (charge port — intermediate connector) charging connector side terminal
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 voltage applied by the insulation resistance tester may damage the parts.

5.  Wear insulating gloves and measure the insulation resistances between the following terminals using the insulation resistance tester (500 V range).

High voltage cable insulation resistance values

Inspection item

Terminal to be measured

Insulation resistance (standard)
High voltage cable (high voltage battery — junction box No.3)
Terminal 1A — Terminal 2A
100 MΩ or more
High voltage cable (DC-DC converter cable)
Terminal 3A — terminal 3D
High voltage cable (electric compressor cable)
Terminal 4A — terminal 4D
Onboard charger cable
(Charge port connector — onboard charger)
Terminal 1A — terminal 1D
Onboard charger cable
(Onboard charger — high voltage battery)
Terminal 2A — terminal 2D
Quick charging cable
(Charge port — intermediate connector)
P side terminal B — N side terminal B

High voltage cable (high voltage battery — junction box No.3)

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High voltage cable (DC-DC converter cable)

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High voltage cable (electric compressor cable)

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Onboard charger cable (charge port — onboard charger)

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Onboard charger cable (onboard charger — high voltage battery)

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Quick charging cable (charge port — intermediate connector)

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•  Wear insulating gloves and replace parts with values not within the standard.