Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: Hybrid/EV Battery Control System Over Temperature (P30004B)

DESCRIPTION

The hybrid vehicle control ECU monitors its internal operation and detects the following malfunction.

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

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1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream on.
3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
4. Turn the power switch off and wait for 2 minutes or more.
5. Turn the power switch on (IG) and turn the Techstream on.
6. Drive the vehicle for approximately 10 minutes according to the freeze frame data items "Vehicle Speed", "Hybrid Battery Temperature 1 to 3", "Hybrid Battery Cooling Fan Intake Air Temperature 1", "Ambient Temperature" and "Hybrid Battery Current".
7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. Check the DTC judgment result.

   HINT:

   • If the judgment result shows NORMAL, the system is normal.
   • If the judgment result shows ABNORMAL, the system has a malfunction.
   • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

CAUTION / NOTICE / HINT

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
• After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

  *a	Without waiting for 10 minutes

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  HINT:

  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

• Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

  If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

• When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

  *a	Dealer
  *b	Battery Collection Agent

• Before returning the HV battery, make sure to perform a recovery inspection.
• Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HV battery.

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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PROCEDURE

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

(a) Check the HV battery cooling system intake port for blockage. HINT: If anything is blocking the HV battery cooling system intake port, remove it.

*a Intake Port

(b) Clean the No. 1 HV battery intake filter.

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(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Read the freeze frame data of DTC P30004B.

NOTICE:

Although freeze frame data is recorded before and after a DTC is stored, for this step it is only necessary to read the freeze frame data recorded before "0s" (when the DTC was stored).

(e) Turn the power switch off.

B

GO TO STEP 7

A

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Read the freeze frame data of DTC P30004B.

NOTICE:

Although freeze frame data is recorded before and after a DTC is stored, for this step it is only necessary to read the freeze frame data recorded at "0s" (when the DTC was stored).

(e) Turn the power switch off.

B

GO TO STEP 8

A

(a) Apply the parking brake and secure the wheels using chocks.

(b) Connect the Techstream to the DLC3.

(c) Turn the power switch on (READY).

(d) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Temperature 1 to 3.

(e) According to the display on the Techstream, read the Data List and check that the value of each "Hybrid Battery Temperature 1 to 3" is 40°C (104°F) or less.

HINT:

If the value of any of "Hybrid Battery Temperature 1 to 3" is more than 40°C (104°F), turn the power switch off and wait until the values to decrease to 40°C (104°F) or less before continuing this procedure.

(f) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Block 1, 2, 9, 10, 11 Voltage.

(g) According to the display on the Techstream, read the Data List and check the value of each "Hybrid Battery Block 1, 2, 9, 10 and 11 Voltage" with the power switch on (IG).

(h) Turn the power switch off.

B

GO TO STEP 8

A

(a) Apply the parking brake and secure the wheels using chocks.

(b) Connect the Techstream to the DLC3.

(c) Turn the power switch on (READY).

(d) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Temperature 1 to 3.

(e) According to the display on the Techstream, read the Data List and check that the value of each "Hybrid Battery Temperature 1 to 3" is 40°C (104°F) or less.

HINT:

If the value of any of "Hybrid Battery Temperature 1 to 3" is more than 40°C (104°F), turn the power switch off and wait until the values to decrease to 40°C (104°F) or less before continuing this procedure.

(f) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Block 3 to 8 Voltage.

(g) According to the display on the Techstream, read the Data List and check the value of each "Hybrid Battery Block 3 to 8 Voltage" with the power switch on (IG).

(h) Turn the power switch off.

A

END

B

GO TO STEP 8

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NEXT

REPLACE HV BATTERY

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REPLACE HV BATTERY