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Inspection Procedure 5: EV system overheating (oil cooling system)
 
 
 
 
COMMENTS ON TROUBLE SYMPTOM
The EV cooling system (oil cooling system), front motor or generator is suspected.
 
 
TROUBLESHOOTING HINTS
  • Malfunction of the EV oil cooling system (EV oil, oil cooling system line)
  • Malfunction of the electric oil pump
  • Malfunction of the EV oil cooler
  • Malfunction of the oil filter
  • Malfunction of the front motor
  • Malfunction of the generator
 
 
DIAGNOSIS
Required Special Tools:
  • MB992744: Vehicle communication interface-Lite (V.C.I.-Lite)
  • MB992745: V.C.I.-Lite main harness A
  • MB992747: V.C.I.-Lite USB cable short
  • MB992748: V.C.I.-Lite USB cable long
1.Check the EV oil replacement history
Is the oil other than genuine one is used in the past?
Replace all of the EV oil cooling system components.
 
2.M.U.T.-IIISE data list
noteIf there is abnormality on the electric oil pump operation (no oil circulation), skip this procedure and go to .
cautionTake care of burn because the EV oil cooler gets hot.
Check the following power drive unit data list.
Item No. 200: PDU OIL TEMP
Check conditionNormal condition
When the temperature of the EV oil reaches to 60°C (140°F) while the temperature is rising.The EV oil cooler gets warm.
noteThe bypass valve inside the EV oil cooler start opening when the oil temperature is between 50 and 55 °C (122 and 131°F), and it is fully opened when the oil temperature is between 60 and 65 °C (140 and 149°F).
Is the check result normal?
Replace the EV oil cooler (Refer to EV OIL COOLER REMOVAL AND INSTALLATION).
 
3.EV oil level check
(1) Park the vehicle on a level surface.
(2) Remove the oil level plug of the generator.
(3) Check that the oil does not come out from the oil level plug hole.
Is the check result normal?
 
4.Front transaxle fluid level check
Check the front transaxle fluid level by looking from the filler plug hole of the front transaxle.
Is the check result normal?
Replace all of the EV oil cooling system components.
 
5.EV oil level check
Check the EV oil level by looking from the oil level plug hole of the generator.
Is the check result normal?
 
6.Front transaxle fluid level check
(1) Park the vehicle on a level surface.
(2) Remove the filler plug of the front transaxle.
(3) Check that the fluid does not come out from the filler plug hole.
Is the check result normal?
Replace all of the EV oil cooling system components.
 
7.OIl filter check
Check that there is no clogging or break on the oil filter of the EV oil cooling system.
Is the check result normal?
<When the oil filter is broken>Replace all of the EV oil cooling system components.
<When the oil filter is clogged>Replace the oil filter (Refer to GENERATOR DISASSEMBLY AND ASSEMBLY).
 
8.EV oil cooling system line check
Visually check that the pipes and hoses for EV oil cooling system are not broken or damaged.
Is the check result normal?
The procedure is complete.
Replace the faulty part.