HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA6-526, P0AA6-611, P0AA6-612, P0AA6-613, P0AA6-614

DTC Code DTC Name
P0AA6-526 Hybrid Battery Voltage System Isolation Fault
P0AA6-611 Hybrid Battery Voltage System Isolation Fault
P0AA6-612 Hybrid Battery Voltage System Isolation Fault
P0AA6-613 Hybrid Battery Voltage System Isolation Fault
P0AA6-614 Hybrid Battery Voltage System Isolation Fault

DESCRIPTION

The hybrid vehicle control ECU monitors the battery smart unit and detects insulation malfunctions in the high-voltage system.

DTC No. INF Code DTC Detection Condition Trouble Area
P0AA6 526(*1) Insulation resistance between the high-voltage circuit and the body has decreased.*2

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly

  • Frame wire

  • No. 2 engine wire

  • Hybrid battery junction block assembly

  • Air conditioning system

  • HV battery

  • Battery smart unit
611 Insulation resistance of the high voltage circuit in the air conditioning system has decreased.*3 Air conditioning system
612 Insulation resistance of the HV battery area has decreased.*3

  • Hybrid battery junction block assembly

  • Battery smart unit

  • HV battery
613 Insulation resistance of the transaxle area has decreased.*3

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly
614 Insulation resistance of the high-voltage DC area has decreased.*3

  • Inverter with converter assembly

  • Frame wire

  • Air conditioning system

  • No. 2 engine wire

  • Hybrid battery junction block assembly

Tech Tips


  • *1: INF code 526 is stored together with P0AA6.

  • *2: The insulation malfunction detection circuit in the battery voltage sensor monitors the insulation resistance between the high voltage circuits and body. If the insulation resistance decreases, the hybrid vehicle control ECU stores DTC P0AA6-526 and illuminates the MIL first.

  • *3: If the following operations are performed within the same trip after DTC P0AA6-526 is stored, just one of the related DTCs (P0AA6-611, 612, 613 or 614) will be stored.


    1. Apply the parking brake firmly.

    2. Wait for 1 minute or more with the vehicle stopped, the brake pedal firmly depressed, the power switch on (READY), drive (D) selected and the air conditioning system on (Lo/COOL MAX, blower speed HI), then turn the power switch off and wait for 1 minute or more.

  • If DTC P0AA6 is stored, the vehicle cannot start.

  • When measuring insulation resistance using a megohmmeter, measure the resistance while jiggling the high voltage wire harness.

WIRING DIAGRAM

B005YHIE01
Text in Illustration
*1 HV Battery *2 Battery Smart Unit
*3 SMRB *4 SMRG
*5 SMRP *6 System Main Resistor
*7 Service Plug Grip *8 Inverter with Converter Assembly
*9 Boost Converter *10 Inverter
*11 MG1 *12 MG2
*13 Compressor with Motor Assembly *14 A/C Inverter
*15 A/C Motor - -
*a High-voltage Areas *b INF Code 526 Vehicle Insulation Resistance Reduction Area
*c INF Code 611 Air Conditioning System Area *d INF Code 612 HV Battery Area
*e INF Code 613 Transaxle Area *f INF Code 614 High Voltage Direct Current Area

SYSTEM DESCRIPTION

Tech Tips

If a decrease in insulation resistance cannot be confirmed using a megohmmeter, check the Short Wave Highest Val in the Data List.


  1. Characteristics of Short Wave Highest Value


    1. The Data List item Short Wave Highest Val and insulation resistance have the relationship shown in the table below. Short Wave Highest Val decreases with a decrease in insulation resistance. However, in some cases, even though the insulation resistance of the vehicle is normal, Short Wave Highest Val may decrease. Therefore, check Short Wave Highest Val while considering the following.


      • Do not check until approximately 1 minute has passed after the power switch is turned on (IG) (*1).

      • Do not check when there is a difference between the system voltages (Power Resource VB, VL-Voltage before Boosting, and VH-Voltage after Boosting) (*2).

        Short Wave Highest Value Trouble Area
        Neither condition (*1) nor (*2) is met and Short Wave Highest Val is approximately 0 V Since the insulation resistance is close to 0 Ω, there is a strong possibility of interference with a metal object.
        Neither condition (*1) nor (*2) is met and Short Wave Highest Val is between 0 and 5 V Since the insulation resistance is several hundred kiloohms, there is a strong possibility of the presence of fluid such as coolant.

  2. How to Determine Part with Insulation Malfunction


    1. Jiggle the high-voltage wire harness to check if the resistance to body ground changes with the position of the wire harness or force applied.

    2. Repeat rotating and stopping of the MG1, MG2 and compressor with motor assembly. Check that the Short Wave Highest Val does not decrease (for example if the motor stops with foreign matter forming a leak path) when the motor stops, or that the Short Wave Highest Val does not return to normal (for example if foreign matter moves away from the leak path) when the motor rotates.

    3. Increase the temperature of MG1and MG2. Check if the Short Wave Highest Val decreases with the temperature increase.

    4. Check that the transaxle fluid is not cloudy and the coolant level in the reserve tank has not dropped as the transaxle fluid will become cloudy when mixed with coolant, resulting in low insulation resistance.

  3. Confirmation After Replacing Parts


    1. After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output. (Do not turn the power switch off during this inspection.)


      1. Apply the parking brake and secure the wheels using chocks.

      2. With the vehicle stationary, turn the power switch on (READY) with park (P) selected and wait for 60 seconds or more.

      3. Turn the air conditioning system on (MAX COLD, blower speed HI).

      4. While depressing the brake pedal without depressing the accelerator pedal, move the shift lever to D and wait for 5 minutes.


        • If step A is performed within the same trip after DTC P0AA6-526 is stored, the parts with insufficient insulation resistance will be determined, and a DTC (P0AA6-611, 612, 613 or 614) will be stored.

        • If no DTCs are output, proceed to the next step.

      5. Drive the vehicle for approximately 5 minutes referring to the following freeze frame data items: "Vehicle Spd", "Shift Sensor Shift Pos", "Accel Pedal Pos #1", "Engine Revolution", "Engine Coolant Temp" and "Master Cylinder Ctrl Trq" (If the freeze frame data item "Vehicle Spd" is 6 mph (10 km/h) or less, drive the vehicle at 6 mph (10 km/h) or more.).


        • If step A is performed within the same trip after DTC P0AA6-526 is stored, the parts with insufficient insulation resistance will be determined, and a DTC (P0AA6-611, 612, 613 or 614) will be stored.

        • If no DTCs are output, insulation fault does not detected.

      6. Wait for 1 minute or more with the vehicle stopped, the power switch on (READY), the shift lever in P and the air conditioning system on (Lo/COOL MAX, blower speed HI), then turn the power switch off and wait for 1 minute or more. (Step A)

CAUTION / NOTICE / HINT

CAUTION:


  • When performing P0AA6 troubleshooting, use either a tool wrapped with vinyl insulation tape or a insulated tool. (It is extremely dangerous when a high-voltage charge passes through a non-insulated tool causing a short.)

  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, 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 Click here.

    Tech Tips

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

  • 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.

  • Before returning the HV battery, make sure to perform a recovery inspection Click here

  • Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HV battery.

Note

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 Click here.

Tech Tips

When measuring insulation resistance using a megohmmeter, set the megohmmeter to 500 V.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0AA6 only is output. A
      P0AA6 and P0A1D (hybrid vehicle control ECU malfunction) are output. B
      P0AA6 and P0AA7 (malfunction in the battery smart unit) are output. C
      P0AA6 and P0AFC-150 (Hybrid Battery Pack Sensor Module), P0B23-129 (Hybrid battery "A" voltage) are output. D

    5. Turn the power switch off.


    B

    GO TO DTC CHART (P0A1D) Click here

    C

    GO TO DTC CHART (P0AA7) Click here

    D

    GO TO DTC CHART (P0AFC-150, P0B23-129) Click here

    A

  2. CHECK INFORMATION CODE


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Access the freeze frame data of DTC P0AA6 and read the INF code.

      Note


      • Information codes 611, 612, 613 and 614 are not stored with 526 simultaneously. If a drop in insulation resistance is detected and DTC P0AA6-526 is output, wait for 1 minute with power switch on (READY), drive (D) selected and the air conditioning system on within the same trip, then turn the power switch off and wait for 1 minute to determine the information code (611, 612, 613 or 614).

      • If only DTC P0AA6-526 is output, perform the diagnosis procedure for INF code 526 to inspect all the high voltage circuits.

      Result
      Result Proceed to
      526 (decrease in the insulation resistance of the high-voltage circuit) only is output. A
      526 and 611 (decrease in the insulation resistance of the air conditioning system area) are output.

      Refer to the troubleshooting procedures for P0AA6-611 (Air conditioning system) Click here

      526 and 612 (decrease in the insulation resistance of the battery area) are output. B
      526 and 613 (decrease in the insulation resistance of the transaxle area) are output. C
      526 and 614 (decrease in the insulation resistance of the high-voltage DC area) are output. D

    5. Turn the power switch off.


    B

    CHECK HV BATTERY AREA Click here

    C

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    D

    CHECK HIGH VOLTAGE DIRECT CURRENT AREA Click here

    A

  3. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

    3. B005YIYE02
      Text in Illustration
      *1 Motor Cable
      *2 Generator Cable

      Disconnect the motor cable e1 and generator cable f1 from the inverter with converter assembly.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

      Tech Tips

      As the insulation resistance may vary when motor (MG2) rotates, perform this inspection while rotating the front wheels.

    5. Turn the power switch on (IG).

      Note

      Turning the power switch on (IG) with the service grip removed causes DTCs to be stored. Clear the DTCs after performing this inspection.

    6. With the neutral (N) selected and lift up the vehicle.

    7. B005YTKE02
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below while rotating the front wheels 2 revolutions in the same direction simultaneously.

      Note


      • Carefully perform this inspection as motor (MG2) may generate current when the front wheels are rotated by hand.

      • Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      e1-3 (V) - Body ground and shield ground Power switch on 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch on 100 MΩ or higher
      e1-1 (W) - Body ground and shield ground Power switch on 100 MΩ or higher

    8. Lower the vehicle and push the P position switch.

    9. Turn the power switch off.

    10. Disconnect the cable from the negative (-) auxiliary battery terminal.


    NG

    CHECK MOTOR CABLE Click here

    OK

  4. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Connect the cable to the negative (-) auxiliary battery terminal.

      Tech Tips

      As the insulation resistance may vary when generator (MG1) rotates, perform this inspection while rotating the front wheels.

    3. Turn the power switch on (IG).

      Note

      Turning the power switch on (IG) with the service grip removed causes DTCs to be stored. Clear the DTCs after performing this inspection.

    4. With the neutral (N) selected and lift up the vehicle.

    5. B005XPBE02
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below while rotating the front wheels 2 revolutions in the same direction simultaneously.

      Note


      • Carefully perform this inspection as generator (MG1) may generate current when the front wheels are rotated by hand.

      • Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-3 (V) - Body ground and shield ground Power switch on 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch on 100 MΩ or higher
      f1-1 (W) - Body ground and shield ground Power switch on 100 MΩ or higher

    6. Lower the vehicle and push the P position switch.

    7. Turn the power switch off.

    8. Disconnect the cable from the negative (-) auxiliary battery terminal.


    NG

    CHECK GENERATOR CABLE Click here

    OK

  5. CHECK NO. 2 ENGINE WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005ZF9E02

      Disconnect the No. 2 engine wire (air conditioning harness) E3 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the connector of the No. 2 engine wire (air conditioning harness) E3.

    3. B005Z2LE02
      Text in Illustration
      *1

      No. 2 Engine Wire (Air Conditioning Harness)

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      E3-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      E3-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher

    NG

    CHECK NO. 2 ENGINE WIRE Click here

    OK

  6. CHECK INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005Z9WE02

      Disconnect the frame wire T1 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the connector of the frame wire T1.

    3. B005ZME

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      High voltage terminal - Body ground Power switch off 1 MΩ or higher

      Tech Tips

      Perform this inspection with the motor cable, generator cable and No. 2 engine wire (air conditioning harness) disconnected from the inverter with converter assembly.


    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    OK

  7. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005Y5TE02
      Text in Illustration
      *1

      Frame Wire

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      T1-2 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the frame wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.


    NG

    CHECK FRAME WIRE Click here

    OK

  8. CHECK HV BATTERY AREA

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    3. B005YVEE02

      Disconnect the z30, z31, z32 and z33 battery smart unit connectors.

    4. B005ZKEE02

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      1 - Body ground Power switch off 10 MΩ or higher
      2 - Body ground Power switch off 10 MΩ or higher

    NG

    CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  9. CHECK HV BATTERY


    1. Check that no electrolyte is leaking from each HV battery stack Click here.

      Result
      Result Proceed to
      Electrolyte is not leaking from the HV battery stack. A
      Electrolyte is leaking from the HV battery stack. B

    A

    REPLACE BATTERY SMART UNIT Click here

    B

    REPLACE HV BATTERY Click here

  10. CHECK INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

    3. B005YIYE02
      Text in Illustration
      *1 Motor Cable
      *2 Generator Cable

      Disconnect the motor cable e1 and generator cable f1 from the inverter with converter assembly.

    4. B005ZDP

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      High voltage terminal - Body ground Power switch off 1 MΩ or higher
      Result
      Result Proceed to
      NG A
      OK B

    A

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    B

    CHECK MOTOR CABLE Click here

  11. CHECK HIGH VOLTAGE DIRECT CURRENT AREA

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

    3. B005ZAWE03

      Disconnect the frame wire T1 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the connector of the frame wire T1.

    4. B005Y5TE02
      Text in Illustration
      *1

      Frame Wire

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      T1-2 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the frame wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.


    NG

    CHECK FRAME WIRE Click here

    OK

  12. CHECK NO. 2 ENGINE WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005Y84E02

      Disconnect the No. 2 engine wire (air conditioning harness) E3 from the inverter with converter assembly.

    3. B005Z2LE02
      Text in Illustration
      *1

      No. 2 Engine Wire (Air Conditioning Harness)

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      E3-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      E3-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

  13. CHECK NO. 2 ENGINE WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005YBYE04
      Text in Illustration
      *1 Green Lock

      Disconnect the No. 2 engine wire (air conditioning harness) E1 from the compressor with motor assembly.

    3. B005Z2LE02
      Text in Illustration
      *1

      No. 2 Engine Wire (Air Conditioning Harness)

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      E3-1 (ACPB) - Body ground and shield ground Power switch off 10 MΩ or higher
      E3-2 (ACPE) - Body ground and shield ground Power switch off 10 MΩ or higher

    OK

    GO TO AIR CONDITIONING SYSTEM (P0AA6-611) Click here

    NG

    REPLACE NO. 2 ENGINE WIRE

  14. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    3. B005Z8V

      Disconnect the frame wire from the hybrid battery junction block assembly.

    4. B005Y12E02
      Text in Illustration
      *1 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T6-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      T5-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the frame wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.


    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE FRAME WIRE Click here

  15. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005ZT2E02

      Disconnect the high voltage cable connector of the HV battery k3 and h3 from the hybrid battery junction block assembly.

    3. B005YZKE02

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      h3-1 (-) - Hybrid Battery Carrier Panel Power switch off 10 MΩ or higher
      k3-1 (+) - Hybrid Battery Carrier Panel Power switch off 10 MΩ or higher

    OK

    REPLACE HV BATTERY Click here

    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

  16. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the motor cable from the hybrid vehicle transaxle assembly Click here.

    3. B005YTKE02
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  17. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the generator cable from the hybrid vehicle transaxle assembly Click here.

    3. B005XPBE02
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  18. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the motor cable from the hybrid vehicle transaxle assembly Click here.

    3. B005YTKE02
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    NG

    REPLACE MOTOR CABLE Click here

    OK

  19. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the generator cable from the hybrid vehicle transaxle assembly Click here.

    3. B005XPBE02
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here