HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA649, P1C7C49, P1C7D49, P1C7E49, P1C7F49

DTC Code DTC Name
P0AA649 Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure
P1C7C49 Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure
P1C7D49 Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure
P1C7E49 Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure
P1C7F49 Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure

DESCRIPTION

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

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P0AA649 Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure

Insulation resistance between the high-voltage circuit and the body has decreased.*1

(1 trip detection logic)

  • Inverter with converter assembly

  • HV floor under wire

  • HV battery junction block assembly

  • Battery ECU assembly

  • Battery voltage sensor (for upper side)

  • Hybrid battery terminal block

  • No. 1 HV supply stack sub-assembly

  • No. 2 HV supply stack sub-assembly

  • Hybrid vehicle transmission assembly

  • Motor cable

  • Generator cable

  • No. 1 HV battery pack wire

  • HV air conditioning wire

  • Air conditioning system

 Does not come on

Master Warning Light:

Comes on
P1C7C49 Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure

Insulation resistance of the compressor with motor assembly or air conditioning inverter has decreased.*2

(1 trip detection logic)

 Air conditioning system Does not come on

Master Warning Light:

Comes on
P1C7D49 Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure

Insulation resistance of the HV battery, battery ECU assembly or SMR has decreased.*2

(1 trip detection logic)

  • HV battery junction block assembly

  • Battery ECU assembly

  • Battery voltage sensor (for upper side)

  • Hybrid battery terminal block

  • No. 1 HV supply stack sub-assembly

  • No. 2 HV supply stack sub-assembly

 Does not come on

Master Warning Light:

Comes on
P1C7E49 Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure

Insulation resistance of the hybrid vehicle transmission assembly or inverter for the generator (MG1) and motor (MG2) has decreased.*2

(1 trip detection logic)

  • Hybrid vehicle transmission assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly

 Does not come on

Master Warning Light:

Comes on
P1C7F49 Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure

Insulation resistance of the inverter for the generator (MG1) and motor (MG2), A/C inverter, SMR or HV floor under wire has decreased.*2

(1 trip detection logic)

  • Inverter with converter assembly

  • HV floor under wire

  • HV battery junction block assembly

  • Air conditioning system

  • HV air conditioning wire

 Does not come on

Master Warning Light:

Comes on

Tech Tips


  • *1: The insulation malfunction detection circuit in the battery ECU assembly monitors the insulation resistance between the high voltage circuits and body. If the insulation resistance decreases, the hybrid vehicle control ECU assembly stores DTC P0AA649 and illuminates the master warning light first regardless of malfunction area.

    Sometimes the insulation malfunction is hard to duplicate due to the vehicle's condition changing. So if DTC P0AA649 outputs, complete the following steps as soon as possible.

  • *2: If the following operations are performed within the same trip after DTC P0AA649 is stored, just one of the related DTCs (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) 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/MAX COOL, blower speed HI).

    3. Turn the power switch off and wait for 2 minutes or more.

      Tech Tips


      • DTCs and freeze frame data are useful information in determining the malfunctioning part. Before performing diagnosis, make sure to check and make a note of all output DTCs and freeze frame data. (Even if a high-voltage insulation malfunction cannot be reproduced, once stored, DTCs of insulation will not be cleared unless the clear operation is performed.)

      • When the insulation resistance of the HV battery area decreases and the power switch is turned on (IG), DTC P1C7D49 is stored within 2 minutes.

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

Related Data List (Reproduction of Phenomenon and Check)
DTC No. Data List
P0AA649

  • Short Wave Highest Value Level

  • Hybrid Battery Voltage

  • VL-Voltage before Boosting

  • VH-Voltage after Boosting

  • Boost Ratio

  • A/C Consumption Power

  • SMRP Status

  • SMRB Status

  • SMRG Status

  • Generator Inverter Shutdown Status

  • Motor Inverter Shutdown Status

  • Insulation Resistance Division Check Completion using MG Inv

  • Insulation Resistance Division Check Completion using A/C Inv

  • Insulation Resistance Division Check Completion using SMR

  • Short Wave Highest Value Availability just after MG Inv On/Off

  • Short Wave Highest Value Availability just after A/C Inv On/Off

  • Short Wave Highest Value Availability just after SMR On/Off
P1C7C49
P1C7D49
P1C7E49
P1C7F49

Use the following items as a reference when duplicating the vehicle conditions at the time when the malfunction occurred.


CONFIRMATION DRIVING PATTERN


  1. Tech Tips

    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. (Do not turn the power switch off (READY off) during this inspection.)

    Click here


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG) and turn the GTS 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. Apply the parking brake and secure the wheels using chocks.

    6. When the vehicle is stationary, turn the power switch on (READY) with park (P) selected and wait for 1 minute or more.

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

    8. While depressing the brake pedal without depressing the accelerator pedal, move the shift lever to select shift state drive (D) and wait for 5 minutes.

      - If step A is performed within the same trip after DTC P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

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

    9. Drive the vehicle for approximately 5 minutes referring to the following freeze frame data items: "Vehicle Speed", "Shift Position", "Accelerator Position Sensor No.1 Voltage %", "Engine Speed", "Coolant Temperature", "Master Cylinder Control Torque", "Inverter Coolant Water Temperature", "Motor Temperature" and "Generator Temperature"

      (If the freeze frame data item "Vehicle Speed" is 10 km/h (6 mph) or less, drive the vehicle at 10 km/h (6 mph) or more.)

      - If step A is performed within the same trip after DTC P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

      - If DTC P0AA649 is output, complete the Step A immediately as quickly as possible.

    10. Wait for 1 minute or more with the vehicle stopped, the power switch on (READY), park (P) selected and the air conditioning system on (Lo/COOL MAX, blower speed HI), then turn the power switch off and wait for 2 minutes or more. (Step A)

    11. Turn the power switch on (IG) and turn the GTS on.

    12. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

    13. Check the DTC judgment result.

      Tech Tips


      • 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, perform driving pattern again.

WIRING DIAGRAM

B004W7VC02
*1 HV Battery *2 Battery ECU assembly
*3 Battery Voltage Sensor (for Lower Side) *4 Battery Voltage Sensor (for Upper Side)
*5 SMRB *6 SMRG
*7 SMRP *8 System Main Resistor
*9 Service Plug Grip *10 Inverter with Converter Assembly
*11 Boost Converter *12 Inverter
*13 Generator (MG1) *14 Motor (MG2)
*15 Compressor with Motor Assembly *16 A/C Inverter
*17 A/C Motor - -
*a High-voltage Areas *b DTC P0AA649 Vehicle Insulation Resistance Reduction Area
*c DTC P1C7C49 Air Conditioning System Area *d DTC P1C7D49 HV Battery Area
*e DTC P1C7E49 Hybrid Vehicle Transmission Assembly or Inverter with Converter Assembly AC (Alternation Current) Section Area *f DTC P1C7F49 High Voltage Direct Current Area
B004XG1E02

Refer to the wiring diagram for DTC P0E2D00.

Click here

SYSTEM DESCRIPTION

Tech Tips

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


  1. SHORT WAVE HIGHEST VALUE LEVEL


    1. "Short Wave Highest Value Level" shows a decrease in insulation resistance. When insulation resistance decreases, "Insulation Lower" will be displayed. However, even though the insulation resistance of the vehicle is normal, "Short Wave Highest Value Level" may decrease, so that "Not Judge" will be displayed for any of the following conditions.


      • Within approximately 1 minute since the power switch was turned on (IG).

      • When the system voltages ("Hybrid Battery Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting") are changing.

      • During boosting. If the Data List item "Boost Ratio" is not 0% or within a few seconds of it becoming 0%. (The values of "Hybrid Battery Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting" are about the same when not boosting.)

      • When "No" is displayed for any of the following Data List items:

        - Short Wave Highest Value Availability just after MG Inv On/Off

        - Short Wave Highest Value Availability just after A/C Inv On/Off

        - Short Wave Highest Value Availability just after SMR On/Off

    2. When "Short Wave Highest Value Level" shows "Insulation Lower LV3", insulation resistance will be close to 0 Ω. In this case, damage to a high-voltage cable or hybrid component (high-voltage), or a short to body ground due to intrusion of foreign matter, such as metal particles, can be suspected.


    • If problem symptoms cannot be reproduced and a malfunction still exists after replacing a part as instructed, checking the following freeze frame data can help determine a trouble area.

    Items to be Checked Using Freeze Frame Data:
    Freeze Frame Data Diagnostic Note
    Short Wave Highest Value Level Indicates that the insulation resistance has decreased.

    • VL-Voltage before Boosting

    • VH-Voltage after Boosting

    • Hybrid Battery Voltage

    • Boost Ratio

    		 During boosting (when "Boost Ratio" is not 0%), or when "VL-Voltage before Boosting", "VH-Voltage after Boosting" or "Hybrid Battery Voltage" is varying, "Short Wave Highest Value Level" may decrease even though the insulation resistance is normal.

    • SMRP Status

    • SMRB Status

    • SMRG Status

    When "SMRP Status", "SMRB Status" and "SMRG Status" are all OFF, the insulation malfunction detection circuit detects a decrease in insulation resistance in the HV battery area ((*d) in the wiring diagram).


      Example:

    • When the power switch is turned on (IG) (not on (READY)), all 3 system main relays are off and it is suspected that the HV battery assembly is disconnected from the high voltage circuits. If "Short Wave Highest Value Level" decreases a few minutes after the power switch is turned on (IG) (not on (READY)), the HV battery assembly may have an insulation malfunction.
    Motor Inverter Shutdown Status

    When "Motor Inverter Shutdown Status" is ON, the insulation malfunction detection circuit cannot detect a decrease in insulation resistance in the motor system AC (alternating current) section (motor (MG2) side of (*e) in the wiring diagram).

    The motor system AC (alternating current) section includes the motor (MG2) in the hybrid vehicle transmission assembly, motor cables and the AC (alternating current) section of the motor drive circuit in the inverter with converter assembly.
    Generator Inverter Shutdown Status

    When "Generator Inverter Shutdown Status" is ON, the insulation malfunction detection circuit cannot detect a decrease in insulation resistance in the generator system AC (alternating current) section (generator (MG1) side of (*e) in the wiring diagram).

    The generator system AC (alternating current) section includes the generator (MG1) in the hybrid vehicle transmission assembly, generator cables and the AC (alternating current) section of the generator drive circuit in the inverter with converter assembly.
    A/C Consumption Power

    The compressor with motor assembly AC (alternating current) section ((*c) in the wiring diagram) includes the air conditioning motor, wiring between the air conditioning motor and air conditioning inverter, and the AC (alternating current) section of the air conditioning motor drive circuit in the air conditioning inverter.

    With the vehicle stopped, turn on/off the air conditioning system and observe "Short Wave Highest Value Level" to use as a diagnosis reference.

    RELATED FREEZE FRAME DATA

    Tech Tips


    • Reproducing the vehicle conditions the moment a DTC was stored according to the freeze frame data and results of the customer problem analysis helps ensure that the same DTC is stored again.

      Driving Status
      Item Diagnostic Note
      Vehicle Speed -
      Accelerator Position Sensor -
      Engine Speed -
      Shift Position -
      Master Cylinder Control Torque -
      Coolant Temperature -
      Operation Conditions
      Item Diagnostic Note
      Motor Temperature

      If any liquid leaks into the ATF, insulation resistance may decrease only when the temperature is high.

      The motor temperature is likely to increase if the motor speed is low and output torque is high such as when cruising uphill slowly or accelerating from a low speed.
      Generator Temperature

      If any liquid leaks into the ATF, insulation resistance may decrease only when the temperature is high.

      The generator temperature is likely to increase under repeat acceleration and deceleration while the vehicle is driven in the mid speed range (60 to 80 km/h (37 to 50 mph)).

    • Customer Problem Analysis

      Ask the customer about the operating conditions and environment when the malfunction occurred.

      Item Diagnostic Note
      Driving Condition (acceleration, deceleration, turning, etc.) Changes in the insulation of the parts with insufficient insulation due to changes in G force or vibration is suspected.
      Road Condition (unpaved, etc.)
      Weather (rain, snow, etc.) Water intrusion is suspected
      Washing the vehicle (Whether the malfunction occurred after washing the vehicle?)
      Whether water was spilled on the rear seats or in the luggage compartment

CAUTION / NOTICE / HINT

CAUTION:


  • B004VRW

    When troubleshooting DTC P0AA649, use either a tool wrapped with vinyl insulation tape or an insulated tool. (It is extremely dangerous when a high-voltage charge passes through a non-insulated tool causing a short.)

  • B004STG

    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

  • B004Y5N

    To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

  • B004SX1

    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.

  • B004W3JC06
    *a Without waiting for 10 minutes

    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.

  • 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.

  • B004SCIC04
    *a Dealer
    *b Battery Collection Agent

    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.


    • Accidents such as electric shock may result if the HV battery or the HV supply stack sub-assembly is disposed of improperly or abandoned.

      Therefore, make sure to return HV battery and all HV supply stack sub-assemblies through an authorized collection agent.

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

    Click here

  • Before returning the hybrid vehicle supply stack sub-assembly, 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 and hybrid vehicle supply stack sub-assemblies.

  • B004X4P

    After removing the HV battery or the HV supply stack sub-assembly, keep it away from water. Exposure to water may cause the HV battery or the HV supply stack sub-assembly to produce heat, resulting in a fire.

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, HV BATTERY)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Powertrain > HV Battery > Trouble Codes
      Result
      Result Proceed to
      P0AA649, P1C7C49, P1C7D49, P1C7E49 or P1C7F49 only is output, or DTCs except the ones in the table below are also output. A
      DTCs of hybrid control system in the tables below are output. B
      DTCs of hybrid battery system in the tables below are output. C
      Malfunction Content System Relevant DTC
      Microcomputer malfunction Hybrid control system P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
      P060A29 Hybrid/EV Powertrain Control Module Monitoring Processor Signal Invalid
      P060A44 Hybrid/EV Powertrain Control Module Monitoring Processor Data Memory Failure
      P060A45 Hybrid/EV Powertrain Control Module Monitoring Processor Program Memory Failure
      P060A49 Hybrid/EV Powertrain Control Module Monitoring Processor Internal Electronic Failure
      P060B1C Hybrid/EV Powertrain Control Module A/D Processing Voltage Out of Range
      P060B71 Hybrid/EV Powertrain Control Module A/D Processing Actuator Stuck
      P1CE31C Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Voltage Out of Range
      P1CE349 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Internal Electronic Failure
      P1CE371 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Actuator Stuck
      Hybrid battery system P060687 Hybrid/EV Battery Energy Control Module Processor to Monitoring Processor Missing Message
      P060A47 Hybrid/EV Battery Energy Control Module Monitoring Processor Watchdog / Safety MCU Failure
      P060A87 Hybrid/EV Battery Energy Control Module Processor from Monitoring Processor Missing Message
      P060B49 Hybrid/EV Powertrain Control Module A/D Processing Internal Electronic Failure
      P062F46 Hybrid/EV Battery Energy Control Module EEPROM Calibration / Parameter Memory Failure
      Power Source Circuit Malfunction Hybrid control system P06881F ECM/PCM Power Relay Sense Circuit Intermittent
      System malfunction Hybrid control system P1C9E9F Hybrid/EV System Reset Stuck Off

      Tech Tips


      • P0AA649 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    A

  2. 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 for DTCs.


      Powertrain > Hybrid Control > Trouble Codes

      Note


      • DTC P1C7C49, P1C7D49, P1C7E49 and P1C7F49 are not stored with P0AA649 at the same time. If a drop in insulation resistance is detected and DTC P0AA649 is output, wait for 1 minute with the power switch on (READY), the shift state is in drive (D) and the air conditioning system on within the same trip, then turn the power switch off and wait for 2 minutes to determine the DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49).

      • If only DTC P0AA649 is output, perform the diagnostic procedure for DTC P0AA649 to inspect all of the high voltage circuits.

      • When any other DTC indicating parts which the insulation resistance dropped are output, perform the diagnostic procedure for each DTC.

      Result
      Result Proceed to
      P0AA649 (decrease in the insulation resistance of the high-voltage circuit) only is output. A
      P0AA649 and P1C7C49 (decrease in the insulation resistance of the air conditioning system area) are output. B
      P0AA649 and P1C7D49 (decrease in the insulation resistance of the HV battery area) are output. C
      P0AA649 and P1C7E49 (decrease in the insulation resistance of the hybrid vehicle transmission assembly area) are output. D
      P0AA649 and P1C7F49 (decrease in the insulation resistance of the high-voltage direct current area) are output. E
      P0AA649 is not output, but any of DTCs P1C7C49, P1C7D49, P1C7E49 or P1C7F49 is output. F

    5. Turn the power switch off.


    B

    GO TO AIR CONDITIONING SYSTEM (P1C7C49) Click here

    C

    CHECK FREEZE FRAME DATA Click here

    D

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    E

    CHECK HIGH VOLTAGE DIRECT CURRENT AREA Click here

    F

    CLEAR DTC Click here

    A

  3. CHECK HYBRID VEHICLE TRANSMISSION 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. B004RTXC02
      *A for LHD
      *B for RHD

      Disconnect the motor cable from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

    3. 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 rear wheels.

    4. Turn the power switch on (IG).

      Note

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

    5. Move the shift lever to select shift state neutral (N) and lift the vehicle.

    6. B004W75C04
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

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

      Note


      • Carefully perform this inspection as the motor (MG2) may generate current when the rear 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
      for LHD:
      Tester Connection Condition Specified Condition
      f3-1 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      f3-2 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      f3-3 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      for RHD:
      Tester Connection Condition Specified Condition
      f1-3 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      f1-2 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      f1-1 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

    7. Lower the vehicle and push the P position switch (shift position indicator).

    8. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK MOTOR CABLE Click here

    OK

  4. CHECK HYBRID VEHICLE TRANSMISSION 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. B004TNOC02
      *A for LHD
      *B for RHD

      Disconnect the generator cable from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

    3. 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 rear wheels.

    4. Turn the power switch on (IG).

      Note

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

    5. Move the shift lever to select shift state neutral (N) and lift the vehicle.

    6. B004SLDC03
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

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

      Note


      • Carefully perform this inspection as the generator (MG1) may generate current when the rear 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
      for LHD:
      Tester Connection Condition Specified Condition
      g3-1 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g3-2 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g3-3 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      for RHD:
      Tester Connection Condition Specified Condition
      g1-3 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g1-2 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g1-1 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

    7. Lower the vehicle and push the P position switch (shift position indicator).

    8. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK GENERATOR CABLE Click here

    OK

  5. CHECK HV AIR CONDITIONING 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. B004UYOC01
      *A for RHD
      *B for LHD

      Disconnect the HV air conditioning wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV air conditioning wire.

    3. B004RI1C62
      *1 Shield Ground
      *a

      HV Air Conditioning Wire

      (Inverter with Converter Assembly Side)

      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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      A82-2 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      A82-1 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 41 Click here

    OK

  6. CHECK HV FLOOR UNDER 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. B004UNAC01
      *A for RHD
      *B for LHD

      Disconnect the HV floor under wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B004R21C44
      *1 Shield Ground
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      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.

      • Be sure not to damage or deform the terminal being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      M2-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      M2-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

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

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 39 Click here

    OK

  7. 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. B004UNAC01
      *A for RHD
      *B for LHD

      Connect the HV floor under wire connector to the inverter with converter assembly.

    3. B004RGXC07
      *1 High Voltage Terminal

      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 HV air conditioning wire disconnected from the inverter with converter assembly.

      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 11 Click here

    NG

    GO TO STEP 37 Click here

  8. GO TO AIR CONDITIONING SYSTEM (P1C7C49)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  9. 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. Remove the motor cable from the hybrid vehicle transmission assembly.

      for 2WD:

      Click here

      for AWD:

      Click here

    3. B004W75C04
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

      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
      for LHD:
      Tester Connection Condition Specified Condition
      f3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      f3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD:
      Tester Connection Condition Specified Condition
      f1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (V) - 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
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 32 Click here

    NG

    GO TO STEP 33 Click here

  10. 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. Remove the generator cable from the hybrid vehicle transmission assembly.

      for 2WD:

      Click here

      for AWD:

      Click here

    3. B004SLDC03
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      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
      for LHD:
      Tester Connection Condition Specified Condition
      g3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD:
      Tester Connection Condition Specified Condition
      g1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 32 Click here

    NG

    GO TO STEP 34 Click here

  11. CHECK FREEZE FRAME DATA


    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. Read the freeze frame data of DTC P0AA649.


      Powertrain > Hybrid Control > Trouble Codes
      Result
      Result Proceed to
      "Short Wave Highest Value Level" is Not Judge. A
      Except above B

    5. Turn the power switch off.


    B

    CHECK HV BATTERY (HIGH VOLTAGE CABLE) Click here

    A

  12. CLEAR DTC

    Tech Tips

    Perform the DTC clear procedure 2 times.


    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. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    5. Turn the power switch off.

    6. Turn the power switch on (IG).

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

    8. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    9. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

    CONDUCT CONFIRMATION TEST Click here

  13. CHECK HV BATTERY (HIGH VOLTAGE CABLE)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Tech Tips

    Make sure that no foreign matter or water has entered the HV battery.


    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. 1 HV battery protector (for upper side).

      Click here

    3. B004RVON02

      Disconnect the z14 and z15 battery voltage sensor (for upper side) connectors.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    4. B004SHTN01

      Disconnect the d2 battery ECU assembly connector.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    5. B004UG6C02
      *a

      Service Plug Grip Removed

      (Service Plug Grip Connecting Terminals)

      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
      Result
      Proceed to
      OK
      NG

    NG

    CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  14. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - BATTERY VOLTAGE SENSOR (for Upper Side))

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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. 1 HV battery protector (for upper side).

      Click here

    3. Disconnect the d1 battery voltage sensor (for upper side) connector.

      CAUTION:

      Before disconnecting the d1 battery voltage sensor (for Upper Side) connector, disconnect the z14 and z15 connectors.

      B004V6WN02
    4. B004SHTN01

      Disconnect the d2 battery ECU assembly connector.

      Note


      • Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

      • Before disconnecting the connector, check that it is not loose or disconnected.

    5. B004XGPC08
      *a

      Rear view of wire harness and connector

      (to Battery ECU Assembly)
      *b

      Rear view of wire harness and connector

      (to Battery Voltage Sensor (for Upper Side))

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      d2-17 (GA0) - d1-19 (GA0) Power switch off Below 1 Ω
      d2-17 (GA0) or d1-19 (GA0) - Body ground and other terminals Power switch off 10 kΩ or higher

    6. Reconnect the d2 battery ECU assembly connector.

    7. B004V6WN02

      Reconnect the d1 battery voltage sensor (for upper side) connector.

      CAUTION:

      Before connecting the z14 and z15 battery voltage sensor (for Upper Side) connectors, connect the d1 connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  15. INSPECT BATTERY VOLTAGE SENSOR (for Upper Side)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

    When checking the battery voltage sensor (for Upper Side) resistance, select a probe of appropriate thickness (approximately 0.5 mm) from the tester lead set, and perform the measurement.


    1. Disconnect the d1 battery voltage sensor (for upper side) connector.

      Click here

      CAUTION:

      Before disconnecting the d1 battery voltage sensor (for Upper Side) connector, disconnect the z14 and z15 connectors.

      B004V6WN02
    2. B004UHGC04
      *a

      Component without harness connected

      (Battery Voltage Sensor (for Upper Side))

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      d1-19 (GA0) - z14-10 (GA0) Power switch off 5.88 to 6.12 kΩ
      d1-19 (GA0) or z14-10 (GA0) - Body ground and other terminals Power switch off 10 kΩ or higher

    3. Reconnect the d1 battery voltage sensor (for upper side) connector.

      CAUTION:

      Before connecting the z14 and z15 battery voltage sensor (for Upper Side) connectors, connect the d1 connector.

      B004V6WN02
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side) Click here

    OK

  16. REPLACE BATTERY ECU ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  17. REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  18. REPLACE BATTERY VOLTAGE SENSOR (for Upper Side)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  19. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Tech Tips

    Make sure that no foreign matter or water has entered the HV battery.


    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. B004X86

      Disconnect the high voltage cable connector of the HV battery from the HV battery junction block assembly.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    3. B004WYQC03
      *a

      Component without harness connected

      (HV Battery Junction Block Assembly)

      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
      z33-1 (+) - Body ground Power switch off 10 MΩ or higher
      A-1 (-) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 40 Click here

    OK

  20. CHECK HYBRID BATTERY TERMINAL BLOCK

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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. B004XOS

      Disconnect the high voltage cable connector of the HV battery from the hybrid battery terminal block.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    3. B004VSSC06
      *a

      Component without harness connected

      (Hybrid Battery Terminal Block)

      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
      z32-1 - Body ground Power switch off 10 MΩ or higher
      z31-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    OK

  21. CHECK BATTERY VOLTAGE SENSOR (for Lower Side)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

    When checking the battery voltage sensor (for Upper Side) resistance, select a probe of appropriate thickness (approximately 0.5 mm) from the tester lead set, and perform the measurement.


    1. Disconnect the d3 battery voltage sensor (for lower side) connector.

      Click here

      CAUTION:

      When disconnecting connector d3 of the battery voltage sensor (for lower side), first disconnect connector z16 and z17 from the battery voltage sensor (for lower side).

      B004RSTN02
    2. B004UHGC11
      *a

      Component without harness connected

      (to Battery Voltage Sensor (for Lower Side))

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      d3-19(GA2) - z16-10(GA2) Always 5.88 to 6.12 kΩ
      d3-19 (GA0) or z16-10 (GA0) - Body ground and other terminals Always 10 kΩ or higher

    3. Reconnect the d3 battery voltage sensor (for lower side) connector.

      CAUTION:

      When connecting connectors z16 and z17 of the battery voltage sensor (for lower Side), first connect connector d3 to the battery voltage sensor (for lower Side).

      B004RSTN02
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side) Click here

    OK

  22. CHECK NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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. B004R9UC04
      *a

      No. 2 HV Supply Stack Sub-assembly

      (to Hybrid Battery Terminal Block)

      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
      z32-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY Click here

    OK

  23. CHECK HV BATTERY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that no electrolyte is leaking from each HV supply stack sub-assembly.

      Click here

      Result
      Result Proceed to
      Electrolyte is not leaking from the HV supply stack sub-assembly. A
      Electrolyte is leaking from the HV supply stack sub-assembly. B

    B

    REPLACE HV BATTERY (HV supply stack sub-assembly that has a leak of electrolyte) Click here

    A

  24. REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  25. REPLACE HYBRID BATTERY TERMINAL BLOCK

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  26. REPLACE BATTERY VOLTAGE SENSOR (for Lower Side)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  27. REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  28. REPLACE HV BATTERY (HV supply stack sub-assembly that has a leak of electrolyte)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  29. 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. B004TKEC03
      *A for LHD
      *B for RHD

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

      Tech Tips

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

    3. B004RGXC07
      *a High Voltage Terminal

      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 and generator cable disconnected from the inverter with converter assembly.

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 37 Click here

    OK

  30. 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. Remove the motor cable from the hybrid vehicle transmission assembly.

      for 2WD:

      Click here

      for AWD:

      Click here

    3. B004W75C04
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

      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
      for LHD:
      Tester Connection Condition Specified Condition
      f3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      f3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD:
      Tester Connection Condition Specified Condition
      f1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (V) - 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
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MOTOR CABLE Click here

    OK

  31. 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. Remove the generator cable from the hybrid vehicle transmission assembly.

      for 2WD:

      Click here

      for AWD:

      Click here

    3. B004SLDC03
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      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
      for LHD:
      Tester Connection Condition Specified Condition
      g3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      for LHD:
      Tester Connection Condition Specified Condition
      g1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE GENERATOR CABLE Click here

    OK

  32. REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY

    for 2WD:

    Click here

    for AWD:

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  33. REPLACE MOTOR CABLE

    for 2WD:

    Click here

    for AWD:

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  34. REPLACE GENERATOR CABLE

    for 2WD:

    Click here

    for AWD:

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  35. 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. B004UNAC01
      *A for RHD
      *B for LHD

      Disconnect the HV floor under wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B004R21C44
      *1 Shield Ground
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      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.

      • Be sure not to damage or deform the terminal being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      M2-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      M2-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK HV FLOOR UNDER WIRE Click here

    OK

  36. CHECK HV AIR CONDITIONING 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. B004UYOC01
      *A for RHD
      *B for LHD

      Disconnect the HV air conditioning wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV air conditioning wire.

    3. B004RI1C62
      *1 Shield Ground
      *a

      HV Air Conditioning Wire

      (Inverter with Converter Assembly Side)

      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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      A82-2 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      A82-1 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    CHECK HV AIR CONDITIONING WIRE Click here

    OK

  37. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  38. CLEAR DTC


    1. Turn the power switch off.

    2. Connect the GTS to the DLC3.

    3. Turn the power switch on (IG).

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

    5. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    6. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

    CONDUCT CONFIRMATION TEST Click here

  39. CHECK HV FLOOR UNDER 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. 10 HV battery shield panel.

      Click here

    3. B004R4W

      Disconnect the HV floor under wire connectors from the HV battery junction block assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    4. B004R21C44
      *1 Shield Ground
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      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.

      • Be sure not to damage or deform the terminal being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      M2-1 (CBI) - Body ground Power switch off 10 MΩ or higher
      M2-2 (CEI) - Body ground Power switch off 10 MΩ or higher

      Tech Tips

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

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV FLOOR UNDER WIRE Click here

    OK

  40. REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  41. CHECK HV AIR CONDITIONING 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. B004VZAC02
      *1 Green Lock

      Disconnect the HV air conditioning wire from the compressor with motor assembly.

      for 2WD:

      Click here

      for AWD:

      Click here

    3. B004RI1C62
      *1 Shield Ground
      *a

      HV Air Conditioning Wire

      (Inverter with Converter Assembly Side)

      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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      A82-2 (ACPB) - Body ground and shield ground Power switch off 10 MΩ or higher
      A82-1 (ACPE) - Body ground and shield ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV AIR CONDITIONING WIRE Click here

    OK

  42. GO TO AIR CONDITIONING SYSTEM (P1C7C49)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  43. REPLACE HV FLOOR UNDER WIRE

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  44. REPLACE HV AIR CONDITIONING WIRE

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here