P1CCC96

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DTC Code	DTC Name
P1CCC96	DC/DC Converter Enable Component Internal Failure

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DESCRIPTION

The DC/DC converter converts the DC 310.8 V of the HV battery into DC 12 V in order to supply power to areas such as the vehicle lighting system, audio system and various ECUs. Additionally, it charges the auxiliary battery.

A transistor bridge circuit initially converts DC 310.8 V into alternating current, and a transformer lowers the voltage. Then, it is rectified and smoothed (into direct current) and converted into DC 12 V.

The DC/DC converter controls the output voltage in order to keep a constant voltage at the terminals of the auxiliary battery.

The hybrid vehicle control ECU assembly sends a signal to the DC/DC converter to prohibit its control and receives signals indicating a normal or abnormal condition of the 12 V charging system via the NODD signal line.

If the DC/DC converter malfunctions, the vehicle will become inoperative. Therefore, the hybrid vehicle control ECU assembly monitors the operation of the DC/DC converter and detects malfunctions.

This DTC is stored when the DC/DC converter circuit has a malfunction or its operation is prohibited by a fail-safe function, or the auxiliary battery voltage drops to 11 V or less with the power switch on (READY).

If a DC/DC converter malfunction occurs, DC/DC converter malfunction signals are sent from the DC/DC converter to the hybrid vehicle control ECU assembly via the NODD signal line.

This DTC may also be stored if a malfunction of the inverter cooling system (blockage, water pump malfunction, etc.) or a high-voltage insulation malfunction occurs.

DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	Warning Indicate
P1CCC96	DC/DC Converter Enable Component Internal Failure	Either of the following conditions is met: The DC/DC converter is malfunctioning and the auxiliary battery voltage is 11 V or less.*2 The DC/DC converter is malfunctioning and inverter coolant temperature is 70°C (154°F) or less for 60 seconds. (1 trip detection logic)	Fusible link block assembly Engine wire Inverter cooling system Cooling fan system Grille shutter system*1 Inverter with converter assembly Hybrid vehicle transmission assembly Motor cable Generator cable Hybrid vehicle control ECU assembly Wire harness or connector	Does not come on	Master Warning Light: Comes on

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P1CCC96

DC/DC Converter Enable Component Internal Failure

Either of the following conditions is met:

The DC/DC converter is malfunctioning and the auxiliary battery voltage is 11 V or less.*2
The DC/DC converter is malfunctioning and inverter coolant temperature is 70°C (154°F) or less for 60 seconds.

(1 trip detection logic)

Fusible link block assembly
Engine wire
Inverter cooling system
Cooling fan system
Grille shutter system*1
Inverter with converter assembly
Hybrid vehicle transmission assembly
Motor cable
Generator cable
Hybrid vehicle control ECU assembly
Wire harness or connector

Does not come on

Master Warning Light:

Comes on

*1: w/ Grille shutter

Tip:

*2: If the DC/DC converter is malfunctioning, its operation and charging will be stopped and the auxiliary battery voltage will drop.

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WIRING DIAGRAM

Refer to the wiring diagram for the Generator High-voltage Circuit.

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Refer to the wiring diagram for the Motor High-voltage Circuit.

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CAUTION / NOTICE / HINT

CAUTION:

Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
- Inspecting the high-voltage system
- Disconnecting the low voltage connector of the inverter with converter assembly
- Disconnecting the low voltage connector of the HV battery
To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
*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.
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Tip:
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.

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.

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Tip:

After repair, clear the DTCs, turn the power switch off and wait for 30 seconds or more and perform the following procedure to confirm that the auxiliary battery low voltage indicated by this DTC has been repaired.
1. Wait for 2 minutes with park (P) selected, the power switch on (READY) and the following conditions met, then confirm that Data List item "BATT Voltage (Hybrid control system)" is between 13.0 and 15.0 V.
  
  (If charging is not performed and the electrical load increases, +B voltage may not be steady and will gradually drop.)
2. 1. Headlight switch is in the HI position.
  2. A/C blower fan switch is in the HI position.
  3. Window defogger switch is turned on.
By performing the following procedure, the DC/DC converter function can be checked.
1. Connect the AC/DC 400 A probe to the positive (+) auxiliary battery cable.
2. 1. Turn the power switch on (READY) and leave the vehicle as is until the electric current flowing to the auxiliary battery becomes 10 A or less.
  2. Turn the power switch on (READY) and turn the headlight switch and A/C blower fan switch to the HI position and the window defogger on.
  3. Confirm that the current drawn from the auxiliary battery is 0 A or lower and the auxiliary battery voltage is between 13.0 and 15.0 V.

This DTC may be also stored when a part other than the DC/DC converter is malfunctioning or depending on user operation.

If this vehicle is used to jump start another vehicle with a discharged battery, a fuse may blow due to overcurrent or the DC/DC converter self-protection may be activated. Also, if this vehicle is jump started by a vehicle with a 24 V battery, the same malfunction may occur and this DTC may be stored. (The suspended DC/DC converter control will return to normal by clearing the DTCs and turning the power switch off.)

Confirm that high electrical load equipment such as a high-capacitance audio device or electric kettle is used in the vehicle. (A fuse of the auxiliary battery may be blown due to overcurrent.)

If the DC/DC converter is malfunctioning, the auxiliary battery cannot be charged. Therefore, once the power switch is turned off, it may be impossible to turn it on (READY) again if the auxiliary battery is completely discharged. In this case, charge the auxiliary battery. Be careful as charging is not performed during the inspection.

If the power switch turns off immediately after it is turned on (READY), the auxiliary battery voltage may be low. Charge the auxiliary battery.

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PROCEDURE

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CHECK DTC OUTPUT

Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control, Motor Generator and engine / Trouble Codes.

Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes

Powertrain > Motor Generator > Trouble Codes

Powertrain > Engine > Trouble Codes

Result

Result	Proceed to
P1CCC96 only is output, or DTCs except the ones in the table below are also output.	A
DTCs of hybrid control system in the table below are output.	B
DTCs of motor generator control system in the table below are output.	C
DTCs of SFI system in the table below are output (w/ Grille shutter).	D

Table 1. Table 1
Malfunction Content	System	Relevant DTC
Insulation Malfunction	Hybrid control system	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
High Voltage Circuit Malfunction	Hybrid control system	P0AA649	Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure
		P0AD911	Hybrid/EV Battery Positive Contactor Circuit Short to Ground
		P0ADD11	Hybrid/EV Battery Negative Contactor Circuit Short to Ground
		P0AE411	Hybrid/EV Battery Precharge Contactor Circuit Short to Ground
		P1C8449	High Voltage Power Resource Circuit Short during Ready ON
		P300449	High Voltage Power Resource Circuit Short during Pre-Charge

Table 2. Table 2
Malfunction Content	System	Relevant DTC
System malfunction	Hybrid control system	P0A9300	Inverter "A" Cooling System Performance
		P0C7396	Motor Electronics Coolant Pump "A" Component Internal Failure
		P314A31	Motor Electronics Coolant Pump "A" No Signal
	Motor generator control system	P0E5717	DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Above Threshold
	SFI system	P059F73	Active Grille Air Shutter "A" Actuator Stuck Closed
		P05A072	Active Grille Air Shutter "A" Actuator Stuck Open
		P05A211	Active Grille Air Shutter "A" Circuit Short to Ground
		P05A212	Active Grille Air Shutter "A" Circuit Short to Battery
		P05A213	Active Grille Air Shutter "A" Circuit Open
		P05A27E	Active Grille Air Shutter "A" Actuator Stuck On
		P05A27F	Active Grille Air Shutter "A" Actuator Stuck Off
		P05B112	Active Grille Air Shutter "B" Circuit Short to Battery
		P05B114	Active Grille Air Shutter "B" Circuit Short to Ground or Open
		P05B131	Active Grille Air Shutter "B" No Signal
		U028487	Lost Communication with Active Grille Air Shutter Module "A" Missing Message

Tip:

P1CCC96 may be output as a result of the malfunction indicated by the DTCs above.

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

Turn the power switch off.

AClick here
B
GO TO DTC CHART (HYBRID CONTROL SYSTEM)Click here
C
GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)Click here
D
GO TO DTC CHART (SFI SYSTEM)Click here

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CHECK FUSE (DC/DC-S)

Remove the DC/DC-S fuse from the No. 1 luggage room relay block.

*1	No. 1 Luggage Room Relay Block
*2	DC/DC-S Fuse

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

Standard Resistance

Tester Connection	Condition	Specified Condition
DC/DC-S fuse terminal 1 - 2	Always	Below 1 Ω

Install the DC/DC-S fuse.

Result

Proceed to
OK
NG

OKClick here
NGClick here

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CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR)

Result

Proceed to
OK
NG

*A	for LHD
*B	for RHD

Check the connector connections and contact pressure of the relevant terminals for the hybrid vehicle control ECU assembly connectors.

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OK
The connectors are connected securely and there are no contact pressure problems.

Result

Proceed to
OK
NG

OKClick here
NG
CONNECT SECURELY

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CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

Result

Result	Proceed to
OK	A
NG (The connector is not connected securely.)	B
NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

CAUTION:

Be sure to wear insulated gloves.

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.

for LHD

for RHD

Check the connection condition of the low voltage connectors of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and the connector for water and foreign matter.

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Note:

Before disconnecting the connector, confirm that it is properly connected by checking that the claws of the lock levers are engaged and that the connector cannot be pulled off.

OK
- The connector is connected securely.
- The terminals are not deformed and are connected securely.
- No water or foreign matter in the connector.

Result

Result	Proceed to
OK	A
NG (The connector is not connected securely.)	B
NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

Tip:

When connecting the connector, connect it with the lock levers raised. Rotate each lock lever downward and make sure that the connector is securely connected. When a lock lever is fully lowered, a click will be heard as its claw engages. After the click is heard, pull up on the connector to confirm that it is securely connected.

AClick here
B
CONNECT SECURELY
C
REPAIR OR REPLACE HARNESS OR CONNECTOR

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CHECK FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)

Check the fusible link block assembly (DC/DC) for improper installation.

OK

The fusible link block assembly is installed securely.
Remove the fusible link block assembly from the No. 2 engine room relay block.

OK
The fusible link block assembly is installed securely.

*1	Fusible Link Block Assembly

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

Standard Resistance

Tester Connection	Condition	Specified Condition
Fusible link block assembly terminal 1 - 2 (DC/DC)	Always	Below 1 Ω

Install the fusible link block assembly.

Result

Proceed to
OK
NG

OKClick here
NG
REPLACE FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)

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CHECK AMD TERMINAL VOLTAGE (NO. 1 FUSIBLE LINK BLOCK ASSEMBLY SIDE)

CAUTION:

Be sure to wear insulated gloves.

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

*A	for LHD
*B	for RHD

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

Standard Voltage

Tester Connection	Condition	Specified Condition
z34-1 (AMD) - Body ground	Power switch off	Same as auxiliary battery voltage

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

Result

Proceed to
OK
NG

OKClick here
NG
REPAIR OR REPLACE HARNESS OR CONNECTOR

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CHECK AMD TERMINAL CONNECTION CONDITION

CAUTION:

Be sure to wear insulated gloves.

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.

*A	for LHD
*B	for RHD

Check that the bolt for the AMD terminal (inverter with converter assembly side and No. 1 fusible link block assembly side) is tightened to the specified torque, the AMD terminal (inverter with converter assembly side and No. 1 fusible link block assembly side) is connected securely, and there is no contact problem.

Torque
T = 18.0 Nm (184 kgfcm, 13 ft.*lbf) (Inverter with converter assembly side)
T = 8.0 Nm (82 kgfcm, 71 in.*lbf) (No. 1 fusible link block assembly side)

Result

Result		Proceed to
There are no arc marks.	The terminal is connected securely and there are no contact problems.	A
There are no arc marks.	The terminal is not connected securely and there is a contact problem.	B
There are arc marks.	-	C

AClick here
B
CONNECT SECURELY
C
REPLACE MALFUNCTIONING PARTS

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CHECK INVERTER BUS-BAR PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

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.
Remove the inverter bus-bar plate sub-assembly from the AMD terminal (inverter with converter assembly side and No. 1 fusible link block assembly side).

*1	Inverter Bus-bar Plate Sub-assembly

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

Standard Resistance

Tester Connection	Condition	Specified Condition
A-1 (AMD) - z34-1	Always	Below 1 Ω

Install the inverter bus-bar plate sub-assembly.

Result

Proceed to
OK
NG

OKClick here
NG
REPLACE INVERTER BUS-BAR PLATE SUB-ASSEMBLYClick here

Click here

CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S FUSE)

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the A79 inverter with converter assembly connector.

*a	Front view of wire harness connector (to Inverter with Converter Assembly)

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

Standard Voltage

Tester Connection	Condition	Specified Condition
A79-3 (S) - Body ground	Always	Same as auxiliary battery voltage

Reconnect the A79 inverter with converter assembly connector.

Result

Proceed to
OK
NG

OKClick here
NG
REPAIR OR REPLACE HARNESS OR CONNECTOR

Click here

CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE HYBRID VEHICLE CONTROL ECU ASSEMBLY)

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the A79 inverter with converter assembly connector.

*a	Front view of wire harness connector (to Inverter with Converter Assembly)

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

Standard Resistance

Tester Connection	Condition	Specified Condition
A79-5 (NODD) - Body ground	Power switch off	110 to 150 kΩ

Reconnect the A79 inverter with converter assembly connector.

Result

Proceed to
OK
NG

OKClick here
NGClick here

Click here

CHECK COOLING SYSTEM

Click here

Result

Proceed to
NEXT

NEXTClick here

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CHECK DC/DC CONVERTER FUNCTION

Tip:

The current at the AMD terminal cannot be measured directly because of space limitations. Measure the current flowing at the auxiliary battery instead.

Connect the AC/DC 400 A probe of the tester to the positive (+) auxiliary battery cable.
Install the service plug grip.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (READY) and leave the vehicle as it is until the electric current flowing to the auxiliary battery becomes 10 A or less.

Tip:
If the power switch turns off immediately after it is turned on (READY), auxiliary battery voltage may be low. Recharge the auxiliary battery and perform this procedure again.

*a	Probe Direction
*b	Current Flowing from Auxiliary Battery

*a	Probe Direction
*b	Current Flowing to Auxiliary Battery

Measure the current flowing from the auxiliary battery with the power switch on (READY), the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.

Standard Current

Item

Condition

Specified Condition

Current flowing from auxiliary battery

Power switch on (READY)

(The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)

0 A or less

(no current from auxiliary battery)

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

Standard Voltage

Item

Condition

Specified Condition

Auxiliary battery voltage

Power switch on (READY)

(The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)

12.5 to 15 V

Turn the power switch off.

Result

Proceed to
OK
NG

OK
REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here
NGClick here

Click here

INSPECT HYBRID VEHICLE CONTROL ECU ASSEMBLY (RESISTANCE VALUE OF NODD INSIDE HYBRID VEHICLE CONTROL ECU ASSEMBLY)

*a
Component without harness connected

(Hybrid Vehicle Control ECU Assembly)

Disconnect all the connectors from the hybrid vehicle control ECU assembly.

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

Standard Resistance

Tester Connection	Condition	Specified Condition
A77-14 (NODD) - G92-6 (E1)	Power switch off	110 to 150 kΩ

Connect the hybrid vehicle control ECU assembly connectors.

Result

Proceed to
OK
NG

OK
REPAIR OR REPLACE HARNESS OR CONNECTOR
NG
REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLYClick here

Click here

CHECK HIGH VOLTAGE INSULATION

CAUTION:

Be sure to wear insulated gloves.

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.
Remove the inverter terminal cover from the inverter with converter assembly.

*A	for LHD
*B	for RHD
*1	Motor Cable
*2	Generator Cable
*3	Shield Ground

Using a megohmmeter set to 500 V, measure the insulation 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

Table 3. for LHD:
Tester Connection	Condition	Specified Condition
g3-1 (U) - Body ground and shield ground	Power switch off	10 MΩ or higher
g3-2 (V) - Body ground and shield ground	Power switch off	10 MΩ or higher
g3-3 (W) - Body ground and shield ground	Power switch off	10 MΩ or higher
f3-1 (U) - Body ground and shield ground	Power switch off	10 MΩ or higher
f3-2 (V) - Body ground and shield ground	Power switch off	10 MΩ or higher
f3-3 (W) - Body ground and shield ground	Power switch off	10 MΩ or higher

Table 4. for RHD:
Tester Connection	Condition	Specified Condition
g1-3 (U) - Body ground and shield ground	Power switch off	10 MΩ or higher
g1-2 (V) - Body ground and shield ground	Power switch off	10 MΩ or higher
g1-1 (W) - Body ground and shield ground	Power switch off	10 MΩ or higher
f1-3 (U) - Body ground and shield ground	Power switch off	10 MΩ or higher
f1-2 (V) - Body ground and shield ground	Power switch off	10 MΩ or higher
f1-1 (W) - Body ground and shield ground	Power switch off	10 MΩ or higher

Tip:

Perform this inspection while the motor cable are connected.

Install the inverter terminal cover to the inverter with converter assembly.

Result

Proceed to
OK
NG

OK
REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here
NGClick here

Click here

CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 1 LUGGAGE ROOM RELAY BLOCK)

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the A79 inverter with converter assembly connector.
Remove the DC/DC-S fuse from the No. 1 luggage room relay block.

No. 1 Luggage Room Relay Block

DC/DC-S Fuse

Front view of wire harness connector

(to Inverter with Converter Assembly)

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

Standard Resistance

Tester Connection	Condition	Specified Condition
A79-3 (S) or 2 (DC/DC-S fuse) - Body ground and other terminals	Power switch off	10 kΩ or higher

Install the DC/DC-S fuse.

Reconnect the A79 inverter with converter assembly connector.

Result

Proceed to
OK
NG

OKClick here
NGClick here

Click here

REPLACE INVERTER WITH CONVERTER ASSEMBLY

Click here

Result

Proceed to
NEXT

NEXT
REPLACE FUSE (DC/DC-S)

Click here

CHECK GENERATOR HIGH-VOLTAGE CIRCUIT

Click here

Result

Proceed to
NEXT

NEXTClick here

Click here

CHECK MOTOR HIGH-VOLTAGE CIRCUIT

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Tip:

If the "Motor High-voltage Circuit" inspection results are normal, perform the next step.

Result

Proceed to
NEXT

NEXT
REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here

Click here

REPAIR OR REPLACE HARNESS OR CONNECTOR

Result

Proceed to
NEXT

NEXT
REPLACE FUSE (DC/DC-S)

HYBRID CONTROL SYSTEM, Diagnostic DTC:P1CCC96