HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A94-127

DTC Code DTC Name
P0A94-127 DC / DC Converter Performance

DESCRIPTION

For a description of the boost converter Click here.

If a malfunction occurs in the boost converter, the MG ECU detects it and transmits this information to the power management control ECU (HV CPU).

DTC No. INF Code DTC Detection Condition Trouble Area
P0A94 127 Boost converter overvoltage signal detection (overvoltage due to system malfunction)

  • Hybrid battery junction block assembly

  • Inverter with converter assembly

  • Service plug grip

  • Frame wire

  • Hybrid vehicle transaxle assembly

  • Generator cable

  • Motor cable

  • Wire harness or connector

  • PCU fuse

  • Power management control ECU

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A1A-200 Click here.

Refer to the wiring diagram for DTC P324E-788 Click here.

Refer to the wiring diagram for DTC U0110-159 Click here.

CAUTION / NOTICE / HINT

CAUTION:


  • 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.

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.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / DTC.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      DTC P0A94-127 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-113, 128, 266, 267, 279, 284, 286, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-172, 442, 547, 548, 549, 553, 554, 555, 556, 557, 564, 585, 587, 589, 590 DC / DC Converter Performance
      P0AA6-526 Hybrid Battery Voltage System Isolation Fault
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 Power Cable Malfunction

      Tech Tips


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • P0A94-127 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. B001L9I

      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.

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector does not pull out.

    2. Check the connection of the low voltage connector of the inverter with converter assembly.

      OK
      The connector is connected securely and there are no contact problems.

      Tech Tips

      When connecting the connector, insert it with the locking lever in the raised position. Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage. After the click is heard, pull up on the connector to confirm that it is properly connected.


    NG

    CONNECT SECURELY

    OK

  3. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. B001LJ6E02
      Text in Illustration
      *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 Switch Condition Specified Condition
      D28-11 (GRF) - Body ground Power switch on (IG) Below 1 V
      D28-12 (GRFG) - Body ground Power switch on (IG) Below 1 V
      D28-7 (GSN) - Body ground Power switch on (IG) Below 1 V
      D28-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      D28-10 (GCS) - Body ground Power switch on (IG) Below 1 V
      D28-9 (GCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    4. Turn the power switch off.

    5. Connect the low voltage connector from the inverter with converter assembly.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  4. CHECK GENERATOR RESOLVER


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. B001LJ6E02
      Text in Illustration
      *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 (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D28-11 (GRF) - D28-12 (GRFG) Power switch off 7.1 to 21.6 Ω
      D28-7 (GSN) - D28-8 (GSNG) Power switch off 13.7 to 34.5 Ω
      D28-10 (GCS) - D28-9 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D28-11 (GRF) or D28-12 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D28-7 (GSN) or D28-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D28-10 (GCS) or D28-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    3. Connect the inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

  5. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. B001MGPE02
      Text in Illustration
      *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 Switch Condition Specified Condition
      D28-1 (MRF) - Body ground Power switch on (IG) Below 1 V
      D28-2 (MRFG) - Body ground Power switch on (IG) Below 1 V
      D28-3 (MSN) - Body ground Power switch on (IG) Below 1 V
      D28-4 (MSNG) - Body ground Power switch on (IG) Below 1 V
      D28-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      D28-5 (MCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    4. Turn the power switch off.

    5. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. CHECK MOTOR RESOLVER


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. B001MGPE02
      Text in Illustration
      *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 (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D28-1 (MRF) - D28-2 (MRFG) Power switch off 7.1 to 21.6 Ω
      D28-3 (MSN) - D28-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      D28-6 (MCS) - D28-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D28-1 (MRF) or D28-2 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D28-3 (MSN) or D28-4 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D28-6 (MCS) or D28-5 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    3. Connect the inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

  7. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    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. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

    3. B001MC8E12

      Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
      Bolt B
      T=9.2 N*m {94 kgf*cm, 81 in.*lbf}

      Note


      • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

    4. Disconnect the generator cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts for the generator cable.

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

    6. Connect the generator cable to the inverter with converter assembly.

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  8. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    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. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

    3. B001N01E01

      Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
      Bolt B
      T=9.2 N*m {94 kgf*cm, 81 in.*lbf}

      Note


      • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

    4. Disconnect the motor cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts for the motor cable.

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

    6. Connect the motor cable to the inverter with converter assembly.

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  9. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

    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. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

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

    4. B001MZEE01
      Text in Illustration
      *1 Generator Cable
      *2 Shield Ground

      Check MG1 for an interphase short using a milliohmmeter.


      1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

        Tech Tips

        If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        d3-1 (W) - d3-2 (U) Power switch off 89.5 to 98.9 mΩ
        d3-2 (U) - d3-3 (V) Power switch off 89.5 to 98.9 mΩ
        d3-3 (V) - d3-1 (W) Power switch off 89.5 to 98.9 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at 20°C (68°F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. 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 Switch Condition Specified Condition
      d3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      d3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      d3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) Click here

    OK

  10. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)

    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. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

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

    4. B001LQME01
      Text in Illustration
      *1 Motor Cable
      *2 Shield Ground

      Check MG2 for an interphase short using a milliohmmeter.


      1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

        Tech Tips

        If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        c3-1 (W) - c3-2 (U) Power switch off 152.6 to 169.0 mΩ
        c3-2 (U) - c3-3 (V) Power switch off 157.6 to 174.0 mΩ
        c3-3 (V) - c3-1 (W) Power switch off 151.6 to 168.0 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at 20°C (68°F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. 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 Switch Condition Specified Condition
      c3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      c3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      c3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) Click here

    OK

  11. CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH VOLTAGE CONNECTOR CONNECTION CONDITION)

    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. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

    3. B001LW8E10

      Check that the bolts for the frame wire are tightened to the specified torque, the frame wire is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
      Bolt B
      T=9.2 N*m {94 kgf*cm, 81 ft.*lbf}

      Note


      • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

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

    5. Check for arc marks at the bolts for the frame wire.

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

    6. Connect the frame wire to the inverter with converter assembly.

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  12. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK
      Dirt or foreign matter has not entered the connection, and there is no evidence of contamination.

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  13. CHECK SERVICE PLUG GRIP


    1. B001LRNE01
      Text in Illustration
      *1 Service Plug Grip

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  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. B001KYK

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

    3. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

    4. B001LW8

      Disconnect the frame wire from the inverter with converter assembly.

    5. B001M6HE01
      Text in Illustration
      *1 Frame Wire (Inverter with Converter Assembly Side)
      *2 Frame Wire (Hybrid Battery Junction Block Assembly Side)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      S1-2 (CBI) - S4-1 (CBI) (Positive terminal) Power switch off Below 1 Ω
      S1-1 (CEI) - S3-1 (CEI) (Negative terminal) Power switch off Below 1 Ω
    6. B001M1RE01
      Text in Illustration
      *1 Frame Wire (Hybrid Battery Junction Block 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
      Tester Connection Switch Condition Specified Condition
      S4-1 (CBI) - Body ground and shielded ground Power switch off 10 MΩ or higher
      S3-1 (CEI) - Body ground and shielded ground Power switch off 10 MΩor higher
      S4-1 (CBI) - S3-1 (CEI) Power switch off 10 MΩ or higher

    7. Connect the frame wire to the hybrid battery junction block assembly.

    8. Connect the frame wire to the inverter with converter assembly.

    9. Install the inverter cover.


    NG

    REPLACE FRAME WIRE Click here

    OK

  15. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    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 hybrid battery junction block assembly.

    3. B001LEPE01
      Text in Illustration
      *1 Hybrid Battery Junction Block Assembly

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      f2-1 (+) - S4-1 (CBI) Auxiliary battery voltage is not applied between terminals i3-4 (SMRB) and i3-2 (GND) 10 kΩ or higher
      f2-1 (+) - S4-1 (CBI) Auxiliary battery voltage is applied between terminals i3-4 (SMRB) and i3-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      i3-4 (SMRB) - i3-2 (GND) -40 to 80°C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  16. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

    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 hybrid battery junction block assembly.

    3. B001MM3E01
      Text in Illustration
      *1 Hybrid Battery Junction Block Assembly

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      h2-1 (-) - S3-1 (CEI) Auxiliary battery voltage is not applied between terminals i3-1 (SMRG) and i3-2 (GND) 10 kΩ or higher
      h2-1 (-) - S3-1 (CEI) Auxiliary battery voltage is applied between terminals i3-1 (SMRG) and i3-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      i3-1 (SMRG) - i3-2 (GND) -40 to 80°C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  17. CHECK FUSE (PCU)


    1. B001N0YE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 PCU Fuse

      Remove the PCU fuse from the engine room junction block assembly.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      PCU fuse terminals Always Below 1 Ω

    3. Install the PCU fuse.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) Click here

    OK

  18. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)

    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 connector A62 from the inverter with converter assembly.

    3. B001M1XE02
      Text in Illustration
      *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 Switch Condition Specified Condition
      A62-28 (GND1) - Body ground Power switch off Below 1 Ω
      A62-27 (GND2) - Body ground Power switch off Below 1 Ω

    4. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A62-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A62-9 (+B2) - Body ground Power switch on (IG) 11 to 14 V

    6. Turn the power switch off.

    7. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

  19. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

    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 connector A62 from the inverter with converter assembly.

    3. Disconnect connector A20 from the power management control ECU.

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

      B001MDQE06
      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A62-8 (HTM+) - A20-24 (HTM+) Power switch off Below 1 Ω
      A62-18 (HTM-) - A20-25 (HTM-) Power switch off Below 1 Ω
      A62-7 (MTH+) - A20-30 (MTH+) Power switch off Below 1 Ω
      A62-17 (MTH-) - A20-29 (MTH-) Power switch off Below 1 Ω
      A62-6 (REQ+) - A20-33 (REQ+) Power switch off Below 1 Ω
      A62-16 (REQ-) - A20-32 (REQ-) Power switch off Below 1 Ω
      A62-5 (CLK+) - A20-21 (CLK+) Power switch off Below 1 Ω
      A62-15 (CLK-) - A20-20 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A62-8 (HTM+) or A20-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-18 (HTM-) or A20-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-7 (MTH+) or A20-30 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-17 (MTH-) or A20-29 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-6 (REQ+) or A20-33 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-16 (REQ-) or A20-32 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-5 (CLK+) or A20-21 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-15 (CLK-) or A20-20 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

    5. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A62-8 (HTM+) or A20-24 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A62-18 (HTM-) or A20-25 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A62-7 (MTH+) or A20-30 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A62-17 (MTH-) or A20-29 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A62-6 (REQ+) or A20-33 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A62-16 (REQ-) or A20-32 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A62-5 (CLK+) or A20-21 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A62-15 (CLK-) or A20-20 (CLK-) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the power management control ECU and inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.

    8. Connect the power management control ECU connector.

    9. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  20. CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect connector A20 from the power management control ECU.

    2. B001LJXE02
      Text in Illustration
      *a

      Component without harness connected

      (Power Management Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A20-24 (HTM+) - A20-25 (HTM-) Power switch off 80 to 170 Ω
      A20-30 (MTH+) - A20-29 (MTH-) Power switch off 80 to 170 Ω
      A20-33 (REQ+) - A20-32 (REQ-) Power switch off 80 to 170 Ω
      A20-21 (CLK+) - A20-20 (CLK-) Power switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  21. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B001MW2

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  22. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B001LMB

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CONNECT SECURELY

  23. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B001MW2

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  24. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)


    1. B001MW2E03

      Disconnect the D7 generator resolver connector.

    2. B001N3YC15
      *a

      Component without harness connected

      (Generator Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D7-1(GRF) - D7-5(GRFG) IG OFF 9.5 to 15.5 Ω
      D7-2(GSN) - D7-6(GSNG) IG OFF 15.0 to 27.0 Ω
      D7-3(GCS) - D7-7(GCSG) IG OFF 14.0 to 26.0 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D7-1 (GRF) - Body ground and other terminals (except D7-5 (GRFG)) Power switch off 1 MΩ or higher
      D7-5 (GRFG) - Body ground and other terminals (except D7-1 (GRF)) Power switch off 1 MΩ or higher
      D7-2 (GSN) - Body ground and other terminals (except D7-6 (GSNG)) Power switch off 1 MΩ or higher
      D7-6 (GSNG) - Body ground and other terminals (except D7-2 (GSN)) Power switch off 1 MΩ or higher
      D7-3 (GCS) - Body ground and other terminals (except D7-7 (GCSG)) Power switch off 1 MΩ or higher
      D7-7 (GCSG) - Body ground and other terminals (except D7-3 (GCS)) Power switch off 1 MΩ or higher

      Tech Tips

      The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Connect the D7 generator resolver connector.


    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  25. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B001LMB

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  26. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)


    1. B001LMBE02

      Disconnect the D1 motor resolver connector.

    2. B001L5DC09
      *a

      Component without harness connected

      (Motor Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      D1-3 (MRF) - D1-6 (MRFG) Power switch off 9.5 to 15.5 Ω
      D1-1 (MSN) - D1-4 (MSNG) Power switch off 15.0 to 27.0 Ω
      D1-2 (MCS) - D1-5 (MCSG) Power switch off 14.0 to 26.0 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      D1-3 (MRF) - Body ground and other terminals (except D1-6 (MRFG)) Power switch off 1 MΩ or higher
      D1-6 (MRFG) - Body ground and other terminals (except D1-3 (MRF)) Power switch off 1 MΩ or higher
      D1-1 (MSN) - Body ground and other terminals (except D1-4 (MSNG)) Power switch off 1 MΩ or higher
      D1-4 (MSNG) - Body ground and other terminals (except D1-1 (MSN)) Power switch off 1 MΩ or higher
      D1-2 (MCS) - Body ground and other terminals (except D1-5 (MCSG)) Power switch off 1 MΩ or higher
      D1-5 (MCSG) - Body ground and other terminals (except D1-2 (MCS)) Power switch off 1 MΩ or higher

      Tech Tips

      The motor resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Connect the D1 motor resolver connector.


    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  27. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    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 inverter with converter assembly.

    3. B001M9TE05

      Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=20 N*m {204 kgf*cm, 15 ft.*lbf}
      Bolt B
      T=10 N*m {102 kgf*cm, 7 ft.*lbf}

      Note


      • Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 and 245 kgf*cm, 12 and 18 ft.*lbf).

      • Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    4. Disconnect the generator cable from the hybrid transaxle assembly.

    5. Check for arc marks at the bolts for the generator cable.

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

    6. Connect the generator cable to the hybrid transaxle assembly.

    7. Install the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  28. 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.

    3. B001L8RE01
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shielded Ground
      *3

      Generator Cable

      (Hybrid Vehicle Transaxle 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
      Tester Connection Switch Condition Specified Condition
      d3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      d3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      d3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      d3-1 (W) - d4-3 (W) Power switch off Below 1 Ω
      d3-2 (U) - d4-2 (U) Power switch off Below 1 Ω
      d3-3 (V) - d4-1 (V) Power switch off Below 1 Ω
      d3-1 (W) - d4-2 (U) Power switch off 100 MΩ or higher
      d3-2 (U) - d4-1 (V) Power switch off 100 MΩ or higher
      d3-3 (V) - d4-3 (W) Power switch off 100 MΩ or higher

    5. Install the generator cable.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  29. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    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. B001L0E

      Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

      Specified Condition
      T=10 N*m {102 kgf*cm, 7 ft.*lbf}

      Note

      Make sure that the tightening torque of the bolts is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    3. Disconnect the motor cable from the hybrid transaxle assembly.

    4. Check for arc marks at the bolts for the motor cable.

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

    5. Connect the motor cable to the hybrid transaxle assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  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.

    3. B001LT8E02
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2 Shielded Ground
      *3

      Motor Cable

      (Hybrid Vehicle Transaxle 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
      Tester Connection Switch Condition Specified Condition
      c3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      c3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      c3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      c3-1 (W) - c4-1 (W) Power switch off Below 1 Ω
      c3-2 (U) - c4-3 (U) Power switch off Below 1 Ω
      c3-3 (V) - c4-2 (V) Power switch off Below 1 Ω
      c3-1 (W) - c4-3 (U) Power switch off 100 MΩ or higher
      c3-2 (U) - c4-2 (V) Power switch off 100 MΩ or higher
      c3-3 (V) - c4-1 (W) Power switch off 100 MΩ or higher

    5. Install the motor cable.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  31. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)

    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 connector A62 from the inverter with converter assembly.

    3. B001LTJE02
      Text in Illustration
      *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 Switch Condition Specified Condition
      A62-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A62-9 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  32. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT

    REPLACE FUSE (PCU)

  33. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (PCU)