HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A94-172

DTC Code DTC Name
P0A94-172 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 172 Boost converter fail signal detection (overcurrent by system malfunction)
  • Wire harness or connector

  • Hybrid vehicle transaxle assembly

  • Generator cable

  • Motor cable

  • Inverter with converter assembly

  • PCU fuse

  • Power management control ECU

WIRING DIAGRAM

Refer to the wiring diagram for DTC P1CAC-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 P0A94-172 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P06B0-163 Sensor Power Supply "A" Circuit/Open
      P06D6-511 Sensor Reference Voltage "F" Circuit/Open
      P06E6-164 Sensor Power Supply "C" Circuit/Open
      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, 504, 506, 549, 556, 808 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, 518, 811 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A78-113, 128, 279, 284, 286, 287, 548, 555, 807 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 810 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0AA6-526 Hybrid Battery Voltage System Isolation Fault
      P0BEA-290 Drive Motor "A" Phase V Current Sensor Circuit Range/Performance
      P0BEE-298 Drive Motor "A" Phase W Current Sensor Circuit Range/Performance
      P0C19-306 Drive Motor "A" Torque Delivered Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-586 Drive Motor "A" Inverter Voltage Sensor Circuit Range/Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Voltage Sensor Circuit High
      P0E05-328 Generator Phase V Current Sensor Circuit Range/Performance
      P0E09-336 Generator Phase W Current Sensor Circuit Range/Performance
      P0E32-585 DC/DC Converter Voltage Sensor "A" Range/Performance
      P0E33-589 DC/DC Converter Voltage Sensor "A" Low
      P0E34-590 DC/DC Converter Voltage Sensor "A" High
      P0E71-344 Generator Torque Delivered Performance
      P1C2A-155 Generator A/D Converter Circuit
      P1C2B-192 Drive Motor "A" A/D Converter Circuit
      P1C2D-587 Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294 Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302 Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333 Generator Phase V Current Sensor Correlation
      P1C3F-341 Generator Phase W Current Sensor Correlation
      P1C4A-288 Drive Motor "A" Phase V Current Sensor Sub Circuit Range/Performance
      P1C4F-296 Drive Motor "A" Phase W Current Sensor Sub Circuit Range/Performance
      P1C54-326 Generator Phase V Current Sensor Sub Circuit Range/Performance
      P1C59-334 Generator Phase W Current Sensor Sub Circuit Range/Performance
      P1C6D-501 Drive Motor "A" Phase V Current Sensor Offset Range/Performance
      P1C6E-502 Drive Motor "A" Phase W Current Sensor Offset Range/Performance
      P1C71-515 Generator Phase V Current Sensor Offset Range/Performance
      P1C72-516 Generator Phase W Current Sensor Offset Range/Performance
      P1C73-512 Sensor Standard Voltage "F" Circuit/Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator

      Tech Tips


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

      • P0A94-172 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
    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
    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
    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
    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
    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
    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
    C
    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
    C
    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
    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
    OK
  11. 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
    OK
  12. 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
    OK
  13. 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
    OK
  14. 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
    OK
  15. 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
    OK
  16. 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
    NG
  17. 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
    OK
  18. 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
    NG
  19. 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
    OK
  20. 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
    NG
  21. 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
    C
    A
  22. 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
    NG
  23. 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
    C
    A
  24. 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
    NG
  25. 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
    OK
  26. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT
  27. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT