HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A94-556

DTC Code DTC Name
P0A94-556 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 556 Boost converter fail signal detection (overcurrent by hybrid vehicle transaxle assembly malfunction)

  • Wire harness or connector

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A1A-200 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 P0A94-556 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
      P0A78-266, 267, 287, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A94-585, 587, 589, 590 DC / DC Converter Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long

      Tech Tips


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

      • P0A94-556 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 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

  8. 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

  9. 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

  10. 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

  11. 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

  12. 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