HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA6-526, P0AA6-611, P0AA6-612, P0AA6-613, P0AA6-614

DTC Code DTC Name
P0AA6-526 Hybrid Battery Voltage System Isolation Fault
P0AA6-611 Hybrid Battery Voltage System Isolation Fault
P0AA6-612 Hybrid Battery Voltage System Isolation Fault
P0AA6-613 Hybrid Battery Voltage System Isolation Fault
P0AA6-614 Hybrid Battery Voltage System Isolation Fault

DESCRIPTION

The power management control ECU monitors the battery smart unit and detects insulation malfunctions in the high-voltage system.

DTC No. INF Code DTC Detection Condition Trouble Area
P0AA6 526

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

(1 trip detection logic)

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly

  • No. 4 floor wire

  • No. 4 engine wire

  • Hybrid battery junction block assembly

  • Air conditioning system

  • HV battery

  • Battery smart unit
611

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

(1 trip detection logic)

 Air conditioning system
612

Insulation resistance of the HV battery, battery smart unit or SMR has decreased.*2

(1 trip detection logic)

  • Hybrid battery junction block assembly

  • Battery smart unit

  • HV battery
613

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

(1 trip detection logic)

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly
614

Insulation resistance of the inverter for the generator (MG1) and motor (MG2), A/C inverter, SMR or No. 2 frame wire has decreased.*2

(1 trip detection logic)

  • Inverter with converter assembly

  • No. 4 floor wire

  • Air conditioning system

  • No. 4 engine wire

  • Hybrid battery junction block assembly

Tech Tips


  • *1: The insulation malfunction detection circuit in the battery smart unit monitors the insulation resistance between the high voltage circuits and body. If the insulation resistance decreases, the power management control ECU stores DTC P0AA6-526 and illuminates the master warning light first regardless of malfunction area. Sometimes the insulation malfunction is hard to duplicate due to the vehicle's condition changing. So if DTC P0AA6-526 outputs, complete the following steps as soon as possible.

  • *2: If the following operations are performed within the same trip after DTC P0AA6-526 is stored, just one of the related DTCs (P0AA6-611, 612, 613 or 614) will be stored.

(a) Apply the parking brake firmly.

(b) Wait for 1 minute or more with the vehicle stopped, the brake pedal firmly depressed, the power switch on (READY), the shift lever in D and the air conditioning system on (Lo/COOL MAX, blower speed HI).

(c) After turning the power switch off (READY off), wait 1 minute or more.

Tech Tips


  • DTCs and freeze frame data are useful information in determining the malfunctioning part. When the vehicle is brought to the workshop, read the DTCs and freeze frame data related to P0AA6 and make sure to record the information. (Even if the high-voltage insulation malfunction could not be reproduced, DTCs once memorized will not be cleared unless the clear operation is performed, so such DTCs can be read.)

  • When the insulation resistance of the HV battery area decreases and the power switch is turned on (IG), DTC P0AA6-612 is stored within 2 minutes.


Related Data List (Reproduction of Phenomenon and Check)
DTC No. Data List
P0AA6-526

  • Short Wave Highest Val

  • Power Resource VB

  • VL-Voltage before Boosting

  • VH-Voltage after Boosting

  • Boost Ratio

  • A/C Consumption Pwr

  • SMRP Status

  • SMRB Status

  • SMRG Status

  • MG1 Gate Status

  • MG2 Gate Status
P0AA6-611
P0AA6-612
P0AA6-613
P0AA6-614

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

Data List


WIRING DIAGRAM

A01I5R0E04
Text in Illustration
*1 HV Battery *2 Battery Smart Unit
*3 SMRB *4 SMRG
*5 SMRP *6 System Main Resistor
*7 Service Plug Grip *8 Inverter with Converter Assembly
*9 Boost Converter *10 Inverter
*11 Generator (MG1) *12 Motor (MG2)
*13 Compressor with Motor Assembly *14 A/C Inverter
*15 A/C Motor - -
*a High-voltage Areas *b Information code 526 indicates that there is a decrease in the insulation resistance in any part of the high voltage circuit.
*c Information code 611 indicates a decrease in insulation resistance of the air conditioning system area. *d Information code 612 indicates that there is a decrease in the insulation resistance of the HV battery area.
*e Information code 613 indicates that there is a decrease in the insulation resistance of the hybrid vehicle transaxle assembly or inverter with converter assembly of the alternating current side. *f Information code 614 indicates a decrease in insulation resistance of the high-voltage direct current side.
*g Built-in abnormal insulation detection circuit - -
A01I4F5E01

SYSTEM DESCRIPTION

Tech Tips

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


  1. SHORT WAVE HIGHEST VALUE


    1. "Short Wave Highest Val" indicates a decrease in insulation resistance and decreases the value as the insulation resistance decreases. In some cases, "Short Wave Highest Val" may decrease even though the insulation resistance of the vehicle is normal, therefore avoid checking "Short Wave Highest Val" when any of the following conditions exist.


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

      • There is change of the system voltages ("Power Resource VB", "VL-Voltage before Boosting", and "VH-Voltage after Boosting").

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

    2. When "Short Wave Highest Val" is approximately 0 V, insulation resistance is close to 0 Ω. In this case, damage to a high-voltage cable or hybrid component (high-voltage), or a short to the body due to intrusion of foreign matter such as metal particles can be suspected.

  2. RELATED FREEZE FRAME DATA

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

    Tech Tips


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

    Driving Status
    Item Diagnostic Note
    Vehicle Spd -
    Accel Pedal Pos #1 -
    Engine Revolution -
    Shift Sensor Shift Pos -
    Master Cylinder Ctrl Trq -
    Engine Coolant Temp -
Operation Conditions
Item Diagnostic Note
Motor Temp No1

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

The motor temperature is likely to increase if the motor speed is low and output torque is high such as when cruising uphill slowly or accelerating from a low speed.
Motor Temp No2

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

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

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

  • CONFIRMATION AFTER REPLACING PARTS


    1. After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output. (Do not turn the power switch off (READY off) during this inspection.)


      1. Apply the parking brake and secure the wheels using chocks.

      2. When the vehicle is stationary, turn the power switch on (READY) with the shift lever in P and wait for 60 seconds or more.

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

      4. While depressing the brake pedal without depressing the accelerator pedal, move the shift lever to D and wait for 5 minutes.


        • If step A is performed within the same trip after DTC P0AA6-526 is stored, the parts with insufficient insulation resistance will be determined, and a DTC (P0AA6-611, 612, 613 or 614) will be stored.

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

      5. Drive the vehicle for approximately 5 minutes referring to the following freeze frame data items: "Vehicle Spd", "Shift Sensor Shift Pos", "Accel Pedal Pos #1", "Engine Revolution", "Engine Coolant Temp", "Master Cylinder Ctrl Trq", "Motor Temp MG2 (No2)" and "Motor Temp MG2 (No1)"

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


        • If step A is performed within the same trip after DTC P0AA6-526 is stored, the parts with insufficient insulation resistance will be determined, and a DTC (P0AA6-611, 612, 613 614) will be stored.

        • If DTC P0AA6-526 is output, complete the Step A immediately as quickly as possible.

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

    Tech Tips

    If a DTC is not output, check the driving condition that the Data List item (Short Wave Highest Val) decreases.

    • INSPECTION PROCEDURE

    CAUTION:


    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

    Tech Tips

    When measuring insulation resistance using a megohmmeter, set the megohmmeter to 500 V.

    PROCEDURE


    1. CHECK DTC OUTPUT (HYBRID CONTROL)


      1. Connect the Techstream to the DLC3.

      2. Turn the power switch on (IG).

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

      4. Check if DTCs are output.

        Result
        Result Proceed to
        P0AA6 only is output. A
        P0AA6 and P0A1D (power management control ECU malfunction) are output. B
        P0AA6 and P0AA7 (malfunction in the battery smart unit) are output. C
        P0AA6 and P0AFC (Hybrid Battery Pack Sensor Module) are output. D

      5. Turn the power switch off.


      B

      GO TO DTC CHART (P0A1D) Click here

      C

      GO TO DTC CHART (P0AA7) Click here

      D

      GO TO DTC CHART (P0AFC) Click here

      A

    2. CHECK INFORMATION CODE


      1. Connect the Techstream to the DLC3.

      2. Turn the power switch on (IG).

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

      4. Access the freeze frame data of DTC P0AA6 and read the INF code.

        Note


        • Information codes 611, 612, 613 and 614 are not stored with 526 simultaneously. If a drop in insulation resistance is detected and DTC P0AA6-526 is output, turn the power switch on (READY) and wait for 1 minute with the shift lever in D and the air conditioning system on, then turn the power switch off and wait for 1 minute to determine on of the information code (611, 612, 613 or 614).

        • If only DTC P0AA6-526 is output, perform the diagnosis procedure for INF code 526 to inspect all the high voltage circuits.

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

        Result
        Result Proceed to
        526 (decrease in the insulation resistance of the high-voltage circuit) only is output A
        526 and 611 (decrease in the insulation resistance of the air conditioning system area) are output

        Refer to the troubleshooting procedures for P0AA6-611 (Air conditioning system) Click here

        526 and 612 (decrease in the insulation resistance of the battery area) are output B
        526 and 613 (decrease in the insulation resistance of the transaxle area) are output C
        526 and 614 (decrease in the insulation resistance of the high-voltage DC area) are output D

      5. Turn the power switch off.


      B

      CHECK HV BATTERY AREA Click here

      C

      CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

      D

      CHECK HIGH VOLTAGE DIRECT CURRENT AREA Click here

      A

    3. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE)

      CAUTION:

      Be sure to wear insulated gloves.


      1. Check that the service plug grip is not installed.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

      2. A01I4TT

        Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.

        Tech Tips

        Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

      3. A01I3AIE03
        Text in Illustration
        *1 Generator Cable
        *2 Motor Cable

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

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

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

        Tech Tips

        As the insulation resistance may vary when motor (MG2) rotates, perform this inspection while rotating the front wheels.

      6. Turn the power switch on (IG).

        Note

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

      7. Move the shift lever to N and lift the vehicle.

      8. A01I62VE07
        Text in Illustration
        *1 Shield Ground
        *a Motor Cable (Inverter with Converter Assembly Side)

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

        Note


        • Carefully perform this inspection as the motor (MG2) may generate current when the front wheels are rotated by hand.

        • Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        n1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
        n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
        n1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

      9. Lower the vehicle and move the shift lever to P.

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


      NG

      CHECK MOTOR CABLE Click here

      OK

    4. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE)

      CAUTION:

      Be sure to wear insulated gloves.


      1. Check that the service plug grip is not installed.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

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

        Tech Tips

        As the insulation resistance may vary when generator (MG1) rotates, perform this inspection while rotating the front wheels.

      3. Turn the power switch on (IG).

        Note

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

      4. Move the shift lever to N and lift the vehicle.

      5. A01I62VE08
        Text in Illustration
        *1 Shield Ground
        *a Generator Cable (Inverter with Converter Assembly Side)

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

        Note


        • Carefully perform this inspection as the generator (MG1) may generate current when the front wheels are rotated by hand.

        • Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        o1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
        o1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
        o1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

      6. Lower the vehicle and move the shift lever to P.

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


      NG

      CHECK GENERATOR CABLE Click here

      OK

    5. CHECK NO. 4 ENGINE 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. A01I5ZB

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

        Tech Tips

        Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

      3. A01I5L4E01

        Disconnect connector G2 of the No. 4 engine wire (air conditioning harness) from the inverter with converter assembly.

        Tech Tips

        Make sure that no foreign matter has entered or contaminated connector G2 of the No. 4 engine wire (air conditioning harness).

      4. A01I2T0E01
        Text in Illustration
        *1 Shield Ground
        *a

        Front view of No. 4 Engine Wire (Air Conditioning Harness) connector

        (to Inverter with Converter Assembly)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        G2-1 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
        G2-2 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher

      NG

      CHECK NO. 4 ENGINE WIRE Click here

      OK

    6. CHECK INVERTER WITH CONVERTER ASSEMBLY

      CAUTION:

      Be sure to wear insulated gloves.


      1. Check that the service plug grip is not installed.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

      2. A01I5AEE01

        Disconnect connector Q1 of the No. 4 floor wire from the inverter with converter assembly.

        Tech Tips

        Make sure that no foreign matter has entered or contaminated connector Q1 of the No. 4 floor wire.

      3. A01I2SZE01
        Text in Illustration
        *1 High Voltage Fuse

        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
        High voltage fuse terminal - Body ground Power switch off 1 MΩ or higher

        Tech Tips

        Perform this inspection with the motor cable, generator cable and No. 4 engine wire (air conditioning harness) disconnected from the inverter with converter assembly.


      NG

      REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

      OK

    7. CHECK NO. 4 FLOOR 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. A01I4JPE01
        Text in Illustration
        *1 Shield Ground
        *a

        Front view of No. 4 Floor Wire connector

        (to Inverter with Converter Assembly)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        Q1-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
        Q1-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

        Tech Tips

        Visually inspect the No. 4 floor wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.


      NG

      CHECK NO. 4 FLOOR WIRE Click here

      OK

    8. CHECK HV BATTERY AREA

      CAUTION:

      Be sure to wear insulated gloves.


      1. Check that the service plug grip is not installed.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

      2. Remove the No. 2 hybrid vehicle battery shield panel Click here.

      3. A01I4CEE01

        Disconnect the z7 battery smart unit connector.

      4. A01I5L2E01

        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
        1 - Body ground Power switch off 10 MΩ or higher
        2 - Body ground Power switch off 10 MΩ or higher

      OK

      REPLACE BATTERY SMART UNIT Click here

      NG

      CHECK HV BATTERY Click here

    9. CHECK INVERTER WITH CONVERTER ASSEMBLY

      CAUTION:

      Be sure to wear insulated gloves.


      1. Check that the service plug grip is not installed.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

      2. A01I4TT

        Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.

        Tech Tips

        Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

      3. A01I3AIE03
        Text in Illustration
        *1 Generator Cable
        *2 Motor Cable

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

      4. A01I5ZB

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

        Tech Tips

        Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

      5. A01I2SZE01
        Text in Illustration
        *1 High Voltage Fuse

        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
        High voltage fuse terminal - Body ground Power switch off 1 MΩ or higher

      OK

      CHECK MOTOR CABLE Click here

      NG

      REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    10. CHECK HIGH VOLTAGE DIRECT CURRENT AREA

      CAUTION:

      Be sure to wear insulated gloves.


      1. Check that the service plug grip is not installed.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

      2. A01I5ZB

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

        Tech Tips

        Make sure that no foreign matter has entered or contaminated the inverter with converter assembly.

      3. A01I4JQE04

        Disconnect connector Q1 of the No. 4 floor wire from the inverter with converter assembly.

        Tech Tips

        Make sure that no foreign matter has entered or contaminated connector Q1 of the No. 4 floor wire.

      4. A01I4JPE01
        Text in Illustration
        *1 Shield Ground
        *a

        Front view of No. 4 Floor Wire connector

        (to Inverter with Converter Assembly)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        Q1-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
        Q1-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

        Tech Tips

        Visually inspect the No. 4 floor wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.


      NG

      CHECK NO. 4 FLOOR WIRE Click here

      OK

    11. CHECK NO. 4 ENGINE 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. A01I5L4E01

        Disconnect connector G2 of the No. 4 engine wire (air conditioning harness) from the inverter with converter assembly.

      3. A01I2T0E01
        Text in Illustration
        *1 Shield Ground
        *a

        Front view of No. 4 Engine Wire (Air Conditioning Harness) connector

        (to Inverter with Converter Assembly)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        G2-1 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
        G2-2 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher

      OK

      REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

      NG

      CHECK NO. 4 ENGINE WIRE Click here

    12. CHECK NO. 4 ENGINE 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. A01I3BJE01
        Text in Illustration
        *1 Green Lock

        Disconnect connector G1 of the No. 4 engine wire (air conditioning harness) from the compressor with motor assembly.

      3. A01I2T0E01
        Text in Illustration
        *1 Shield Ground
        *a

        Front view of No. 4 Engine Wire (Air Conditioning Harness) connector

        (to Inverter with Converter Assembly)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        G2-1 (ACPE) - Body ground and shield ground Power switch off 10 MΩ or higher
        G2-2 (ACPB) - Body ground and shield ground Power switch off 10 MΩ or higher

      OK

      AIR CONDITIONING SYSTEM (P0AA6-611) Click here

      NG

      REPLACE NO. 4 ENGINE WIRE Click here

    13. CHECK NO. 4 FLOOR WIRE

      CAUTION:

      Be sure to wear insulated gloves.


      1. Check that the service plug grip is not installed.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

      2. Remove the No. 4 hybrid battery shield panel Click here.

      3. A01I5G7E04

        Disconnect connector Q2 and connector Q3 of the No. 4 floor wire from the hybrid battery junction block assembly.

        Tech Tips

        Make sure that no foreign matter has entered or contaminated connector Q2 and Q3 of the No. 4 floor wire.

      4. A01I348E01
        Text in Illustration
        *1 Shield Ground
        *a

        Front view of No. 4 Floor Wire connector

        (to Hybrid Battery Junction Bock Assembly)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        Q3-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
        Q2-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher

        Tech Tips

        Visually inspect the No. 4 floor wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.


      OK

      REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

      NG

      REPLACE NO. 4 FLOOR WIRE Click here

    14. CHECK HV BATTERY

      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 Click here.

      3. A01I5L2E01

        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
        1 - Body ground Power switch off 10 MΩ or higher
        2 - Body ground Power switch off 10 MΩ or higher

      OK

      REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

      NG

      REPLACE HV BATTERY Click here

    15. 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. Disconnect the motor cable from the hybrid vehicle transaxle assembly Click here.

      3. A01I62VE07
        Text in Illustration
        *1 Shield Ground
        *a Motor Cable (Inverter with Converter Assembly Side)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        n1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
        n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
        n1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

      OK

      REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

      NG

      REPLACE MOTOR CABLE Click here

    16. 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. Disconnect the generator cable from the hybrid vehicle transaxle assembly Click here.

      3. A01I62VE08
        Text in Illustration
        *1 Shield Ground
        *a Generator Cable (Inverter with Converter Assembly Side)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        o1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
        o1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
        o1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

      OK

      REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

      NG

      REPLACE GENERATOR CABLE Click here

    17. CHECK MOTOR CABLE

      CAUTION:

      Be sure to wear insulated gloves.


      1. Turn the power switch off.

      2. 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.

      3. Disconnect the motor cable from the hybrid vehicle transaxle assembly Click here.

      4. A01I62VE07
        Text in Illustration
        *1 Shield Ground
        *a Motor Cable (Inverter with Converter Assembly Side)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        n1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
        n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
        n1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

      NG

      REPLACE MOTOR CABLE Click here

      OK

    18. 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. Disconnect the generator cable from the hybrid vehicle transaxle assembly Click here.

      3. A01I62VE08
        Text in Illustration
        *1 Shield Ground
        *a Generator Cable (Inverter with Converter Assembly Side)

        Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

        Note

        Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        o1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
        o1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
        o1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

      NG

      REPLACE GENERATOR CABLE Click here

      OK

    19. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

      Click here (When Not Using the Engine Support Bridge))

      Click here (When Using the Engine Support Bridge))


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    20. REPLACE INVERTER WITH CONVERTER ASSEMBLY

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    21. REPLACE BATTERY SMART UNIT

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    22. REPLACE NO. 4 ENGINE WIRE


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    23. AIR CONDITIONING SYSTEM (P0AA6-611)

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    24. REPLACE NO. 4 FLOOR WIRE

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    25. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    26. REPLACE HV BATTERY

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    27. REPLACE MOTOR CABLE

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS

    28. REPLACE GENERATOR CABLE

      Click here


      NEXT

      PERFORM CONFIRMATION AFTER REPLACING PARTS