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 hybrid vehicle 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 (*1) Insulation resistance between the high-voltage circuit and the body has decreased.

  • Hybrid vehicle transmission assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly

  • Frame wire

  • Air conditioning harness assembly

  • HV battery junction block

  • With motor compressor assembly

  • HV battery

  • Battery smart unit

  • Hybrid vehicle converter

  • Power steering converter wire

  • Power steering converter

  • HV battery terminal block
P0AA6 611 Insulation resistance of the with motor compressor assembly has decreased. With motor compressor assembly
P0AA6 612 Insulation resistance of the HV battery area has decreased.

  • HV battery junction block

  • Battery smart unit

  • HV battery

  • Hybrid vehicle converter
P0AA6 613 Insulation resistance of the transmission area has decreased.

  • Hybrid vehicle transmission assembly

  • Inverter with converter assembly

  • Motor cable

  • Generator cable
P0AA6 614 Insulation resistance of the high-voltage DC area has decreased.

  • Inverter with converter assembly

  • Frame wire

  • Air conditioning harness assembly

  • Air conditioner harness assembly

  • HV battery junction block

  • Hybrid vehicle converter

  • Power steering converter wire

  • Power steering converter

  • HV battery terminal block

Tech Tips


  • *1: INF code 526 is stored together with P0AA6.

  • If P0AA6 is stored, the hybrid system cannot be turned on until the DTC is cleared using the intelligent tester.

  • If P0AA6 is stored while driving, the vehicle can drive for the remainder of that trip.

  • When measuring insulation resistance using a megohmmeter, measure the resistance while jiggling the high-voltage wire harness.

WIRING DIAGRAM

A000US3E05

CAUTION / NOTICE / HINT

CAUTION:


  • When troubleshooting P0AA6, be sure to wrap tools with electrical tape. (It is very dangerous if high voltage is shorted to ground through tools.)

  • 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 disconnecting 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.

Tech Tips


  • Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

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

PROCEDURE


  1. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0AA6 only is output. A
      P0AA6 and P0A1D (hybrid vehicle control ECU malfunction) are output. B
      P0AA6 and P0AA7 (malfunction in the battery smart unit) are output. C
      P0AA6 and P0AFC (battery ECU malfunction) are output. D

    B

    GO TO INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P0A1D) Click here

    C

    GO TO INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P0AA7) Click here

    D

    GO TO INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P0AFC) Click here

    A

  2. CHECK INFORMATION CODE


    1. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

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

      Note

      INF codes 611, 612, 613, and 614 are not stored at the same time with INF code 526. If only INF code 526 is output, turn the power switch off and wait 30 seconds to determine the malfunctioning area. Then, turn the power switch on (IG) and read the INF code again.

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

    B

    GO TO AIR CONDITIONING SYSTEM (P0AA6-611) Click here

    C

    CHECK HV BATTERY AREA Click here

    D

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    E

    CHECK MOTOR CABLE Click here

    A

  3. CHECK AIR CONDITIONING HARNESS ASSEMBLY (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Remove the service plug grip. Click here

      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. Check the condition of the air conditioning harness assembly connector.

      A000WX4E01
      *1 for LHD:
      *2 for RHD:
      OK
      The connector is connected securely and there are no contact problems.

    4. Check for arc marks on the terminals of the air conditioning harness assembly.

      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

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  4. CHECK AIR CONDITIONING HARNESS ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. Disconnect the air conditioning harness assembly from the inverter with converter assembly.

      A000WX4E01
      *1 for LHD:
      *2 for RHD:

    3. Make sure that no foreign objects have entered or contaminated the connector of the air conditioning harness assembly.

    4. A000Z5LE03
      *a Air Conditioning Harness Assembly
      *b Shielded Wire Ground

      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
      j1-1 (ACPE) - Body ground and shielded wire ground Power switch off 3 MΩ or higher
      j1-2 (ACPB) - Body ground and shielded wire ground Power switch off 3 MΩ or higher

    NG

    CHECK AIR CONDITIONING HARNESS ASSEMBLY Click here

    OK

  5. CHECK CONDITION OF FRAME WIRE CONNECTION(S)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. Check the connection between the frame wire and the inverter with converter assembly.

      A000VIJE01
      *1 for LHD:
      *2 for RHD:
      OK
      The connector is connected securely and there are no contact problems.

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the inverter with converter assembly.


    NG

    CONNECT SECURELY

    OK

  6. CHECK INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


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

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

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the connector of the frame wire.

      A000VIJE01
      *1 for LHD:
      *2 for RHD:

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

      A000UOHE01
      *1 for LHD:
      *2 for RHD:
      *3 A/C Fuse

      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
      A/C fuse - Body ground Power switch off 1.0 MΩ or higher

      Tech Tips

      Perform this inspection with the air conditioning harness assembly disconnected from the inverter with converter assembly.


    NG

    CHECK MOTOR CABLE Click here

    OK

  7. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000VQNE01
      *1 Frame Wire (HV Battery Junction Block Side)

      Check that the service plug grip is not installed.

    2. Disconnect the frame wire from the HV battery junction block.

      Tech Tips

      For the removal and installation procedures related to the frame wire, (See page for LHD, Click here for RHD).

    3. A000XC7E02
      *1 Frame Wire (HV Battery Junction Block Side)
      *2 Red Mark
      *3 Shielded Wire Ground

      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 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      g3-1 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      Result
      Result Proceed to
      OK A
      NG (for LHD) B
      NG (for RHD) C

    B

    REPLACE FRAME WIRE Click here

    C

    REPLACE FRAME WIRE Click here

    A

  8. CHECK HV BATTERY JUNCTION BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000Y57

      Disconnect the high-voltage connectors of the HV battery from the HV battery junction block.

    3. A000WGUE02
      *1 Battery Carrier

      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
      g3-1 - Battery carrier Power switch off 10 MΩ or higher
      g2-1 - Battery carrier Power switch off 10 MΩ or higher

    NG

    CHECK POWER STEERING CONVERTER Click here

    OK

  9. CHECK HV BATTERY AREA

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. A000WNAE02

      Remove the service plug grip. Click here

      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 orange-colored connector z32 from the battery smart unit.

      Tech Tips

      For the removal and installation procedures related to the battery smart unit connector, Click here.

    4. A000XC9E03

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

      Note

      Perform this inspection with the high-voltage connectors of the hybrid vehicle converter connected.


    OK

    REPLACE BATTERY SMART UNIT Click here

    NG

  10. CHECK HV CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000WMXE03
      *1 Hybrid Vehicle Converter

      Disconnect the hybrid vehicle converter connectors from the HV battery junction block.

      Tech Tips

      For the removal and installation procedures related to the hybrid vehicle converter connectors, Click here.

    3. A000Z8NE02
      *1 Hybrid Vehicle Converter

      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
      z60-1 (INR) - Hybrid vehicle converter Power switch off 10 MΩ or higher
      z58-1 (CBD) - Hybrid vehicle converter Power switch off 10 MΩ or higher
      z59-1 (CED) - Hybrid vehicle converter Power switch off 10 MΩ or higher

    NG

    REPLACE HV CONVERTER Click here

    OK

  11. CHECK HV BATTERY JUNCTION BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000Y57

      Disconnect the high-voltage connectors of the HV battery from the HV battery junction block.

    3. A000V9ME02
      *1 Battery Carrier

      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
      z30-1 - Battery carrier Power switch off 10 MΩ or higher
      z34-1 - Battery carrier Power switch off 10 MΩ or higher

    OK

    REPLACE HV BATTERY Click here

    NG

    REPLACE HV BATTERY JUNCTION BLOCK Click here

  12. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Remove the service plug grip. Click here

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


      • For LHD vehicles, use the following procedures Click here.

      • For RHD vehicles, use the following procedures Click here.

      Note

      Lift the inverter terminal cover horizontally so that it does not tilt. Failure to do so may break the inverter cover guide pins.

      A000TY6E01
      *1 for LHD:
      *2 for RHD:

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

      A000Z8GE01
      *1 for LHD:
      *2 for RHD:

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

      A000WF5E02
      *1 Motor Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      V - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      W - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    CHECK MOTOR CABLE Click here

    OK

  13. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


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

      A000WF5E01
      *1 Generator Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

    2. 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
      U - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      V - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      W - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    CHECK GENERATOR CABLE Click here

  14. CHECK AIR CONDITIONING HARNESS ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. A000TPTE01
      *1 Green Lock

      Remove the service plug grip. Click here

      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 air conditioning harness assembly from the with motor compressor assembly.

    4. A000Z5LE03
      *a Air Conditioning Harness Assembly
      *b Shielded Wire Ground

      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
      j1-1 (ACPE) - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      j1-2 (ACPB) - Body ground and shielded wire ground Power switch off 10 MΩ or higher

    OK

    GO TO AIR CONDITIONING SYSTEM (P0AA6-611) Click here

    NG

    REPLACE AIR CONDITIONING HARNESS ASSEMBLY

  15. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Remove the service plug grip. Click here

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


      • For LHD vehicles, use the following procedures Click here.

      • For RHD vehicles, use the following procedures Click here.

      Note

      Lift the inverter terminal cover horizontally so that it does not tilt. Failure to do so may break the inverter cover guide pins.

      A000TY6E01
      *1 for LHD:
      *2 for RHD:

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

      A000Z8GE01
      *1 for LHD:
      *2 for RHD:

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

      A000WF5E02
      *1 Motor Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      V - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      W - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    CHECK MOTOR CABLE Click here

    OK

  16. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


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

      A000WF5E01
      *1 Generator Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

    2. 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
      U - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      V - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      W - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    CHECK GENERATOR CABLE Click here

    OK

  17. CHECK HIGH-VOLTAGE DIRECT CURRENT AREA

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Remove the service plug grip Click here.

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

      A000YZ3E01
      *1 for LHD:
      *2 for RHD:

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

      A000VIJE01
      *1 for LHD:
      *2 for RHD:
    5. A000W93E02
      *a Frame Wire

      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
      g1-1 (CBI) - Body ground Power switch off 10 MΩ or higher
      g1-2 (CEI) - Body ground Power switch off 10 MΩ or higher

    NG

    CHECK FRAME WIRE Click here

    OK

  18. CHECK AIR CONDITIONING HARNESS ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. Disconnect the air conditioning harness assembly from the inverter with converter assembly.

      A000ZEZE02
      *1 for LHD:
      *2 for RHD:
    3. A000Z5LE03
      *a Air Conditioning Harness Assembly
      *b Shielded Wire Ground

      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
      j1-1 (ACPE) - Body ground and shielded wire ground Power switch off 3 MΩ or higher
      j1-2 (ACPB) - Body ground and shielded wire ground Power switch off 3 MΩ or higher
      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

  19. CHECK AIR CONDITIONING HARNESS ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000TPTE01
      *1 Green Lock

      Check that the service plug grip is not installed.

    2. Disconnect the air conditioning harness assembly from the with motor compressor assembly.

    3. A000Z5LE03
      *a Air Conditioning Harness Assembly
      *b Shielded Wire Ground

      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
      j1-1 (ACPE) - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      j1-2 (ACPB) - Body ground and shielded wire ground Power switch off 10 MΩ or higher

    OK

    GO TO AIR CONDITIONING SYSTEM (P0AA6-611) Click here

    NG

    REPLACE AIR CONDITIONING HARNESS ASSEMBLY

  20. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000VQNE01
      *1 Frame Wire (HV Battery Junction Block Side)

      Check that the service plug grip is not installed.

    2. Disconnect the frame wire from the HV battery junction block.

      Tech Tips

      For the removal and installation procedures related to the frame wire, (See page for LHD, Click here for RHD).

    3. A000XC7E02
      *1 Frame Wire (HV Battery Junction Block Side)
      *2 Red Mark
      *3 Shielded Wire Ground

      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 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      g3-1 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      Result
      Result Proceed to
      OK A
      NG (for LHD) B
      NG (for RHD) C

    B

    REPLACE FRAME WIRE Click here

    C

    REPLACE FRAME WIRE Click here

    A

  21. CHECK HV CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000WMXE03
      *1 Hybrid Vehicle Converter

      Disconnect the hybrid vehicle converter connectors from the HV battery junction block.

      Tech Tips

      For the removal and installation procedures related to the hybrid vehicle converter connectors, Click here.

    3. A000Z8NE02
      *1 Hybrid Vehicle Converter

      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
      z60-1 (INR) - Hybrid vehicle converter Power switch off 10 MΩ or higher
      z58-1 (CBD) - Hybrid vehicle converter Power switch off 10 MΩ or higher
      z59-1 (CED) - Hybrid vehicle converter Power switch off 10 MΩ or higher

    NG

    REPLACE HV CONVERTER Click here

    OK

  22. CHECK POWER STEERING CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A00105S

      Disconnect the connector of the frame wire No. 3 (high-voltage wire of the power steering converter) from the HV battery junction block.

    3. A000UJ7E02
      *1 CBPE
      *2 CEPE

      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
      z27-1 (CBPE) - Body ground Power switch off 30 MΩ or higher
      z27-4 (CEPE) - Body ground Power switch off 30 MΩ or higher

    NG

    CHECK POWER STEERING CONVERTER WIRE (HV BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER) Click here

    OK

  23. CHECK HV BATTERY JUNCTION BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000VGD

      Check that the service plug grip is not installed.

    2. Remove the HV battery terminal block.

    3. A000TFZE02
      *1 Battery Carrier

      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 Condition Specified Condition
      g2-1 - Battery carrier Power switch off 10 MΩ or higher
      g3-1 - Battery carrier Power switch off 10 MΩ or higher

    OK

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    NG

    REPLACE HV BATTERY JUNCTION BLOCK Click here

  24. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000UQD

      Check that the service plug grip is not installed.

    2. Disconnect the motor cable from the hybrid vehicle transmission assembly.

      Tech Tips

      For the removal and installation procedures related to the motor cable, Click here.

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

      A000WF5E02
      *1 Motor Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  25. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000TAA

      Check that the service plug grip is not installed.

    2. Disconnect the generator cable from the hybrid vehicle transmission assembly.

      Tech Tips

      For the removal and installation procedures related to the generator cable, Click here.

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

      A000WF5E01
      *1 Generator Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  26. CHECK POWER STEERING CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A00105S

      Disconnect the connector of the frame wire No. 3 (high-voltage wire of the power steering converter) from the HV battery junction block.

    3. A000UJ7E02
      *1 CBPE
      *2 CEPE

      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
      z27-1 (CBPE) - Body ground Power switch off 30 MΩ or higher
      z27-4 (CEPE) - Body ground Power switch off 30 MΩ or higher

    NG

    CHECK POWER STEERING CONVERTER WIRE (HV BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER) Click here

    OK

  27. CHECK HV CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000WMXE03
      *1 Hybrid Vehicle Converter

      Disconnect the hybrid vehicle converter connectors from the HV battery junction block.

      Tech Tips

      For the removal and installation procedures related to the hybrid vehicle converter connectors, Click here.

    3. A000Z8NE02
      *1 Hybrid Vehicle Converter

      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
      z60-1 (INR) - Hybrid vehicle converter Power switch off 10 MΩ or higher
      z58-1 (CBD) - Hybrid vehicle converter Power switch off 10 MΩ or higher
      z59-1 (CED) - Hybrid vehicle converter Power switch off 10 MΩ or higher

    NG

    REPLACE HV CONVERTER Click here

    OK

  28. CHECK HV BATTERY JUNCTION BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000VGD

      Check that the service plug grip is not installed.

    2. Remove the HV battery terminal block.

    3. A000TFZE02
      *1 Battery Carrier

      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 Condition Specified Condition
      g2-1 - Battery carrier Power switch off 10 MΩ or higher
      g3-1 - Battery carrier Power switch off 10 MΩ or higher

    OK

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    NG

    REPLACE HV BATTERY JUNCTION BLOCK Click here

  29. CHECK INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Remove the service plug grip. Click here

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


      • For LHD vehicles, use the following procedures Click here.

      • For RHD vehicles, use the following procedures Click here.

      Note

      Lift the inverter terminal cover horizontally so that it does not tilt. Failure to do so may break the inverter cover guide pins.

      A000TY6E01
      *1 for LHD:
      *2 for RHD:

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

      A000Z8GE01
      *1 for LHD:
      *2 for RHD:

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

      A000YZ3E01
      *1 for LHD:
      *2 for RHD:

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the inverter with converter assembly.

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

      A000UOHE01
      *1 for LHD:
      *2 for RHD:
      *3 A/C Fuse

      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
      A/C Fuse - Body ground Power switch off 1.0 MΩ or higher
      Result
      Result Proceed to
      OK A
      NG (for LHD) B
      NG (for RHD) C

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    A

  30. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000UQD

      Check that the service plug grip is not installed.

    2. Disconnect the motor cable from the hybrid vehicle transmission assembly.

      Tech Tips

      For the removal and installation procedures related to the motor cable, Click here.

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

      A000WF5E02
      *1 Motor Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher

    NG

    REPLACE MOTOR CABLE Click here

    OK

  31. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000TAA

      Check that the service plug grip is not installed.

    2. Disconnect the generator cable from the hybrid vehicle transmission assembly.

      Tech Tips

      For the removal and installation procedures related to the generator cable, Click here.

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

      A000WF5E01
      *1 Generator Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  32. CHECK POWER STEERING CONVERTER WIRE (HV BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. Disconnect the frame wire No. 3 (connector for the HV battery) from the power steering converter.

    3. A000ZKHE02
      *1 CBP
      *2 CEP

      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
      z28-1 (CBP) - Body ground Power switch off 10 MΩ or higher
      z28-5 (CEP) - Body ground Power switch off 10 MΩ or higher

    OK

    REPLACE POWER STEERING CONVERTER Click here

    NG

    REPLACE POWER STEERING CONVERTER WIRE

  33. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000UQD

      Check that the service plug grip is not installed.

    2. Disconnect the motor cable from the hybrid vehicle transmission assembly.

      Tech Tips

      For the removal and installation procedures related to the motor cable, Click here.

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

      A000WF5E02
      *1 Motor Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  34. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000TAA

      Check that the service plug grip is not installed.

    2. Disconnect the generator cable from the hybrid vehicle transmission assembly.

      Tech Tips

      For the removal and installation procedures related to the generator cable, Click here.

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

      A000WF5E01
      *1 Generator Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here