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 assembly monitors the battery voltage sensor and detects insulation malfunctions in the high-voltage system.

Tech Tips

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

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P0AA6-526 Hybrid Battery Voltage System Isolation Fault Insulation resistance between the high-voltage circuit and the body has decreased.*1

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly

  • Frame wire

  • No. 2 engine wire

  • Hybrid battery junction block assembly

  • Air conditioning system

  • HV battery

  • Battery voltage sensor

 Does not come on

Master Warning Light:

Comes on
P0AA6-611 Hybrid Battery Voltage System Isolation Fault Insulation resistance of the high voltage circuit in the air conditioning system has decreased.*2 Air conditioning system Does not come on

Master Warning Light:

Comes on
P0AA6-612 Hybrid Battery Voltage System Isolation Fault Insulation resistance of the HV battery area has decreased.*2

  • Hybrid battery junction block assembly

  • Battery voltage sensor

  • HV battery

 Does not come on

Master Warning Light:

Comes on
P0AA6-613 Hybrid Battery Voltage System Isolation Fault Insulation resistance of the transaxle area has decreased.*2

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Generator cable

  • Inverter with converter assembly

 Does not come on

Master Warning Light:

Comes on
P0AA6-614 Hybrid Battery Voltage System Isolation Fault Insulation resistance of the high-voltage DC area has decreased.*2

  • Inverter with converter assembly

  • Frame wire

  • Air conditioning system

  • No. 2 engine wire

  • Hybrid battery junction block assembly

 Does not come on Master Warning Light:

Tech Tips


  • *1: The insulation malfunction detection circuit in the battery voltage sensor monitors the insulation resistance between the high voltage circuits and body. If the insulation resistance decreases, the hybrid vehicle control ECU assembly stores DTC P0AA6-526 and illuminates the MIL first.

  • *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.


    1. Apply the parking brake firmly.

    2. Wait for 1 minute or more with the vehicle stopped, the brake pedal firmly depressed, the power switch is on (READY), the shift lever in D 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.

WIRING DIAGRAM

A01SFCKC03
*1 HV Battery *2 Battery Voltage Sensor
*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 MG1 *12 MG2
*13 Compressor with Motor Assembly *14 A/C Inverter
*15 A/C Motor - -
*a High-voltage Areas *b INF Code 526 Vehicle Insulation Resistance Reduction Area
*c INF Code 611 Air Conditioning System Area *d INF Code 612 HV Battery Area
*e INF Code 613 Transaxle Area *f INF Code 614 High Voltage Direct Current Area
A01SFJZE05

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. Characteristics of Short Wave Highest Value


    1. The Data List item Short Wave Highest Val and insulation resistance have the relationship shown in the table below. Short Wave Highest Val decreases with a decrease in insulation resistance. However, in some cases, even though the insulation resistance of the vehicle is normal, Short Wave Highest Val may decrease. Therefore, check Short Wave Highest Val under the following conditions:


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

      • There is no difference between the system voltages ("Power Resource VB", "VL-Voltage before Boosting", and "VH-Voltage after Boosting").*2

        Short Wave Highest Value Trouble Area
        Both conditions (*1 and *2) are met and Short Wave Highest Val is approximately 0 V Since the insulation resistance is close to 0 Ω, there is a strong possibility of interference with a metal object.
        Both conditions (*1 and *2) are met and Short Wave Highest Val is between 0 and 5 V Since the insulation resistance is several hundred kilo ohms, there is a strong possibility of the presence of fluid, such as coolant.

  2. How to Determine Part with Insulation Malfunction


    1. Jiggle the high-voltage wire harness to check if the resistance to body ground changes with the position of the wire harness or force applied.

    2. Repeatedly operate MG1, MG2 and the compressor with motor assembly. Check that the Short Wave Highest Val does not decrease (for example if the motor stops with foreign matter forming a leak path) when the motor stops, or that the Short Wave Highest Val does not return to normal (for example if foreign matter moves away from the leak path) when the motor rotates.

    3. Increase the temperature of MG1 and MG2. Check if the Short Wave Highest Val decreases with the temperature increase.

    4. Check that the transaxle fluid is not cloudy and the coolant level in the reserve tank has not dropped. The transaxle fluid will become cloudy when mixed with coolant, resulting in low insulation resistance.

CAUTION / NOTICE / HINT

CAUTION:


  • When troubleshooting DTC P0AA6, use either a tool wrapped with vinyl insulation tape or an insulated tool. (It is extremely dangerous when a high-voltage charge passes through a non-insulated tool causing a short.)

  • 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.

  • When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

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


  • If DTC P0AA6 is stored, the hybrid control system cannot be turned on.

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

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

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Result
      Result Proceed to
      P0AA6 only is output. A
      P0AA6 and P0A1D are output. B
      P0AA6 and P0AA7 are output. C
      P0AA6 and P0AFC are output. D
      P0AA6 and P0B23 are output. E

    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

    E

    GO TO DTC CHART (P0B23) Click here

    A

  2. CHECK INFORMATION CODE (HYBRID CONTROL)


    1. Connect the GTS 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.


      Powertrain > Hybrid Control > Trouble Codes

      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, wait for 1 minute with power switch on (READY), drive (D) selected and the air conditioning system on within the same trip, then turn the power switch off and wait for 1 minute to determine 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.

      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 procedure 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

    GO TO STEP 8 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. A01SF6L

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

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

    3. A01SFNLC06
      *1 Generator Cable
      *2 Motor Cable

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

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the motor cable terminals and generator cable terminals.

    4. 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.

    5. 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.

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

    7. A01SFUYC11
      *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 Condition Specified Condition
      k1-1 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      k1-2 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      k1-3 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

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

    9. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    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. A01SFFUC12
      *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 Condition Specified Condition
      m1-1 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      m1-2 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      m1-3 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

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

    7. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK GENERATOR CABLE Click here

    OK

  5. CHECK NO. 2 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. A01SFLY

      Disconnect the No. 2 engine wire from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the No. 2 engine wire (air conditioning harness) terminals.

    3. A01SFCTC12
      *1 Shield Ground
      *a

      No. 2 Engine Wire (Air Conditioning Harness)

      (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 Condition Specified Condition
      s6-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      s6-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    CHECK NO. 2 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. A01SFTL

      Disconnect the frame wire from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the frame wire terminals.

    3. A01SFD7C01
      *1 High Voltage Terminal

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

      Tech Tips

      Perform this inspection with the motor cable, generator cable and No. 2 engine wire (air conditioning harness) disconnected from the inverter with converter assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    OK

  7. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01SFKEC08
      *1 Shield Ground
      *a

      Frame Wire

      (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 Condition Specified Condition
      W1-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      W1-2 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the frame wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK FRAME 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. 1 hybrid vehicle battery cover panel LH.

      Click here

    3. A01SFHON02

      Disconnect the y1 battery voltage sensor connector.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the y1 battery voltage sensor connector.

    4. A01SFIGN01

      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
      1 - Body ground Power switch off 10 MΩ or higher
      2 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    REPLACE BATTERY VOLTAGE SENSOR Click here

    NG

  9. 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. A01SFIGN01

      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
      1 - Body ground Power switch off 10 MΩ or higher
      2 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE HV BATTERY Click here

  10. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the hybrid battery cover sub-assembly RH.

      Click here

    3. A01SFU3N03

      Disconnect the W2 and W3 hybrid battery junction block assembly connectors.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the W2 and W3 hybrid battery junction block assembly connectors.

    4. A01SFF0C04
      *1 Shield Ground
      *a

      Frame Wire

      (Hybrid Battery Junction Block Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      W3-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      W2-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the frame wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE FRAME WIRE Click here

  11. CHECK NO. 2 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. A01SFR3N02

      Disconnect the s5 compressor with motor assembly connector.

      Click here

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the s5 No. 2 engine wire connector.

    3. A01SFCTC13
      *1 Shield Ground
      *a

      No. 2 Engine Wire (Air Conditioning Harness)

      (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 Condition Specified Condition
      s6-1 (ACPB) - Body ground and shield ground Power switch off 10 MΩ or higher
      s6-2 (ACPE) - Body ground and shield ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

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

    NG

    REPLACE NO. 2 ENGINE WIRE

  12. 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. A01SFFUC13
      *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 Condition Specified Condition
      m1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  13. 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. A01SFUYC12
      *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 Condition Specified Condition
      k1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  14. 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. A01SF6L

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

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

    3. A01SFNLC07
      *1 Generator Cable
      *2 Motor Cable

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

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the motor cable terminals and generator cable terminals.

    4. A01SFD7C01
      *1 High Voltage Terminal

      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
      High voltage terminal - Body ground Power switch off 1 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    OK

  15. 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. A01SFUYC13
      *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 Condition Specified Condition
      k1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE 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.

      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. A01SFFUC14
      *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 Condition Specified Condition
      m1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  17. 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. A01SF6L

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

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

    3. A01SFC0

      Disconnect the frame wire from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the frame wire terminals.

    4. A01SFKEC09
      *1 Shield Ground
      *a

      Frame Wire

      (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 Condition Specified Condition
      W1-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      W1-2 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the frame wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 10 Click here

    OK

  18. CHECK NO. 2 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. A01SFLY

      Disconnect the No. 2 engine wire from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the No. 2 engine wire (air conditioning harness) terminals.

    3. A01SFCTC14
      *1 Shield Ground
      *a

      No. 2 Engine Wire (Air Conditioning Harness)

      (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 Condition Specified Condition
      s6-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      s6-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    GO TO STEP 11 Click here