HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA649, P1C7C49, P1C7D49, P1C7E49, P1C7F49

DTC Code DTC Name
P0AA649 Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure
P1C7C49 Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure
P1C7D49 Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure
P1C7E49 Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure
P1C7F49 Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure

DESCRIPTION

The hybrid vehicle control ECU monitors the battery voltage sensor and detects insulation malfunctions in the high-voltage system.

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P0AA649 Hybrid/EV Battery Voltage System Insulation Resistance Decreased

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

(1 trip detection logic)

  • Inverter with converter assembly

  • HV floor under wire

  • HV battery junction block assembly

  • Battery voltage sensor

  • Hybrid battery terminal block

  • HV battery

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Air conditioning system

  • Air conditioning wire

 Does not come on

Master Warning Light:

Comes on
P1C7C49 Hybrid/EV Battery Voltage System (A/C Area) Insulation Resistance Decreased

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

(1 trip detection logic)

 Air conditioning system Does not come on

Master Warning Light:

Comes on
P1C7D49 Hybrid/EV Battery Voltage System (Hybrid/EV Battery Area) Insulation Resistance Decreased

Insulation resistance of the HV battery, battery voltage sensor or SMR has decreased.*2

(1 trip detection logic)

  • HV battery junction block assembly

  • Battery voltage sensor

  • Hybrid battery terminal block

  • HV battery

 Does not come on

Master Warning Light:

Comes on
P1C7E49 Hybrid/EV Battery Voltage System (Transaxle Area) Insulation Resistance Decreased

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

  • Inverter with converter assembly

 Does not come on

Master Warning Light:

Comes on
P1C7F49 Hybrid/EV Battery Voltage System (Direct Current Area) Insulation Resistance Decreased

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

(1 trip detection logic)

  • Inverter with converter assembly

  • HV floor under wire

  • HV battery junction block assembly

  • Air conditioning system

  • Air conditioning wire

 Does not come on

Master Warning Light:

Comes on

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 stores DTC P0AA649 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 P0AA649 outputs, complete the following steps as soon as possible.

  • *2: If the following operations are performed within the same trip after DTC P0AA649 is stored, just one of the related DTCs (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) 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 on (READY), drive (D) selected and the air conditioning system on (Lo/MAX COOL, blower speed HI).

    3. Turn the power switch off and wait for 2 minutes or more.

      Tech Tips


      • DTCs and freeze frame data are useful information in determining the malfunctioning part. Before performing diagnosis, make sure to check and make a note of all output DTCs and freeze frame data. (Even if a high-voltage insulation malfunction cannot be reproduced, once stored, DTCs of insulation will not be cleared unless the clear operation is performed.)

      • When the insulation resistance of the HV battery area decreases and the power switch is turned on (IG), DTC P1C7D49 is stored within 2 minutes.

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

Related Data List (Reproduction of Phenomenon and Check)
DTC No. Data List
P0AA649

  • Short Wave Highest Value Level

  • Hybrid Battery Voltage

  • VL-Voltage before Boosting

  • VH-Voltage after Boosting

  • Boost Ratio

  • A/C Consumption Power

  • SMRP Status

  • SMRB Status

  • SMRG Status

  • Generator Inverter Shutdown Status

  • Motor Inverter Shutdown Status

  • Insulation Resistance Division Check Completion using MG Inv

  • Insulation Resistance Division Check Completion using A/C Inv

  • Insulation Resistance Division Check Completion using SMR

  • Short Wave Highest Value Availability just after MG Inv On/Off

  • Short Wave Highest Value Availability just after A/C Inv On/Off

  • Short Wave Highest Value Availability just after SMR On/Off
P1C7C49
P1C7D49
P1C7E49
P1C7F49

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


CONFIRMATION DRIVING PATTERN


  1. CONFIRMATION AFTER REPLACING PARTS

    Tech Tips

    After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure. (Do not turn the power switch off (READY off) during this inspection.)

    Click here


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG) and turn the GTS on.

    3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

    4. Turn the power switch off and wait for 2 minutes or more.

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

    6. When the vehicle is stationary, turn the power switch on (READY) with park (P) selected and wait for 1 minute or more.

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

    8. 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 P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

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

    9. Drive the vehicle for approximately 5 minutes referring to the following freeze frame data items: "Vehicle Speed", "Shift Position", "Accelerator Position Sensor No.1 Voltage %", "Engine Speed", "Coolant Temperature", "Master Cylinder Control Torque", "Motor Temperature" and "Generator Temperature"

      (If the freeze frame data item "Vehicle Speed" 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 P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

      - If DTC P0AA649 is output, complete the Step A immediately as quickly as possible.

    10. Wait for 1 minute or more with the vehicle stopped, the power switch on (READY), park (P) selected and the air conditioning system on (Lo/COOL MAX, blower speed HI), then turn the power switch off and wait for 2 minutes or more. (Step A)

    11. Turn the power switch on (IG) and turn the GTS on.

    12. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

    13. Check the DTC judgment result.

      Tech Tips


      • If the judgment result shows NORMAL, the system is normal.

      • If the judgment result shows ABNORMAL, the system has a malfunction.

      • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

WIRING DIAGRAM

B004OZFC03
*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 Generator (MG1) *12 Motor (MG2)
*13 Compressor with Motor Assembly *14 A/C Inverter
*15 A/C Motor - -
*a High-voltage Areas *b DTC P0AA649 Vehicle Insulation Resistance Reduction Area
*c DTC P1C7C49 Air Conditioning System Area *d DTC P1C7D49 HV Battery Area
*e DTC P1C7E49 Hybrid Vehicle Transaxle Assembly Area *f DTC P1C7F49 High Voltage Direct Current Area
B004PHUE02

SYSTEM DESCRIPTION

Tech Tips

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


  1. SHORT WAVE HIGHEST VALUE LEVEL


    1. "Short Wave Highest Value Level" shows a decrease in insulation resistance. When insulation resistance decreases, "Insulation Lower" will be displayed. However, even though the insulation resistance of the vehicle is normal, "Short Wave Highest Value Level" may decrease, so that "Not Judge" will be displayed for any of the following conditions.


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

      • When the system voltages ("Hybrid Battery Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting") are changing.

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

      • When "No" is displayed for any of the following Data List items:

        - Short Wave Highest Value Availability just after MG Inv On/Off

        - Short Wave Highest Value Availability just after A/C Inv On/Off

        - Short Wave Highest Value Availability just after SMR On/Off

    2. When "Short Wave Highest Value Level" shows "Insulation Lower LV3", insulation resistance will be close to 0 Ω. In this case, damage to a high-voltage cable or hybrid component (high-voltage), or a short to body ground due to intrusion of foreign matter, such as metal particles, can be suspected.


    • 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.

    Items to be Checked Using Freeze Frame Data:
    Freeze Frame Data Diagnostic Note
    Short Wave Highest Value Level Indicates that the insulation resistance has decreased.

    • VL-Voltage before Boosting

    • VH-Voltage after Boosting

    • Hybrid Battery Voltage

    • Boost Ratio

    		 During boosting (when "Boost Ratio" is not 0%), or when "VL-Voltage before Boosting", "VH-Voltage after Boosting" or "Hybrid Battery Voltage" is varying, "Short Wave Highest Value Level" may decrease even though the insulation resistance is normal.

    • SMRP Status

    • SMRB Status

    • SMRG Status

    When "SMRP Status", "SMRB Status" and "SMRG Status" are all OFF, the insulation malfunction detection circuit detects a decrease in insulation resistance in the HV battery area ((*d) in the wiring diagram).


      Example:

    • When the power switch is turned on (IG) (not on (READY)), all 3 system main relays are off and it is suspected that the HV battery assembly is disconnected from the high voltage circuits. If "Short Wave Highest Value Level" decreases a few minutes after the power switch is turned on (IG) (not on (READY)), the HV battery assembly may have an insulation malfunction.
    Motor Inverter Shutdown Status

    When "Motor Inverter Shutdown Status" is ON, the insulation malfunction detection circuit cannot detect a decrease in insulation resistance in the motor system AC (alternating current) section (motor (MG2) side of (*e) in the wiring diagram).

    The motor system AC (alternating current) section includes the motor (MG2) in the hybrid vehicle transaxle assembly, motor cables and the AC (alternating current) section of the motor drive circuit in the inverter with converter assembly.
    Generator Inverter Shutdown Status

    When "Generator Inverter Shutdown Status" is ON, the insulation malfunction detection circuit cannot detect a decrease in insulation resistance in the generator system AC (alternating current) section (generator (MG1) side of (*e) in the wiring diagram).

    The generator system AC (alternating current) section includes the generator (MG1) in the hybrid vehicle transaxle assembly, generator cables and the AC (alternating current) section of the generator drive circuit in the inverter with converter assembly.
    A/C Consumption Power

    The compressor with motor assembly AC (alternating current) section ((*c) in the wiring diagram) includes the air conditioning motor, wiring between the air conditioning motor and air conditioning inverter, and the AC (alternating current) section of the air conditioning motor drive circuit in the air conditioning inverter.

    With the vehicle stopped, turn on/off the air conditioning system and observe "Short Wave Highest Value Level" to use as a diagnosis reference.

    RELATED FREEZE FRAME DATA

    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 Speed -
      Accelerator Position Sensor No.1 Voltage % -
      Engine Speed -
      Shift Position -
      Master Cylinder Control Torque -
      Coolant Temperature -
      Operation Conditions
      Item Diagnostic Note
      Motor Temperature

      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.
      Generator Temperature

      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)).

    • Customer Problem Analysis

      Ask the customer about the operating conditions and environment when the malfunction occurred.

      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?)

CAUTION / NOTICE / HINT

CAUTION:


  • When troubleshooting DTC P0AA649, 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.

  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

  • 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

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

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.


      Powertrain > Hybrid Control > Trouble Codes

    4. Check for DTCs.

      Result
      Result Proceed to
      P0AA649, P1C7C49, P1C7D49, P1C7E49 or P1C7F49 only is output, or DTCs except the ones in the table below are also output. A
      Any of the following DTCs are also output. B
      Malfunction Content Relevant DTC
      Microcomputer malfunction P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
      P060687 Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message
      P060A29 Hybrid/EV Powertrain Control Module Monitoring Processor Signal Invalid
      P060A44 Hybrid/EV Powertrain Control Module Monitoring Processor Data Memory Failure
      P060A45 Hybrid/EV Powertrain Control Module Monitoring Processor Program Memory Failure
      P060A47 Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure
      P060A49 Hybrid/EV Powertrain Control Module Monitoring Processor Internal Electronic Failure
      P060A87 Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message
      P060B1C Hybrid/EV Powertrain Control Module A/D Processing Voltage Out of Range
      P060B49 Hybrid/EV Powertrain Control Module A/D Processing Internal Electronic Failure
      P060B71 Hybrid/EV Powertrain Control Module A/D Processing Actuator Stuck
      P1CE31C Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Voltage Out of Range
      P1CE349 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Internal Electronic Failure
      P1CE371 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Actuator Stuck
      P0AFC96 Hybrid/EV Battery Sensor Module Component Internal Failure
      P0AFC00 Hybrid/EV Battery Sensor Module
      P0AFC49 Hybrid/EV Battery Sensor Module Internal Electronic Failure
      P0AFC62 Hybrid/EV Battery Sensor Module Signal Compare Failure
      Power Source Circuit Malfunction P06881F ECM/PCM Power Relay Sense Circuit Intermittent
      P0AFC16 Hybrid/EV Battery Sensor Module Circuit Voltage Below Threshold
      System malfunction P1C9E9F Hybrid/EV System Reset Stuck Off

      Tech Tips


      • P0AA649 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. 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.


      Powertrain > Hybrid Control > Trouble Codes

    4. Check for DTCs.

      Note


      • DTC P1C7C49, P1C7D49, P1C7E49 and P1C7F49 are not stored with P0AA649 at the same time. If a drop in insulation resistance is detected and DTC P0AA649 is output, wait for 1 minute with the power switch on (READY), the shift lever in D and the air conditioning system on within the same trip, then turn the power switch off and wait for 2 minutes to determine the DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49).

      • If only DTC P0AA649 is output, perform the diagnostic procedure for DTC P0AA649 to inspect all of the high voltage circuits.

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

      Result
      Result Proceed to
      Only P0AA649 is output A
      P0AA649 and P1C7C49 are output B
      P0AA649 and P1C7D49 are output C
      P0AA649 and P1C7E49 are output D
      P0AA649 and P1C7F49 are output E
      Other than above F

    5. Turn the power switch off.


    B

    CHECK CAN COMMUNICATION SYSTEM Click here

    C

    CHECK FREEZE FRAME DATA Click here

    D

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    E

    CHECK HIGH VOLTAGE DIRECT CURRENT AREA Click here

    F

    CLEAR DTC Click here

    A

  3. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG2))

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. B004PVB

      Disconnect the motor cable from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

    3. 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.

    4. 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.

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

    6. B004PFLC04
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (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
      h2-2 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      h2-3 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      h2-1 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

    7. Lower the vehicle and push the P position switch (transmission shift main switch).

    8. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK MOTOR CABLE (FOR MG2) Click here

    OK

  4. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG1))

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. 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. B004PFLC05
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (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
      h2-5 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      h2-6 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      h2-4 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

    6. Lower the vehicle and push the P position switch (transmission shift main switch).

    7. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK MOTOR CABLE (FOR MG1) Click here

    OK

  5. CHECK AIR CONDITIONING 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. B004QU6

      Disconnect the air conditioning wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the air conditioning wire.

    3. B004PN7C04
      *1 Shield Ground
      *a

      Air conditioning wire

      (Inverter with Converter Assembly Side)
      *b Tip of 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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T2-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      T2-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 44 Click here

    OK

  6. CHECK HV FLOOR UNDER 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. B004OLV

      Disconnect the HV floor under wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B004QCBC04
      *1 Shield Ground
      *a

      HV Floor Under 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.

      • Be sure not to damage or deform the terminal being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the HV floor under 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 42 Click here

    OK

  7. 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. B004OLV

      Connect the HV floor under wire connector to the inverter with converter assembly.

    3. B004PCCC02
      *a 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 and air conditioning wire disconnected from the inverter with converter assembly.

      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 22 Click here

    NG

    GO TO STEP 40 Click here

  8. CHECK CAN COMMUNICATION SYSTEM


    1. Using the GTS, check if the CAN communication system is functioning normally.

      Tech Tips

      Click here

      Result
      Result Proceed to
      CAN communication system DTCs are not output A
      CAN communication system DTCs are output B

    B

    GO TO CAN COMMUNICATION SYSTEM Click here

    A

  9. INSPECT COMPRESSOR WITH MOTOR ASSEMBLY

    CAUTION:

    Because the compressor with motor assembly has a high-voltage circuit, put on insulated gloves and remove the service plug grip to cut off the high-voltage circuit before inspecting the compressor with motor assembly.


    1. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    2. Turn the power switch on (READY).

    3. Prepare the vehicle according to the table below for 3 minutes.

      Item Condition
      Blower speed HI
      Temperature setting MAX COLD
      A/C switch On

    4. Turn the power switch off.

    5. Remove the service plug grip.

      Tech Tips

      Click here

      CAUTION:

      Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed.

      Note

      After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) with the service plug grip removed.

    6. B004OWGC01
      *a

      Component without harness connected

      (Compressor with Motor Assembly)

      Disconnect the compressor with motor assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (PE) - Body ground Always 2 MΩ or higher
      T1-2 (PB) - Body ground Always 2 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

    OK

  10. CONFIRM MODEL


    1. Choose the model to be inspected.

      Result
      Result Proceed to
      for HFC-134a (R134a) A
      for HFO-1234yf (R1234yf) B

    B

    INSPECT REFRIGERANT CYCLE Click here

    A

  11. INSPECT REFRIGERANT CYCLE

    CAUTION:

    Because the compressor with motor assembly has a high-voltage circuit, put on insulated gloves and remove the service plug grip to cut off the high-voltage circuit before inspecting the compressor with motor assembly.


    1. Connect the compressor with motor assembly connector.

    2. Install the service plug grip.

      Tech Tips

      Click here

    3. Turn the power switch on (READY).

    4. Set the A/C temperature to 25°C (77°F) and blower switch to LO and operate the compressor with motor assembly for 10 minutes to circulate the refrigerant and collect as much compressor oil as possible in the compressor with motor assembly.

    5. Turn the power switch off.

    6. Using a spot cooler or other tool, cool down the compressor with motor assembly for 30 minutes, or leave the vehicle overnight before inspection.

      Note

      Do not operate the compressor before inspection.

    7. Remove the service plug grip.

      CAUTION:

      Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed.

      Note

      After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) with the service plug grip removed.

      Tech Tips

      Click here

    8. B004OWGC01
      *a

      Component without harness connected

      (Compressor with Motor Assembly)

      Disconnect the compressor with motor assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (PE) - Body ground Always 3 MΩ or higher
      T1-2 (PB) - Body ground Always 3 MΩ or higher

      Note

      If the result is not as specified, replace the compressor without operating it.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE Click here

    OK

  12. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  13. CHECK MOTOR CABLE (FOR MG2)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the motor cable from the hybrid vehicle transaxle assembly.

      Tech Tips

      Click here

    3. B004PFLC04
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (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
      h2-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 34 Click here

    NG

    GO TO STEP 36 Click here

  14. CHECK MOTOR CABLE (FOR MG1)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the motor cable from the hybrid vehicle transaxle assembly.

      Tech Tips

      Click here

    3. B004PFLC05
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (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
      h2-5 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-6 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-4 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 34 Click here

    NG

    GO TO STEP 37 Click here

  15. CHECK FREEZE FRAME DATA


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Read the freeze frame data of DTC P0AA649.


      Powertrain > Hybrid Control > DTC(P0AA649) > Freeze Frame Data
      Tester Display
      Short Wave Highest Value Level
      Result
      Result Proceed to
      The value of Short Wave Highest Value Level is Not Judge A
      Other than above B

    4. Turn the power switch off.


    B

    CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    A

  16. CLEAR DTC

    Tech Tips

    Perform the DTC clear procedure 2 times.


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    4. Turn the power switch off.

    5. Turn the power switch on (IG).

    6. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    7. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

    CONDUCT CONFIRMATION TEST Click here

  17. GO TO CAN COMMUNICATION SYSTEM

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  18. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  19. INSPECT REFRIGERANT CYCLE

    CAUTION:

    Because the compressor with motor assembly has a high-voltage circuit, put on insulated gloves and remove the service plug grip to cut off the high-voltage circuit before inspecting the compressor with motor assembly.


    1. Connect the compressor with motor assembly connector.

    2. Install the service plug grip.

      Tech Tips

      Click here

    3. Turn the power switch on (READY).

    4. Set the A/C temperature to 25°C (77°F) and blower switch to LO and operate the compressor with motor assembly for 10 minutes to circulate the refrigerant and collect as much compressor oil as possible in the compressor with motor assembly.

    5. Turn the power switch off.

    6. Using a spot cooler or other tool, cool down the compressor with motor assembly for 30 minutes, or leave the vehicle overnight before inspection.

      Note

      Do not operate the compressor before inspection.

    7. Remove the service plug grip.

      CAUTION:

      Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed.

      Note

      After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) with the service plug grip removed.

      Tech Tips

      Click here

    8. B004OWGC01
      *a

      Component without harness connected

      (Compressor with Motor Assembly)

      Disconnect the compressor with motor assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (PE) - Body ground Always 3 MΩ or higher
      T1-2 (PB) - Body ground Always 3 MΩ or higher

      Note

      If the result is not as specified, replace the compressor without operating it.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE Click here

    OK

  20. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  21. REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  22. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.

    Tech Tips

    Make sure that no foreign matter or water has entered the HV battery.


    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 HV battery cover panel RH.

      Tech Tips

      Click here

    3. B004Q4V

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

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    4. B004QK6C06
      *a

      Component without harness connected

      (HV Battery Junction Block 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 Condition Specified Condition
      A-1 (+) - Body ground Power switch off 10 MΩ or higher
      z12-1 (-) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 43 Click here

    OK

  23. CHECK HV BATTERY (HIGH VOLTAGE 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. B004PNVC02
      *a

      Service Plug Grip Removed

      (Service Plug Grip Connecting Terminals)

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

    NG

    GO TO STEP 35 Click here

    OK

  24. 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. B004PNVC02
      *a

      Service Plug Grip Removed

      (Service Plug Grip Connecting Terminals)

      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
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 30 Click here

    NG

    CHECK HV BATTERY (HIGH VOLTAGE CABLE) Click here

  25. REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  26. CHECK HV BATTERY (HIGH VOLTAGE CABLE)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 HV battery shield panel.

      Tech Tips

      Click here

    3. B004OR5

      Remove the bolt from the hybrid battery terminal block.

    4. B004Q30

      Disconnect the high voltage connector.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    5. B004P1DC04
      *a

      High Voltage Cable

      (Hybrid Battery Terminal Block 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
      z21-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 35 Click here

    OK

  27. CHECK HV BATTERY (HIGH VOLTAGE CABLE)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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. B004QER

      Disconnect the high voltage connector.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    3. B004PFZC04
      *a

      High Voltage Cable

      (Hybrid Battery Terminal Block 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
      z20-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    CHECK HV BATTERY (HIGH VOLTAGE CABLE) Click here

    OK

  28. REPLACE HYBRID BATTERY TERMINAL BLOCK

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  29. CHECK HV BATTERY (HIGH VOLTAGE CABLE)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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. B004OYY

      Disconnect the z8 battery voltage sensor connector.

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    3. B004PFZC05
      *a

      High Voltage Cable

      (Hybrid Battery Terminal Block 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
      z20-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY Click here

    OK

  30. REPLACE BATTERY VOLTAGE SENSOR

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  31. 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. B004PVB

      Disconnect the motor cable from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

    3. B004QQMC01
      *a 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 disconnected from the inverter with converter assembly.

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 40 Click here

    OK

  32. CHECK MOTOR CABLE (FOR MG2)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the motor cable from the hybrid vehicle transaxle assembly.

      Tech Tips

      Click here

    3. B004PFLC04
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (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
      h2-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MOTOR CABLE Click here

    OK

  33. CHECK MOTOR CABLE (FOR MG1)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the motor cable from the hybrid vehicle transaxle assembly.

      Tech Tips

      Click here

    3. B004PFLC05
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (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
      h2-5 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-6 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      h2-4 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MOTOR CABLE Click here

    OK

  34. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  35. REPLACE HV BATTERY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  36. REPLACE MOTOR CABLE

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  37. REPLACE MOTOR CABLE

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  38. 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. B004QIR

      Disconnect the HV floor under wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B004QCBC04
      *1 Shield Ground
      *a

      HV Floor Under 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.

      • Be sure not to damage or deform the terminal being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the HV floor under 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 HV FLOOR UNDER WIRE Click here

    OK

  39. CHECK AIR CONDITIONING 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. B004QU6

      Disconnect the air conditioning wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the air conditioning wire.

    3. B004PN7C04
      *1 Shield Ground
      *a

      Air conditioning wire

      (Inverter with Converter Assembly Side)
      *b Tip of 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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T2-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      T2-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    CHECK AIR CONDITIONING WIRE Click here

    OK

  40. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  41. CLEAR DTC


    1. Turn the power switch off.

    2. Connect the GTS to the DLC3.

    3. Turn the power switch on (IG).

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

    5. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    6. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

    CONDUCT CONFIRMATION TEST Click here

  42. CHECK HV FLOOR UNDER 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. 1 HV battery cover panel RH.

      Tech Tips

      Click here

    3. B004QYD

      Disconnect the HV floor under wire connectors from the HV battery junction block assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    4. B004QCBC04
      *1 Shield Ground
      *a

      HV Floor Under 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.

      • Be sure not to damage or deform the terminal being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - Body ground Power switch off 10 MΩ or higher
      S1-2 (CEI) - Body ground Power switch off 10 MΩ or higher

      Tech Tips

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

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV FLOOR UNDER WIRE Click here

    OK

  43. REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  44. CHECK AIR CONDITIONING 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. B004PH5

      Disconnect the air conditioning wire from the compressor with motor assembly.

      Tech Tips

      Click here

    3. B004PN7C04
      *1 Shield Ground
      *a

      Air conditioning wire

      (Inverter with Converter Assembly Side)
      *b Tip of 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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T2-1 (ACPB) - Body ground and shield ground Power switch off 10 MΩ or higher
      T2-2 (ACPE) - Body ground and shield ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE AIR CONDITIONING WIRE Click here

    OK

  45. CHECK CAN COMMUNICATION SYSTEM


    1. Using the GTS, check if the CAN communication system is functioning normally.

      Tech Tips

      Click here

      Result
      Result Proceed to
      CAN communication system DTCs are not output A
      CAN communication system DTCs are output B

    B

    GO TO CAN COMMUNICATION SYSTEM Click here

    A

  46. INSPECT COMPRESSOR WITH MOTOR ASSEMBLY

    CAUTION:

    Because the compressor with motor assembly has a high-voltage circuit, put on insulated gloves and remove the service plug grip to cut off the high-voltage circuit before inspecting the compressor with motor assembly.


    1. Clear the DTCs.


      Powertrain > Hybrid Control > Clear DTCs

    2. Turn the power switch on (READY).

    3. Prepare the vehicle according to the table below for 3 minutes.

      Item Condition
      Blower speed HI
      Temperature setting MAX COLD
      A/C switch On

    4. Turn the power switch off.

    5. Remove the service plug grip.

      Tech Tips

      Click here

      CAUTION:

      Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed.

      Note

      After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) with the service plug grip removed.

    6. B004OWGC01
      *a

      Component without harness connected

      (Compressor with Motor Assembly)

      Disconnect the compressor with motor assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (PE) - Body ground Always 2 MΩ or higher
      T1-2 (PB) - Body ground Always 2 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

    OK

  47. CONFIRM MODEL


    1. Choose the model to be inspected.

      Result
      Result Proceed to
      for HFC-134a (R134a) A
      for HFO-1234yf (R1234yf) B

    B

    INSPECT REFRIGERANT CYCLE Click here

    A

  48. INSPECT REFRIGERANT CYCLE

    CAUTION:

    Because the compressor with motor assembly has a high-voltage circuit, put on insulated gloves and remove the service plug grip to cut off the high-voltage circuit before inspecting the compressor with motor assembly.


    1. Connect the compressor with motor assembly connector.

    2. Install the service plug grip.

      Tech Tips

      Click here

    3. Turn the power switch on (READY).

    4. Set the A/C temperature to 25°C (77°F) and blower switch to LO and operate the compressor with motor assembly for 10 minutes to circulate the refrigerant and collect as much compressor oil as possible in the compressor with motor assembly.

    5. Turn the power switch off.

    6. Using a spot cooler or other tool, cool down the compressor with motor assembly for 30 minutes, or leave the vehicle overnight before inspection.

      Note

      Do not operate the compressor before inspection.

    7. Remove the service plug grip.

      CAUTION:

      Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed.

      Note

      After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) with the service plug grip removed.

      Tech Tips

      Click here

    8. B004OWGC01
      *a

      Component without harness connected

      (Compressor with Motor Assembly)

      Disconnect the compressor with motor assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (PE) - Body ground Always 3 MΩ or higher
      T1-2 (PB) - Body ground Always 3 MΩ or higher

      Note

      If the result is not as specified, replace the compressor without operating it.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE Click here

    OK

  49. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  50. REPLACE HV FLOOR UNDER WIRE

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  51. REPLACE AIR CONDITIONING WIRE

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  52. GO TO CAN COMMUNICATION SYSTEM

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  53. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  54. INSPECT REFRIGERANT CYCLE

    CAUTION:

    Because the compressor with motor assembly has a high-voltage circuit, put on insulated gloves and remove the service plug grip to cut off the high-voltage circuit before inspecting the compressor with motor assembly.


    1. Connect the compressor with motor assembly connector.

    2. Install the service plug grip.

      Tech Tips

      Click here

    3. Turn the power switch on (READY).

    4. Set the A/C temperature to 25°C (77°F) and blower switch to LO and operate the compressor with motor assembly for 10 minutes to circulate the refrigerant and collect as much compressor oil as possible in the compressor with motor assembly.

    5. Turn the power switch off.

    6. Using a spot cooler or other tool, cool down the compressor with motor assembly for 30 minutes, or leave the vehicle overnight before inspection.

      Note

      Do not operate the compressor before inspection.

    7. Remove the service plug grip.

      CAUTION:

      Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed.

      Note

      After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) with the service plug grip removed.

      Tech Tips

      Click here

    8. B004OWGC01
      *a

      Component without harness connected

      (Compressor with Motor Assembly)

      Disconnect the compressor with motor assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T1-1 (PE) - Body ground Always 3 MΩ or higher
      T1-2 (PB) - Body ground Always 3 MΩ or higher

      Note

      If the result is not as specified, replace the compressor without operating it.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE Click here

    OK

  55. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  56. REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  57. REPLACE MAIN COMPONENTS OF REFRIGERANT CYCLE

    Tech Tips

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here