HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA6-526, P0AA6-611, P0AA6-612, P0AA6-613, P0AA6-614, P0AA6-655

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
P0AA6-655 Hybrid Battery Voltage System Isolation Fault

DESCRIPTION

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

DTC No. INF Code DTC Detection Condition Trouble Area
P0AA6 526(*1) Insulation resistance between the high-voltage circuit and the body has decreased.

  • Hybrid vehicle transaxle assembly

  • Inverter with converter assembly

  • No. 3 wire frame

  • No. 4 engine wire

  • Hybrid battery junction block assembly

  • Compressor with motor assembly

  • HV battery

  • Battery smart unit

  • Power steering converter assembly

  • Electric vehicle battery plug assembly

  • No. 2 HV battery pack cable
P0AA6 611 Insulation resistance of the with motor compressor assembly has decreased. Compressor with motor assembly
P0AA6 612 Insulation resistance of the HV battery area has decreased.

  • Hybrid battery junction block assembly

  • Battery smart unit

  • HV battery

  • Electric vehicle battery plug assembly

  • No. 2 HV battery pack cable
P0AA6 613 Insulation resistance of the transaxle area has decreased.

  • Hybrid vehicle transaxle assembly

  • Inverter with converter assembly
P0AA6 614 Insulation resistance of the high-voltage DC area has decreased.

  • Inverter with converter assembly

  • No. 3 wire frame

  • Compressor with motor assembly

  • No. 4 engine wire

  • Hybrid battery junction block assembly

  • Power steering converter assembly

  • Hybrid vehicle transaxle assembly
P0AA6 655 Insulation resistance of the rear traction motor with transaxle area has decreased.

  • Rear traction motor with transaxle assembly

  • Inverter with converter assembly

  • No. 3 wire frame

  • Extension wire assembly

Tech Tips


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

  • If DTC P0AA6 is stored, the vehicle cannot start.

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

WIRING DIAGRAM

A01NF04E01

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 while considering the following.


      • Do not check until approximately 1 minute has passed after the power switch is turned on (IG) (*1).

      • Do not check when there is a difference between the system voltages (HV battery voltage, VL-Voltage before boosting, and VH-Voltage after boosting) (*2).

        Short Wave Highest Value Trouble Area
        Neither condition (*1) nor (*2) is 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.
        Neither condition (*1) nor (*2) is met and Short Wave Highest Val is between 0 and 5 V Since the insulation resistance is several hundred kiloohms, 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. Repeat rotating and stopping of the MG1, MG2, MGR and compressor with motor. 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, MG2 and MGR. Check if the Short Wave Highest Val decreases with the temperature increase.

INSPECTION PROCEDURE

CAUTION:


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

  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

Tech Tips


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

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

PROCEDURE


  1. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0AA6 only is output. A
      P0AA6 and P0A1D (power management control ECU malfunction) are output. B
      P0AA6 and P0AA7 (malfunction in the battery smart unit) are output. C
      P0AA6 and P0A1F (battery ECU malfunction) are output. D

    5. Turn the power switch off.


    B

    GO TO DTC CHART (P0A1D) Click here

    C

    GO TO DTC CHART (P0AA7) Click here

    D

    GO TO DTC CHART (P0AFC) Click here

    A

  2. CHECK INFORMATION CODE


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

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

      Note

      INF codes 611, 612, 613, 614 and 655 are not stored at the same time with INF code 526. If INF code 526 only is output, turn the power switch off and wait 30 seconds to determine the malfunctioning area. Then, turn the power switch on (IG) and read the INF code again.

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

      Refer to the troubleshooting procedures for P0AA6-611 (Heater and 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
      526 and 655 (decrease in the insulation resistance of the rear area) are output E

    B

    CHECK HV BATTERY AREA Click here

    C

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    D

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE) Click here

    E

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    A

  3. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (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. A01NEKJ

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

      Tech Tips

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

    4. A01NFD5E01

      Disconnect the motor cable z38 and generator cable z36 from the inverter with converter assembly.

    5. A01NEK6E02
      Text in Illustration
      *1 Motor Cable
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      z38-3 (U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z38-2 (V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z38-1 (W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 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. A01ND30E04
      Text in Illustration
      *1 Generator Cable
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      z36-3 (U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z36-2 (V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z36-1 (W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    OK

  5. CHECK NO. 4 ENGINE WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01NG2HE01

      Disconnect the No. 4 engine wire (air conditioning harness) e2 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the connector of the air conditioning harness assembly e2.

    3. A01NFOVE01
      Text in Illustration
      *1

      No. 4 Engine Wire

      (Air Conditioning Harness)
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      e2-1 (ACPB) - Body ground and shielded wire ground Power switch off 3 MΩ or higher
      e2-2 (ACPE) - Body ground and shielded wire ground Power switch off 3 MΩ or higher

    NG

    CHECK NO. 4 ENGINE WIRE Click here

    OK

  6. CHECK REAR TRACTION MOTOR WITH TRANSAXLE 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. A01NGMHE01

      Disconnect the No. 3 wire frame (three-phase AC cable for MGR) g4 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the connector of the No. 3 wire frame g4.

    3. A01NCLKE04
      Text in Illustration
      *1 Rear Traction Motor Cable
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g4-3 (R-U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      g4-2 (R-V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      g4-1 (R-W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY 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. A01NFVXE01

      Disconnect the No. 3 wire frame g1 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the connector of the No. 3 wire frame g1.

    3. A01NE6X

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      High voltage terminal - Body ground Power switch off 1 MΩ or higher

      Tech Tips

      Perform this inspection with the motor cable, generator cable, rear traction motor cable and air conditioning harness assembly disconnected from the inverter with converter assembly.


    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    OK

  8. CHECK NO. 3 WIRE FRAME

    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. A01NHTJE01
      Text in Illustration
      *1 No. 3 Wire Frame

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g1-1 (CEI) - Body ground Power switch off 10 MΩ or higher
      g1-2 (CBI) - Body ground Power switch off 10 MΩ or higher

    NG

    CHECK NO. 3 WIRE FRAME Click here

    OK

  9. CHECK HV BATTERY AREA

    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. A01NHY6E01

      Disconnect connector z25 from the battery smart unit

      Tech Tips

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

    4. A01NDZ8E01

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      1 - Body ground Power switch off 10 MΩ or higher
      2 - Body ground Power switch off 10 MΩ or higher

    NG

    CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

    REPLACE BATTERY SMART UNIT Click here

  10. CHECK INVERTER WITH CONVERTER ASSEMBLY

    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. A01NEKJ

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

      Tech Tips

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

    4. A01NFD5E01

      Disconnect the motor cable z38 and generator cable z36 from the inverter with converter assembly.

    5. A01NH4H

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      High voltage terminal - Body ground Power switch off 1 MΩ or higher

    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  11. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (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. A01NEKJ

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

      Tech Tips

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

    4. A01NFD5E01

      Disconnect the motor cable z38 and generator cable z36 from the inverter with converter assembly.

    5. A01NEK6E02
      Text in Illustration
      *1 Motor Cable
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      z38-3 (U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z38-2 (V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z38-1 (W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    OK

  12. 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. A01ND30E04
      Text in Illustration
      *1 Generator Cable
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      z36-3 (U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z36-2 (V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      z36-1 (W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    OK

  13. CHECK REAR TRACTION MOTOR WITH TRANSAXLE 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. A01NG13E01

      Disconnect the No. 3 wire frame (three-phase AC cable for MGR) g4 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the connector of the No. 3 wire frame g4.

    3. A01NCLKE04
      Text in Illustration
      *1 Rear Traction Motor Cable
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g4-3 (R-U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      g4-2 (R-V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      g4-1 (R-W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY Click here

    OK

  14. CHECK HIGH VOLTAGE DIRECT CURRENT AREA

    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. A01NGMGE01

      Disconnect the No. 3 wire frame g1 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the connector of the No. 3 wire frame g1.

    4. A01NHTJE01
      Text in Illustration
      *1 No. 3 Wire Frame

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g1-1 (CEI) - Body ground Power switch off 10 MΩ or higher
      g1-2 (CBI) - Body ground Power switch off 10 MΩ or higher

    NG

    CHECK NO. 3 WIRE FRAME Click here

    OK

  15. CHECK NO. 4 ENGINE WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01NHMOE01

      Disconnect the No. 4 engine wire (air conditioning harness) e2 from the inverter with converter assembly.

    3. A01NFOVE01
      Text in Illustration
      *1

      No. 4 Engine Wire

      (Air Conditioning Harness)
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      e2-1 (ACPB) - Body ground and shielded wire ground Power switch off 3 MΩ or higher
      e2-2 (ACPE) - Body ground and shielded wire ground Power switch off 3 MΩ or higher

    NG

    CHECK NO. 4 ENGINE WIRE Click here

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  16. CHECK NO. 4 ENGINE WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01NDU9E02
      Text in Illustration
      *1 Green Lock

      Disconnect the No. 4 engine wire (air conditioning harness) e1 from the compressor with motor assembly.

    3. A01NFOVE01
      Text in Illustration
      *1

      No. 4 Engine Wire

      (Air Conditioning Harness)
      *2 Shielded Wire Ground

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      e2-1 (ACPB) - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      e2-2 (ACPE) - Body ground and shielded wire ground Power switch off 10 MΩ or higher

    NG

    REPLACE NO. 4 ENGINE WIRE

    OK

    AIR CONDITIONING SYSTEM (P0AA6-611) Click here

  17. CHECK NO. 3 WIRE FRAME

    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. A01NFUIE01

      Disconnect the No. 3 wire frame g2 and g3 from the hybrid battery junction block assembly.

      Tech Tips

      For the removal and installation procedures related to the No. 3 wire frame, Click here.

    3. A01NGB0E01

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g2-1 (CBI) - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      g3-1 (CEI) - Body ground and shielded wire ground Power switch off 10 MΩ or higher

    NG

    REPLACE NO. 3 WIRE FRAME Click here

    OK

  18. CHECK POWER STEERING 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. Disconnect the connector of the No. 3 wire frame (high voltage wire of the power steering converter) g6 from the hybrid battery junction block assembly.

    3. A01NGDFE01

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g6-1 (CBPE) - Body ground Power switch off 30 MΩ or higher
      g6-4 (CEPE) - Body ground Power switch off 30 MΩ or higher

    NG

    CHECK NO. 3 WIRE FRAME (HYBRID BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER) Click here

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

  19. CHECK NO. 3 WIRE FRAME (HYBRID BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER)

    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 connector of the No. 3 wire frame g7 from the power steering converter assembly.

    3. A01NDJ1E01

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g7-1 (CBP) - Body ground Power switch off 10 MΩ or higher
      g7-5 (CEP) - Body ground Power switch off 10 MΩ or higher

    NG

    REPLACE NO. 3 WIRE FRAME Click here

    OK

    REPLACE POWER STEERING CONVERTER ASSEMBLY Click here

  20. 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. A01NEKJ

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

    3. A01NEMYE02

      Disconnect the No. 3 wire frame (three-phase AC cable for MGR) g4 from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign objects have entered or contaminated the connector of the No. 3 wire frame.

    4. A01NDIH

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      High voltage terminal - Body ground Power switch off 1 MΩ or higher

    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    OK

  21. CHECK REAR TRACTION MOTOR WITH TRANSAXLE 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. A01NE5VE01

      Disconnect the No. 3 wire frame (three-phase AC cable for MGR) g5 from the rear traction motor with transaxle assembly.

    3. A01NCLKE04
      Text in Illustration
      *1 Rear Traction Motor Cable
      *2 Shielded Wire Ground

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

      Note


      • Wrap terminals R-U, R-V, and R-W of the No. 3 frame wire (three-phase AC cable for MGR) on the inverter with converter assembly side with insulating tape to prevent them from shorting to ground.

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g4-3 (R-U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      g4-2 (R-V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      g4-1 (R-W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

    REPLACE NO. 3 WIRE FRAME Click here

    OK

  22. CHECK EXTENSION WIRE 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. Remove the rear traction motor with transaxle assembly Click here.

    3. Remove the extension wire assembly from the rear traction motor with transaxle assembly Click here.

    4. A01NFEFE03
      Text in Illustration
      *1 Extension Wire Assembly
      *2 Shielded Shell

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      R-U - shielded shell Power switch off 100 MΩ or higher
      R-V - shielded shell Power switch off 100 MΩ or higher
      R-W - shielded shell Power switch off 100 MΩ or higher

    NG

    REPLACE EXTENSION WIRE ASSEMBLY Click here

    OK

    REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY Click here

  23. CHECK HYBRID BATTERY JUNCTION BLOCK 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. A01NEYKE02

      Disconnect the high voltage cable connector of the HV battery z19 and z22 from the hybrid battery junction block assembly.

    3. A01NDBWE02

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      z22-1 - Hybrid Battery Carrier Panel Power switch off 10 MΩ or higher
      z19-1 - Hybrid Battery Carrier Panel Power switch off 10 MΩ or higher

    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  24. CHECK NO. 2 HV BATTERY PACK 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. Remove the No. 2 HV battery cable Click here.

    3. Visually check that there is no scratched or peeling insulation on the No. 2 main battery cable.

      OK
      There are no insulation defects (scratched or peeling insulation).

    NG

    REPLACE NO. 2 HV BATTERY PACK CABLE Click here

    OK

  25. CHECK ELECTRIC VEHICLE BATTERY PLUG 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. Remove the electric vehicle battery plug assembly Click here.

    3. Visually check that there is no scratched or peeling insulation on the electric vehicle battery plug assembly.

      OK
      There are no insulation defects (scratched or peeling insulation).

    NG

    REPLACE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY Click here

    OK

    REPLACE HV BATTERY Click here