HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A08-264

DTC Code DTC Name
P0A08-264 DC / DC Converter Status Circuit

DESCRIPTION

The DC/DC converter converts the DC 144 V of the HV battery into DC 12 V in order to supply power to areas such as the vehicle's lighting, audio, and ECU systems. In addition, it charges the auxiliary battery. A transistor bridge circuit initially converts DC 144 V into alternating current, and a transformer lowers its voltage. Then, it is rectified and smoothed (into DC) and converted into DC 12 V. The DC/DC converter controls the output voltage in order to keep a constant voltage at the terminals of the auxiliary battery.

The power management control ECU uses the NODD signal line to transmit a stop command to the DC/DC converter and receive signals indicating the normal or abnormal condition of the 12 V charging system. If the vehicle is being driven with an inoperative DC/DC converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the power management control ECU monitors the operation of the DC/DC converter and alerts the driver if it detects a malfunction.

A01UYWWE05
DTC No. INF Code DTC Detection Condition Trouble Area
P0A08 264 DC/DC converter malfunction

  • Wire harness or connector

  • Inverter water pump assembly

  • Inverter cooling system

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Inverter with converter assembly

  • Fuse (IGCT-MAIN, IGCT NO. 4)

  • Fusible link (DC/DC)

  • Power management control ECU

WIRING DIAGRAM

A01UXXWE02

Refer to the wiring diagram for DTC P0AA6-526 Click here.

CAUTION / NOTICE / HINT

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, turn the ignition switch off and 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.

Note

After turning the ignition 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


  • After repair, clear the DTCs, turn the ignition switch off and wait for 30 seconds or more and perform the following procedure to confirm that the auxiliary battery low voltage indicated by this DTC has been repaired.


    1. Wait for 2 minutes with the shift lever in P, the ignition switch to ON (READY) and the following conditions met, then confirm that Data List item "+B" is between 13.0 and 15.0 V.

      (If charging is not performed and the electrical load increases, +B voltage may not be steady and gradually drops.)


      1. Headlight switch is in the HI position.

      2. A/C blower fan switch is in the HI position.

      3. Window defogger switch is turned on.


    • If the DC/DC converter has an internal malfunction, DTC P0A08-264 is stored regardless of the auxiliary battery voltage after performing this procedure.

    • If the auxiliary battery voltage drops, the ignition switch turns off regardless of DTCs being stored or not.

  • By performing the following procedure, the DC/DC converter function can be checked.


    1. Connect the AC/DC 400 A probe to the positive auxiliary battery cable.


      1. Turn the ignition switch to ON (READY) and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.

      2. Turn the ignition switch to ON (READY) and the headlight switch and A/C blower fan switch in the HI position, and the window defogger turned on.

      3. Confirm that the current drawn from the auxiliary battery is 0 A or lower and the auxiliary battery voltage is between 13.0 and 15.0 V.

  • This DTC is stored when the DC/DC converter is malfunctioning (charging has stopped) or when the ignition switch to ON (READY) and the auxiliary battery voltage is 11 V or less. Therefore, this DTC may be also stored when a part other than the DC/DC converter is malfunctioning or depending on user operation.

    Malfunction cases to store DTC P0A08-264
    Malfunction Case Remarks Inspection Step
    Fuse is blown. (IGCT-MAIN, IGCT NO. 4, DC/DC) - 2, 3, 6
    High-voltage insulation between the inverter, generator (MG1), motor (MG2) and body ground is poor (body ground). DTC P0AA6 may be stored if the ground potential fluctuates due to a high-voltage insulation malfunction. 1
    A signal connector of the power management control ECU or inverter is not connected securely. - 4, 5
    The DC/DC converter is malfunctioning. Inspect the DC/DC converter function. 12
    Control is suspended due to overheating. (The inverter water pump assembly is malfunctioning, the coolant is not sufficient, a hose is clogged, etc.)

    When the inverter is overheating, the DC/DC converter has self protection control that suspends the DC/DC converter control. As that time, this DTC may be stored.

    The suspended DC/DC converter control will return to normal by clearing the DTCs and turning the ignition switch off.

    		 13 to 16, 20

  • If this vehicle is used to jump start another vehicle with a discharged battery, a fuse may blow due to overcurrent or the DC/DC converter self-protection may be activated.

    Also, if this vehicle is jump started by a vehicle with a 24 V battery, the same malfunction may occur and this DTC may be stored. (The suspended DC/DC converter control will return to normal by clearing the DTCs and turning the ignition switch off.)

  • Confirm that high electrical load equipment such as a high-capacitance audio device or electric kettle is used on the vehicle. (A fuse of the auxiliary battery may be blown due to overcurrent.)

  • If the DC/DC converter is malfunctioning, the auxiliary battery cannot be charged. Therefore, once the ignition switch is turned off, it may be impossible to turn it on (READY) again if the auxiliary battery is completely discharged. In this case, charge the auxiliary battery. Be careful as charging is not performed during the inspection.

  • If the ignition switch turns off immediately after it is turned on (READY), the auxiliary battery voltage may be low. Charge the auxiliary battery.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      Only P0A08-264 is output, or DTCs other than the ones in the table below are also output. A
      Any of the following DTCs including pending DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A93-346 Inverter Cooling System Performance
      P0A94-547, 548, 549 DC / DC Converter Performance
      P0AA6-526, 613 Hybrid Battery Voltage System Isolation Fault
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P3004-131, 803 High Voltage Power Resource
      P314A-828 Inverter Coolant Pump Speed Signal

    5. Turn the ignition switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. CHECK FUSE (IGCT NO. 4)


    1. Remove the IGCT NO. 4 fuse from the No. 2 engine room relay block.

    2. A01UYEUE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 IGCT NO. 4 Fuse

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      IGCT NO. 4 fuse terminals Always Below 1 Ω

    3. Install the IGCT NO. 4 fuse.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 2 ENGINE ROOM RELAY BLOCK) Click here

    OK

  3. CHECK FUSE (IGCT-MAIN)


    1. A01V06QE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 IGCT-MAIN Fuse

      Remove the IGCT-MAIN fuse from the No. 2 engine room relay block.

    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      IGCT-MAIN fuse terminals Always Below 1 Ω

    3. Install the IGCT-MAIN fuse.


    NG

    CHECK NO. 2 ENGINE ROOM RELAY BLOCK (IGCT RELAY, IGCT-MAIN FUSE, IGCT NO. 4 FUSE) Click here

    OK

  4. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)


    1. A01V0I0E01
      Text in Illustration
      *A for LHD
      *B for RHD

      Check the connector connections and contact pressure of the relevant terminals for the power management control ECU connectors Click here.

      OK
      The connectors are connected securely and there are no contact pressure problems.

    NG

    CONNECT SECURELY

    OK

  5. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UY1U

      Check the connector connections and contact pressure of the low voltage connectors of the inverter with converter assembly Click here.

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector does not pull out.

      OK
      The connectors are connected securely and there are no contact pressure problems.

      Tech Tips

      When connecting the connector, insert it with the locking lever in the raised position. Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage. After the click is heard, pull up on the connector to confirm that it is properly connected.


    NG

    CONNECT SECURELY

    OK

  6. CHECK FUSIBLE LINK (DC/DC)


    1. Disconnect the engine room relay block connector.

    2. A01UYRKE02

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      1E-1 - 1D-1 (AMD) Always Below 1 Ω

    3. Check the fusible link (DC/DC) in the engine room relay block for improper installation.

      OK
      The fusible link is installed securely.

    4. Connect the engine room relay block connector.


    NG

    REPLACE FUSIBLE LINK (DC/DC)

    OK

  7. CHECK CABLE AND WIRE HARNESS

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZ06

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

    3. A01UXQS

      Remove the inverter cover from the inverter with converter assembly.

    4. A01V0W6E02
      Text in Illustration
      *1 Motor Cable (for MG1)
      *2 Motor Cable (for MG2)

      Using a megohmmeter set to 500 V, measure the insulation 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
      W2-1 (W) - Body ground and shield ground Ignition switch off 1 MΩ or higher
      W2-2 (U) - Body ground and shield ground Ignition switch off 1 MΩ or higher
      W2-3 (V) - Body ground and shield ground Ignition switch off 1 MΩ or higher
      W4-1 (W) - Body ground and shield ground Ignition switch off 1 MΩ or higher
      W4-2 (U) - Body ground and shield ground Ignition switch off 1 MΩ or higher
      W4-3 (V) - Body ground and shield ground Ignition switch off 1 MΩ or higher

      Tech Tips

      Perform this inspection while the motor cable (for MG1) and motor cable (for MG2) are connected.

    5. Install the inverter cover.

    6. Install the inverter terminal cover.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) Click here

    OK

  8. CHECK AMD TERMINAL VOLTAGE (ENGINE ROOM RELAY BLOCK)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A01UYP5E02

      Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      1D-1 (AMD) - Body ground Ignition switch off Same as auxiliary battery voltage

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


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  9. CHECK AMD TERMINAL CONNECTION CONDITION

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UYZW

      Check that the bolt for the AMD terminal is tightened to the specified torque, the AMD terminal is connected securely, and there is no contact problem.

      Torque
      T=8.0 N*m {82 kgf*cm, 71 in.*lbf }

    3. Disconnect the AMD terminal from the engine room relay block.

    4. Check for arc marks on the AMD terminal.

      Result
      Result Proceed to
      There are no arc marks. The terminal is connected securely and there is no contact problem. A
      There are no arc marks. The terminal is not connected securely and there is a contact problem. B
      There are arc marks. - C

    5. Connect the AMD terminal to the engine room relay block.


    B

    CONNECT SECURELY

    C

    REPLACE MALFUNCTIONING PARTS

    A

  10. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 4 FUSE)

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

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

    4. Turn the ignition switch to ON (IG).

    5. A01UXNIE02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A33-1 (IGCT) - Body ground Ignition switch ON (IG) Same as auxiliary battery voltage

      Note

      Turning the ignition switch to ON (IG) with the inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    6. Turn the ignition switch off.

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

    8. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  11. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU)

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

    3. A01UZITE01
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A33-12 (NODD) - Body ground Ignition switch off 120 to 140 kΩ

    4. Connect the inverter with converter assembly connector.


    NG

    INSPECT POWER MANAGEMENT CONTROL ECU (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU) Click here

    OK

  12. CHECK DC/DC CONVERTER FUNCTION

    Tech Tips

    The current at the AMD terminal cannot be measured directly because of space limitations. Measure the current flowing at the auxiliary battery instead.


    1. A01UY4YE02
      *1 Probe Direction
      *2 Current Flowing into Auxiliary Battery

      Connect the AC/DC 400 A probe to the positive auxiliary battery line.

    2. Install the service plug grip.

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

    4. Turn the ignition switch to ON (READY) and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.

    5. A01UYOVE02
      *1 Probe Direction
      *2 Current Flowing from Auxiliary Battery

      Measure the current flowing from the auxiliary battery with the ignition switch to ON (READY), the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.

      Standard Current
      Item Condition Specified Condition
      Current flowing from auxiliary battery

      Ignition switch ON (READY)

      (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)

      0 A or less

      (no current from auxiliary battery)

    6. Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Item Condition Specified Condition
      Auxiliary battery voltage

      Ignition switch ON (READY)

      (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)

      		 13 to 15 V

    7. Turn the ignition switch off.


    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    OK

  13. CHECK QUANTITY OF HV COOLANT


    1. Check the HV coolant level in the inverter reserve tank.

    2. Check for HV coolant leaks.

      Result
      Result Proceed to
      HV coolant leaks are not evident. HV coolant level is above the low line in the inverter reserve tank. A
      HV coolant leaks are not evident. HV coolant level is below the low line in the inverter reserve tank. B
      HV coolant leaks are evident. C

      Tech Tips

      After repairing the HV coolant leaks and adding coolant, perform the "Activate the Water Pump" Active Test (HV Active Test item) and the "Control the Electric Cooling Fan" Active Test (Engine Active Test item) and make sure that there are no malfunctions.


    B

    ADD HV COOLANT

    C

    REPAIR FOR HV COOLANT LEAK AND ADD HV COOLANT

    A

  14. CHECK COOLANT HOSE


    1. Check if the hoses of the cooling system are kinked or clogged.


    NG

    CORRECT THE PROBLEM

    OK

  15. PERFORM ACTIVE TEST USING GTS (CONTROL THE ELECTRIC COOLING FAN)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Electric Cooling Fan.

    4. Perform the "Control the Electric Cooling Fan" Active Test.

      OK
      The cooling fan rotates.

    5. Turn the ignition switch off.


    NG

    CHECK COOLING FAN SYSTEM Click here

    OK

  16. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

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

    4. Read the freeze frame data Ambient Temperature using the GTS.

    5. Check if the freeze frame data Ambient Temperature is below freezing.

      Result
      Result Proceed to
      Ambient Temperature value is above freezing temperature of the HV coolant. A
      Ambient Temperature value is below freezing temperature of the HV coolant. B

      Tech Tips


      • HV coolant (SLLC) with a 30% concentration freezes at -15°C (5°F) and HV coolant (SLLC) with a 50% concentration freezes at -35°C (-31°F).

      • If the HV coolant freezes in the HV radiator or HV water pump, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be set.

      • A DTC is set when the water pump impeller cannot rotate due to freezing of the HV coolant.

      • If a DTC is set due to freezing of HV coolant, the problem cannot be reproduced. Judge whether freezing of HV coolant occurred according to the freeze point of the HV coolant, HV coolant change history and ambient temperature when the DTC was set.

    6. Turn the ignition switch off.


    A

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    B

    REPLACE HV COOLANT Click here

  17. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZ06

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

    3. A01UXQS

      Remove the inverter cover from the inverter with converter assembly.

    4. A01V0VB

      Disconnect the motor cable (for MG1) from the inverter with converter assembly.

    5. A01V1HDE01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (Inverter with Converter Assembly Side)

      Using a megohmmeter set to 500 V, measure the insulation 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
      W2-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    6. Connect the motor cable (for MG1).

    7. Install the inverter cover.

    8. Install the inverter terminal cover.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG1) CONNECTION CONDITION) Click here

    OK

  18. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZ06

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

    3. A01UY3H

      Disconnect the motor cable (for MG2) from the inverter with converter assembly.

    4. A01V12AE01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (Inverter with Converter Assembly Side)

      Using a megohmmeter set to 500 V, measure the insulation 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
      W4-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    5. Connect the motor cable (for MG2).

    6. Install the inverter terminal cover.


    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG2) CONNECTION CONDITION) Click here

  19. INSPECT POWER MANAGEMENT CONTROL ECU (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU)


    1. A01V1VXE02
      Text in Illustration
      *a

      Component without harness connected

      (Power Management Control ECU)

      Disconnect all the connectors from the power management control ECU.

    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A26-21 (NODD) - F55-6 (E1) Ignition switch off 120 to 140 kΩ

    3. Connect the power management control ECU connectors.


    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

  20. REPLACE HV COOLANT


    1. Replace the HV coolant with coolant having an appropriate concentration (appropriate freeze point) for the vehicle usage conditions Click here.


    NEXT

    COMPLETED

  21. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG1) CONNECTION CONDITION)

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the inverter with converter assembly Click here.

    3. A01V0HVE03

      Check that the bolts for the motor cable (for MG1) are tightened to the specified torque, the motor cable (for MG1) is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=19.5 N*m (199 kgf*cm, 14 ft.*lbf)
      Bolt B
      T=10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note


      • Make sure that the tightening torque of the bolt A is between 13.5 and 25 N*m (138 and 255 kgf*cm, 10 and 18 ft.*lbf).

      • Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    4. Disconnect the motor cable (for MG1) from the hybrid vehicle transaxle assembly.

    5. Check for arc marks at the terminals for the motor cable (for MG1).

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the motor cable (for MG1) to the hybrid vehicle transaxle assembly.

    7. Install the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  22. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the motor cable Click here.

    3. A01UYRZE01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (Inverter with Converter Assembly Side)
      *b

      Motor Cable (for MG1)

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W2-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

      Note

      Wrap the connector W1 terminal of the motor cable (for MG1) with insulating tape to prevent it from coming into contact with body ground

    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W2-1 (W) - W1-1 (W) Ignition switch off Below 1 Ω
      W2-2 (U) - W1-2 (U) Ignition switch off Below 1 Ω
      W2-3 (V) - W1-3 (V) Ignition switch off Below 1 Ω
      W2-1 (W) - W1-2 (U) Ignition switch off 100 MΩ or higher
      W2-2 (U) - W1-3 (V) Ignition switch off 100 MΩ or higher
      W2-3 (V) - W1-1 (W) Ignition switch off 100 MΩ or higher

    5. Install the motor cable.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  23. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG2) CONNECTION CONDITION)

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZNOE03

      Check that the bolts for the motor cable (for MG2) are tightened to the specified torque, the motor cable (for MG2) is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=19.5 N*m (199 kgf*cm, 14 ft.*lbf)
      Bolt B
      T=10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note


      • Make sure that the tightening torque of the bolt A is between 13.5 and 25 N*m (138 and 255 kgf*cm, 10 and 18 ft.*lbf).

      • Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    3. Disconnect the motor cable (for MG2) from the hybrid vehicle transaxle assembly.

    4. Check for arc marks at the terminals for the motor cable (for MG2).

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    5. Connect the motor cable (for MG2) to the hybrid vehicle transaxle assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  24. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the motor cable Click here.

    3. A01UYRDE01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (Inverter with Converter Assembly Side)
      *b

      Motor Cable (for MG2)

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W4-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

      Note

      Wrap the connector W3 terminal of the motor cable (for MG2) with insulating tape to prevent it from coming into contact with body ground

    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W4-1 (W) - W3-1 (W) Ignition switch off Below 1 Ω
      W4-2 (U) - W3-3 (U) Ignition switch off Below 1 Ω
      W4-3 (V) - W3-2 (V) Ignition switch off Below 1 Ω
      W4-1 (W) - W3-3 (U) Ignition switch off 100 MΩ or higher
      W4-2 (U) - W3-2 (V) Ignition switch off 100 MΩ or higher
      W4-3 (V) - W3-1 (W) Ignition switch off 100 MΩ or higher

    5. Install the motor cable.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  25. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 2 ENGINE ROOM RELAY BLOCK)

    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

    3. A01UYEUE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 IGCT NO. 4 Fuse

      Remove the IGCT NO. 4 fuse from the No. 2 engine room relay block.

    4. Measure the resistance according to the value(s) in the table below.

      A01V21HE02
      Text in Illustration
      *1 No. 2 Engine Room Relay Block *2 IGCT NO. 4 Fuse
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 - -
      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A33-1 (IGCT) or 2 (IGCT NO. 4 fuse) - Body ground and other terminals Ignition switch off 10 kΩ or higher

    5. Install the IGCT NO. 4 fuse.

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  26. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  27. CHECK NO. 2 ENGINE ROOM RELAY BLOCK (IGCT RELAY, IGCT-MAIN FUSE, IGCT NO. 4 FUSE)


    1. A01UZECE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 IGCT-MAIN Fuse
      *3 IGCT NO. 4 Fuse
      *4 IGCT Relay

      Remove the IGCT relay, IGCT-MAIN fuse and IGCT NO. 4 fuse from the No. 2 engine room relay block.

    2. A01UYDZE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 IGCT Relay

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      3 (IGCT relay) - Body ground and other terminals Always 10 kΩ or higher
      5 (IGCT relay) - Body ground and other terminals Always 10 kΩ or higher

    3. Install the IGCT relay, IGCT-MAIN fuse and IGCT NO. 4 fuse.


    OK

    REPLACE FUSE (IGCT-MAIN)

    NG

    REPAIR OR REPLACE NO. 2 ENGINE ROOM RELAY BLOCK Click here

  28. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  29. REPAIR OR REPLACE NO. 2 ENGINE ROOM RELAY BLOCK


    NEXT

    REPLACE FUSE (IGCT-MAIN)