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

DTC Code DTC Name
P0AA6-526 Hybrid Battery Voltage System Isolation Fault
P0AA6-611 Hybrid Battery Voltage System Isolation Fault
P0AA6-612 Hybrid Battery Voltage System Isolation Fault
P0AA6-613 Hybrid Battery Voltage System Isolation Fault
P0AA6-614 Hybrid Battery Voltage System Isolation Fault

DESCRIPTION

The hybrid vehicle control ECU using 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.*2

(1 trip detection logic)

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Inverter with converter assembly

  • Frame wire

  • No. 2 engine wire

  • Hybrid battery junction block assembly

  • Air conditioning system

  • HV battery

  • Battery smart unit
611

Insulation resistance of the compressor with motor assembly or air conditioning inverter has decreased.*3

(1 trip detection logic)

 Air conditioning system
612

Insulation resistance of the HV battery, battery smart unit, SMR or SMRG has decreased.*3

(1 trip detection logic)

  • Hybrid battery junction block assembly

  • Battery smart unit

  • HV battery
613

Insulation resistance of the hybrid vehicle transmission assembly or inverter for generator (MG1) and motor (MG2) has decreased.*3

(1 trip detection logic)

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Inverter with converter assembly
614

Insulation resistance of the inverter for generator (MG1) and motor (MG2), A/C inverter, SMR, SMRG or frame wire has decreased.*3

(1 trip detection logic)

  • Inverter with converter assembly

  • Frame wire

  • Air conditioning system

  • No. 2 engine wire

  • Hybrid battery junction block assembly

Tech Tips


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

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

  • *2: 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 P0AA6-526 and illuminates the MIL first.

  • *3: If the following operations are performed within the same trip after DTC P0AA6-526 is stored, just one of the related DTCs (P0AA6-611, 612, 613 or 614) will be stored.


    1. Apply the parking brake firmly.

    2. Wait for 1 minute or more with the vehicle stopped, the brake pedal firmly depressed, the ignition switch to ON (READY), the shift lever in D and the air conditioning system on (Lo/COOL MAX, blower speed HI).

    3. Then turn the ignition switch off and wait for 1 minute or more.

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

Related Data List
DTC No. Data List

P0AA6-526

P0AA6-611

P0AA6-612

P0AA6-613

P0AA6-614

  • Short Wave Highest Val

  • Power Resource VB

  • VL-Voltage before Boosting

  • VH-Voltage after Boosting

  • Boost Ratio

  • A/C Consumption Pwr

  • SMRP Status

  • SMRB Status

  • SMRG Status

  • MG1 Gate Status

  • MG2 Gate Status

The following items can be helpful when performing repairs:


WIRING DIAGRAM

A004ER9E03
Text in Illustration
*1 HV Battery *2 Battery Smart Unit
*3 SMRB *4 SMRG
*5 SMRP *6 System Main Resistor
*7 Service Plug Grip *8 Inverter with Converter Assembly
*9 Boost Converter *10 Inverter
*11 MG1 *12 MG2
*13 Compressor with Motor Assembly *14 A/C Inverter
*15 A/C Motor - -
*a High-voltage Areas *b INF Code 526 Vehicle Insulation Resistance Reduction Area
*c INF Code 611 Air Conditioning System Area *d INF Code 612 HV Battery Area
*e INF Code 613 Transaxle Area *f INF Code 614 High Voltage Direct Current Area
*g

Insulation Monitoring Circuit

(Equipped with insulation malfunction detection circuit)

 - -
A004F65E19

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. SHORT WAVE HIGHEST VALUE


    1. "Short Wave Highest Val" indicates a decrease in insulation resistance and decreases the value as the insulation resistance decreases. In some cases, "Short Wave Highest Val" may decrease even though the insulation resistance of the vehicle is normal, therefore avoid checking "Short Wave Highest Val" when any of the following conditions exist.


      • Within approximately 1 minute has passed since the ignition switch was turned on (IG).

      • There is change of the system voltages ("Power Resource VB", "VL-Voltage before Boosting", and "VH-Voltage after Boosting").

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

    2. When "Short Wave Highest Val" is approximately 0 V, insulation resistance is close to 0 Ω. In this case, damage to a high-voltage cable or hybrid component (high-voltage), or a short to the body due to intrusion of foreign matter such as metal particles can be suspected.

  2. RELATED FREEZE FRAME DATA

    If problem symptoms cannot be duplicated and a malfunction still exists after replacing a part as instructed, checking the following freeze frame data can help determine a trouble area.

    Freeze Frame Data Diagnostic Note
    Short Wave Highest Val Indicates that the insulation resistance has decreased.

    • VL-Voltage before Boosting

    • VH-Voltage after Boosting

    • Power Resource VB

    • Boost Ratio

    		 During boosting (when "Boost Ratio" is not 0%), or when "VL-Voltage before Boosting", "VH-Voltage after Boosting" or "Power Resource VB" is varying, "Short Wave Highest Val" 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 ignition 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 Val" decreases a few minutes after the ignition switch is turned on (IG) (not on (READY)), the HV battery assembly may have an insulation malfunction.
    MG2 Gate Status When "MG2 Gate 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 transmission assembly, motor cables and the AC (alternating current) section of the motor drive circuit in the inverter with converter assembly.
    MG1 Gate Status

    When "MG1 Gate 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 transmission assembly, generator cables and the AC (alternating current) section of the generator drive circuit in the inverter with converter assembly.
    A/C Consumption Pwr

    When the air conditioning system is off (air conditioning system power consumption is 0 W), the insulation malfunction detection circuit cannot detect a decrease in insulation resistance in the compressor with motor assembly AC (alternating current) section ((*c) in the wiring diagram).

    The compressor with motor assembly AC (alternating current) section 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 Val" to use as a diagnosis reference.

    Tech Tips


    • Items to be checked using the freeze frame data.

      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 Spd -
      Accel Pedal Pos #1 -
      Engine Revolution -
      Shift Sensor Shift Pos -
      Master Cylinder Ctrl Trq -
      Engine Coolant Temp -
      Operation Conditions
      Item Diagnostic Note
      Motor Temp No1

      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.
      Motor Temp No2

      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?)

  3. CONFIRMATION AFTER REPLACING PARTS


    1. After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output. (Do not turn the ignition switch off (READY off) during this inspection.)


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

      2. When the vehicle is stationary, turn the ignition switch to ON (READY) with the shift lever in P and wait for 60 seconds or more.

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

      4. While depressing the brake pedal without depressing the accelerator pedal, move the shift lever to D and wait for 5 minutes.

        If step (*) is performed within the same trip after DTC P0AA6-526 is stored, the parts with insufficient insulation resistance will be determined, and DTC one of the P0AA6-611, 612, 613 or 614 will be stored.

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

      5. Drive the vehicle for approximately 5 minutes referring to the following freeze frame data items: "Vehicle Spd", "Shift Sensor Shift Pos", "Accel Pedal Pos #1", "Engine Revolution", "Engine Coolant Temp" and "Master Cylinder Ctrl Trq".

        (If the freeze frame data item "Vehicle Spd" is 10 km/h (6 mph) or less, drive the vehicle at 10 (6 mph) km/h or more.)


        • If step (*) is performed within the same trip after DTC P0AA6-526 is stored, the parts with insufficient insulation resistance will be determined, and DTC one of the P0AA6-611, 612, 613 or 614 will be stored.

        • If no DTCs are output, insulation fault does not detected.

      6. Wait for 1 minute or more with the vehicle stopped, the ignition switch to ON (READY), the shift lever in P and the air conditioning system on (Lo/COOL MAX, blower speed HI), then turn the ignition switch off and wait for 1 minute or more. (*)

    Tech Tips

    If the DTC is not output again, check for driving conditions that would cause the Data List item "Short Wave Highest Val" to decrease.

CAUTION / NOTICE / HINT

CAUTION:


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

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

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

    Tech Tips

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

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

Note

After turning the 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

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 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
      P0AA6 only is output. A
      P0AA6 and P0A1D (hybrid vehicle control ECU malfunction) are output. B
      P0AA6 and P0AA7 (malfunction in the battery smart unit) are output. C
      P0AA6 and P0AFC-150 (Hybrid Battery Pack Sensor Module), P0B23-129 (Hybrid Battery "A" Voltage) are output. D

    5. Turn the ignition switch off.


    B

    GO TO DTC CHART (P0A1D) Click here

    C

    GO TO DTC CHART (P0AA7) Click here

    D

    GO TO DTC CHART (P0AFC-150, P0B23-129) Click here

    A

  2. CHECK INFORMATION CODE


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

      Note


      • Information codes 611, 612, 613 and 614 are not stored with 526 simultaneously. If a drop in insulation resistance is detected and DTC P0AA6-526 is output, wait for 1 minute with the ignition switch to ON (READY) the shift lever in D and the air conditioning system on within the same trip, then turn the ignition switch off and wait for 1 minute to determine the information code (611, 612, 613 or 614).

      • If only DTC P0AA6-526 is output, perform the diagnosis procedure for INF code 526 to inspect all the high voltage circuits.

      • When any other INF codes indicating parts which the insulation resistance dropped are output, perform the diagnosis procedure for each INF code.

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

      Refer to the troubleshooting procedures for P0AA6-611 (Air conditioning system) Click here

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

    5. Turn the ignition switch off.


    B

    CHECK HV BATTERY AREA Click here

    C

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    D

    CHECK HIGH VOLTAGE DIRECT CURRENT AREA Click here

    A

  3. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (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. A004EQ3

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

      Tech Tips

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

    3. A004G00

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

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

    4. A004FPXE03
      Text in Illustration
      *1 Motor Cable (MG1)
      *2 Motor Cable (MG2)

      Disconnect the motor cable from the inverter with converter assembly.

    5. 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.

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

      Note

      Turning the ignition switch to ON (IG) with the service grip removed causes DTCs to be stored. Clear the DTCs after performing this inspection.

    7. With the shift lever in N and lift up the vehicle.

    8. A004ESTE01
      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 resistance according to the value(s) in the table below.

      Note


      • Carefully perform this inspection as 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 Switch Condition Specified Condition
      W4-3 (V) - 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
      W4-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    9. Lower the vehicle and move the shift lever to P position.

    10. Turn the ignition switch off.

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


    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 ignition switch to 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 ignition switch to ON (IG).

      Note

      Turning the ignition switch to ON (IG) with the service grip removed causes DTCs to be stored. Clear the DTCs after performing this inspection.

    4. With the shift lever in N and lift up the vehicle.

    5. A004EU4E01
      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 resistance according to the value(s) in the table below.

      Note


      • Carefully perform this inspection as 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 Switch Condition Specified Condition
      W2-3 (V) - 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
      W2-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher

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

    7. Turn the ignition switch off.

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


    NG

    CHECK MOTOR CABLE (FOR MG1) Click here

    OK

  5. CHECK NO. 2 ENGINE WIRE (AIR CONDITIONING 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. A004EJVE02

      Disconnect the No. 2 engine wire (air conditioning harness) connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated connector D2 of the No. 2 engine wire (air conditioning harness).

    3. A004G0AE01
      Text in Illustration
      *1 Shield Ground
      *a

      No. 2 Engine Wire (Air Conditioning Harness)

      (Inverter with Converter Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      D2-1 (ACPB) - Body ground and shield ground Ignition switch off 3 MΩ or higher
      D2-2 (ACPE) - Body ground and shield ground Ignition switch off 3 MΩ or higher

    NG

    CHECK NO. 2 ENGINE WIRE (AIR CONDITIONING HARNESS) Click here

    OK

  6. CHECK INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A004GF4E02

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

      Tech Tips

      Make sure that no foreign matter has entered or contaminated connector L1 of the frame wire.

    3. A004GEYE01
      Text in Illustration
      *1 High Voltage Terminal

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

      Note

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

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

      Tech Tips

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


    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    OK

  7. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A004FLJE01
      Text in Illustration
      *1 Shield Ground
      *a

      Frame Wire

      (Inverter with Converter Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      L1-1 (CEI) - Body ground and shield ground Ignition switch off 10 MΩ or higher
      L1-2 (CBI) - Body ground and shield ground Ignition switch off 10 MΩ or higher

      Tech Tips

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


    NG

    CHECK FRAME WIRE Click here

    OK

  8. CHECK HV BATTERY AREA

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the No. 1 hybrid battery shield sub-assembly Click here.

    3. A004FG2E02

      Disconnect the battery smart unit connector Click here.

    4. A004F8JE03
      Text in Illustration
      *1 Service Plug Grip Installation Socket

      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 Ignition switch off 10 MΩ or higher
      2 - Body ground Ignition switch off 10 MΩ or higher

    NG

    CHECK HV BATTERY Click here

    OK

  9. REPLACE BATTERY SMART UNIT


    1. Replace the battery smart unit Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

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

    2. A004EQ3

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

      Tech Tips

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

    3. A004G00

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

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

    4. A004FPXE01
      Text in Illustration
      *1 Motor Cable (for MG1)
      *2 Motor Cable (for MG2)

      Disconnect the motor cable from the inverter with converter assembly.

    5. A004FZJE01
      Text in Illustration
      *1 High Voltage Terminal

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      High voltage terminal - Body ground Ignition switch off 1 MΩ or higher
      Result
      Result Proceed to
      NG A
      OK B

    B

    CHECK MOTOR CABLE (FOR MG2) Click here

    A

  11. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

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

    2. A004EQ3

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

      Tech Tips

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

    3. A004G00

      Remove the inverter cover from the inverter with converter assembly.

      Tech Tips

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

    4. A004EAFE02

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

      Tech Tips

      Make sure that no foreign matter has entered or contaminated connector L1 of the frame wire.

    5. A004G3HE01
      Text in Illustration
      *1 Shield Ground
      *a

      Frame Wire

      (Inverter with Converter Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      L1-1 (CEI) - Body ground and shield ground Ignition switch off 10 MΩ or higher
      L1-2 (CBI) - Body ground and shield ground Ignition switch off 10 MΩ or higher

      Tech Tips

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


    NG

    CHECK FRAME WIRE Click here

    OK

  13. CHECK NO. 2 ENGINE WIRE (AIR CONDITIONING 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. A004ERNE02

      Disconnect the No. 2 engine wire (air conditioning harness) connector from the inverter with converter assembly.

    3. A004G0AE01
      Text in Illustration
      *1 Shield Ground
      *a

      No. 2 Engine Wire (Air Conditioning Harness)

      (Inverter with Converter Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      D2-1 (ACPB) - Body ground and shield ground Ignition switch off 3 MΩ or higher
      D2-2 (ACPE) - Body ground and shield ground Ignition switch off 3 MΩ or higher

    NG

    CHECK NO. 2 ENGINE WIRE (AIR CONDITIONING HARNESS) Click here

    OK

  14. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  15. CHECK NO. 2 ENGINE WIRE (AIR CONDITIONING 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. A004E39E02

      Disconnect the No. 2 engine wire (air conditioning harness) connector from the compressor with motor assembly Click here.

    3. A004G0AE01
      Text in Illustration
      *1 Shield Ground
      *a

      No. 2 Engine Wire (Air Conditioning Harness)

      (Inverter with Converter Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      D2-1 (ACPB) - Body ground and shield ground Ignition switch off 10 MΩ or higher
      D2-2 (ACPE) - Body ground and shield ground Ignition switch off 10 MΩ or higher

    OK

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

    NG

    REPLACE NO.2 ENGINE WIRE Click here

  16. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the No. 1 hybrid vehicle battery cover panel LH Click here.

    3. A004FSHE02

      Disconnect connector L4 and connector L3 of the frame wire from the hybrid battery junction block assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated connector P5 and P4 of the frame wire.

    4. A004F71E01
      Text in Illustration
      *1 Shield Ground
      *a

      Frame Wire

      (Hybrid Battery Junction Block Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      L3-1 (CEI) - Body ground and shield ground Ignition switch off 10 MΩ or higher
      L4-1 (CBI) - Body ground and shield ground Ignition switch off 10 MΩ or higher

      Tech Tips

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


    NG

    REPLACE FRAME WIRE Click here

    OK

  17. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY


    1. Replace the hybrid battery junction block assembly Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

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

    2. Remove the hybrid battery junction block assembly Click here.

    3. A004EPTE04
      Text in Illustration
      *1 Battery Carrier
      *2 Service Plug Grip Installation Socket

      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.

      Tech Tips

      The HV battery was moved when the hybrid battery junction block assembly was removed. Therefore, the resistance needs to be measured between the service plug terminal and battery carrier.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      1 - Battery carrier Ignition switch off 10 MΩ or higher
      2 - Battery carrier Ignition switch off 10 MΩ or higher

    NG

    REPLACE HV BATTERY Click here

    OK

  19. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY


    1. Replace the hybrid battery junction block assembly Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  20. 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. Disconnect the motor cable (for MG2) from the hybrid vehicle transaxle assembly Click here.

    3. A004GCWE01
      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 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
      W4-3 (V) - 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
      W4-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  21. 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. Disconnect the motor cable (for MG1) from the hybrid vehicle transaxle assembly Click here.

    3. A004E8LE01
      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 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
      W2-3 (V) - 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
      W2-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  22. CHECK MOTOR CABLE (FOR MG2)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the ignition switch off.

    2. 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.

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

    4. A004E5LE01
      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 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
      W4-3 (V) - 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
      W4-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    NG

    REPLACE MOTOR CABLE Click here

    OK

  23. 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. Disconnect the motor cable (for MG1) from the hybrid vehicle transaxle assembly Click here.

    3. A004EW7E01
      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 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
      W2-3 (V) - 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
      W2-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  24. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  25. REPLACE NO.2 ENGINE WIRE


    1. Replace the No. 2 engine wire Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  26. REPLACE FRAME WIRE


    1. Replace the frame wire Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  27. REPLACE HV BATTERY


    1. Replace the HV battery Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  28. REPLACE MOTOR CABLE


    1. Replace the motor cable Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  29. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Replace the hybrid vehicle transaxle assembly Click here.


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))

  30. GO TO AIR CONDITIONING SYSTEM (P0AA6-611)

    Click here


    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS (REFER TO SYSTEM DESCRIPTION (DTC P0AA6-526))