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 207.2 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 207.2 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.

A0042MLE20
DTC No. INF Code DTC Detection Condition Trouble Area
P0A08 264

DC/DC converter malfunction or the auxiliary battery voltage drops to 11 V or less with the power switch on (READY).*1

(1 trip detection logic)

  • Wire harness or connector

  • Inverter cooling system

  • Hybrid vehicle transaxle assembly

  • Generator cable

  • Motor cable

  • Frame wire

  • Inverter with converter assembly

  • Fusible link block assembly (MAIN)

  • Fuse (DC/DC-S)

  • Fusible link (DC/DC)

  • Power management control ECU

*1: If the DC/DC converter is malfunctioning, operation and charging will be stopped and the auxiliary battery voltage will drop.

Related Data List
DTC No. INF Code Data List Item
P0A08 264

  • +B

  • Inverter Coolant Water Temperature

  • Short Wave Highest Val

If the inverter is overheating, control may be suspended for self-protection of the DC/DC converter and this DTC may be stored.


WIRING DIAGRAM

A0043LME07

INSPECTION PROCEDURE

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly or electric vehicle charger assembly, turn the power switch off. Also, 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 and electric vehicle charger assembly.

Note

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

Tech Tips


  • After repair, clear the DTCs, turn the power 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 park (P) selected, the power switch 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.

  • 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 power switch 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 power switch 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 may be 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 NO. 2, DC/DC-S, IGCT) - 2
    The connector between the auxiliary battery and DC/DC converter is not connected securely. - 24, 26
    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. 11
    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 power switch off.

    		 12 to 15, 19

  • 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 power switch off.)

  • If the DC/DC converter is malfunctioning, the auxiliary battery cannot be charged. Therefore, once the power 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 power 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 power switch 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 Power Cable Malfunction
      P314A-828 Inverter Coolant Pump Speed Signal

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. CHECK FUSE (DC/DC-S)


    1. A0040FXE01
      Text in Illustration
      *1 Engine Room Relay Block and Junction Block Assembly
      *2 DC/DC-S Fuse

      Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      DC/DC-S fuse terminals Always Below 1 Ω

    3. Install the DC/DC-S fuse.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S FUSE) Click here

    OK

  3. CHECK FUSIBLE LINK (DC/DC)


    1. A0041YWE12

      Disconnect the 1E engine room relay block and junction block assembly connector.

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

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

    3. Check the fusible links (DC/DC) in the engine room relay block and junction block assembly for improper installation.

      OK
      The fusible link is installed securely.

    4. Reconnect the 1E engine room relay block and junction block assembly connector.


    NG

    REPLACE FUSIBLE LINK (DC/DC)

    OK

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


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

      A00444GE01
      OK
      The connectors are connected securely and there are no contact pressure problems.
      Text in Illustration
      *A for LHD *B for RHD

    NG

    CONNECT SECURELY

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. A0043XQ

      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.

      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.

    2. Check the connection of the low voltage connector of the inverter with converter assembly.

      OK
      The connector is connected securely and there are no contact 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 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A00446H

      Remove the inverter cover from the inverter with converter assembly.

    3. A0041AZE04
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2

      Motor Cable

      (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 Condition Specified Condition
      f1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      e1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      e1-3 (V) - Body ground and shield ground Power switch off 1 MΩ or higher

      Tech Tips

      Perform this inspection while the generator cable and motor cable are connected.

    4. Install the inverter cover to the inverter with converter assembly.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) Click here

    OK

  7. CHECK ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY (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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A0042WL

      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.

      Specified Condition
      8.0 N*m (82 kgf*cm, 71 in.*lbf)
      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

    B

    CONNECT SECURELY

    C

    REPLACE MALFUNCTIONING PARTS

    A

  8. CHECK TERMINAL VOLTAGE (AMD TERMINAL VOLTAGE)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A0042WLE03

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      1J-1 (AMD) - Body ground Power switch off 11 to 14 V

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


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  9. CHECK HARNESS AND CONNECTOR (ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY - 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. Disconnect the A58 inverter with converter assembly connector.

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

    4. A0043Z3E02
      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 Condition Specified Condition
      A58-11 (S) - Body ground Always Same as auxiliary battery voltage

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

    6. Reconnect the A58 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  10. 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the A58 inverter with converter assembly connector.

    3. A00411XE89
      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 Condition Specified Condition
      A58-12 (NODD) - Body ground Power switch off 110 to 150 kΩ

    4. Reconnect the A58 inverter with converter assembly connector.


    NG

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

    OK

  11. 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. 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 power switch on (READY) and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.

      Tech Tips

      If the power switch turns off immediately after it is turned on (READY), auxiliary battery voltage may be low. Recharge the auxiliary battery and perform this procedure again.

    5. A0044C6E02
      A0042MQE02

      Measure the current flowing from the auxiliary battery with the power switch 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

      Power 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

      Power switch on (READY)

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

      		 Same as auxiliary battery voltage

    7. Turn the power switch off.


    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    OK

  12. CHECK QUANTITY OF HV COOLANT


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

    2. Check for coolant leaks.

      Result
      Result Proceed to
      No leaks are found and coolant level in the inverter reserve tank assembly is above the low line. A
      No leaks are found and coolant level in the inverter reserve tank assembly is below the low line. B
      Coolant leaks are evident. C

      Tech Tips

      After repairing the 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

    INSPECT FOR COOLANT LEAK AND ADD COOLANT

    A

  13. CHECK COOLANT HOSE


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


    NG

    CORRECT THE PROBLEM

    OK

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


    1. Connect the GTS to the DLC3.

    2. Turn the power switch 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 power switch off.


    NG

    CHECK COOLING FAN SYSTEM Click here

    OK

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


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. 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 power switch off.


    B

    Click here

    A

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

  16. 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A00446H

      Remove the inverter cover from the inverter with converter assembly.

    3. A0041HGE01
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)

      Disconnect the generator cable from the inverter with converter assembly.

    4. A0041TKE14
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      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 Condition Specified Condition
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    5. Connect the generator cable to the inverter with converter assembly.

    6. Install the inverter cover to the inverter with converter assembly.


    NG

    Click here

    OK

  17. 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A00446H

      Remove the inverter cover from the inverter with converter assembly.

    3. A0041R4E01
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)

      Disconnect the motor cable from the inverter with converter assembly.

    4. A0042RHE15
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      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 Condition Specified Condition
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    5. Connect the motor cable to the inverter with converter assembly.

    6. Install the inverter cover to the inverter with converter assembly.


    NG

    Click here

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

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


    1. A0041YQE41
      Text in Illustration
      *a

      Component without harness connected

      (Power Management Control ECU)

      Disconnect the A20, A21, L5 and L6 power management control ECU connectors.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A20-21 (NODD) - L5-6 (E1) Power switch off 110 to 150 kΩ

    3. Reconnect the A20, A21, L5 and L6 power management control ECU connectors.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  19. 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

  20. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the inverter with converter assembly.

    3. A0040OWE01

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

      Specified Condition
      Bolt A
      20 N*m (204 kgf*cm, 15 ft.*lbf)
      Bolt B
      10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note


      • Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 and 245 kgf*cm, 12 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 generator cable from the hybrid vehicle transaxle assembly.

    5. Check for arc marks at the bolts and terminals for the generator cable.

      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 generator cable to the hybrid vehicle transaxle assembly.

    7. Install the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  21. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the generator cable.

    3. A0042Y8E09
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2

      Generator Cable

      (Hybrid Vehicle Transaxle Assembly Side)
      *3 Shield 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 Condition Specified Condition
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-1 (W) - f2-3 (W) Power switch off Below 1 Ω
      f1-2 (U) - f2-2 (U) Power switch off Below 1 Ω
      f1-3 (V) - f2-1 (V) Power switch off Below 1 Ω
      f1-1 (W) - f2-2 (U) Power switch off 100 MΩ or higher
      f1-2 (U) - f2-1 (V) Power switch off 100 MΩ or higher
      f1-3 (V) - f2-3 (W) Power switch off 100 MΩ or higher

    5. Install the generator cable.


    NG

    REPLACE GENERATOR CABLE Click here

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  22. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A0043ML

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

      Specified Condition
      10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note

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

    3. Disconnect the motor cable from the hybrid vehicle transaxle assembly.

    4. Check for arc marks at the bolts and terminals for the motor cable.

      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 to the hybrid vehicle transaxle assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  23. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the motor cable.

    3. A004169E10
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2

      Motor Cable

      (Hybrid Vehicle Transaxle Assembly Side)
      *3 Shield 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 Condition Specified Condition
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      e1-1 (W) - e2-1 (W) Power switch off Below 1 Ω
      e1-2 (U) - e2-3 (U) Power switch off Below 1 Ω
      e1-3 (V) - e2-2 (V) Power switch off Below 1 Ω
      e1-1 (W) - e2-3 (U) Power switch off 100 MΩ or higher
      e1-2 (U) - e2-2 (V) Power switch off 100 MΩ or higher
      e1-3 (V) - e2-1 (W) Power switch off 100 MΩ or higher

    5. Install the motor cable.


    NG

    REPLACE MOTOR CABLE Click here

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  24. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the A58 inverter with converter assembly connector.

    3. A0040FXE01
      Text in Illustration
      *1 Engine Room Relay Block and Junction Block Assembly
      *2 DC/DC-S Fuse

      Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.

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

      A00438SE02
      Text in Illustration
      *1 Engine Room Relay Block and Junction Block Assembly *2 DC/DC-S Fuse
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      A58-11 (S) or 2 (DC/DC-S fuse) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Install the DC/DC-S fuse.

    6. Reconnect the A58 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  25. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT

    REPLACE FUSE (DC/DC-S)

  26. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (DC/DC-S)