HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A94-553

DTC Code DTC Name
P0A94-553 DC / DC Converter Performance

DESCRIPTION

For a description of the boost converter Click here.

If a malfunction occurs in the boost converter, the MG ECU detects it and transmits this information to the power management control ECU (HV CPU).

DTC No. INF Code DTC Detection Condition Trouble Area
P0A94 553 Boost converter fail signal detection (boost converter overheating)

  • Wire harness or connector

  • Inverter cooling system

  • Inverter water pump assembly

  • Hybrid vehicle transaxle assembly

  • Generator cable

  • Motor cable

  • Inverter with converter assembly

  • Cooling fan circuit

  • PCU fuse

  • Power management control ECU

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A1A-200 Click here.

Refer to the wiring diagram for DTC P324E-788 Click here.

Refer to the wiring diagram for DTC U0110-159 Click here.

INSPECTION PROCEDURE

CAUTION:


  • 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.

PROCEDURE


  1. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      DTC P0A94-553 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-113, 128, 266, 267, 279, 284, 286, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC / DC Converter Performance
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P314A-828 Inverter Coolant Pump Speed Signal

      Tech Tips


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • P0A94-553 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART Click here

    A

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. A003SZV

      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

  3. CHECK QUANTITY OF HV COOLANT


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

    2. Check for coolant leaks.

      Result
      Result Proceed to
      Coolant leaks are not evident. A sufficient amount of coolant remains in the inverter reserve tank. A
      Coolant leaks are not evident. No coolant remains in the inverter reserve tank. 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

  4. CHECK COOLANT HOSE


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


    NG

    CORRECT THE PROBLEM

    OK

  5. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE ELECTRIC COOLING FAN)


    1. Connect the intelligent tester 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

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


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Read the freeze frame data Ambient Temperature using the intelligent tester.

    4. 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 inverter water pump assembly, 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 inverter water pump assembly 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.

    5. Turn the power switch off.


    B

    Click here

    A

  7. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector B138 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. A003U17E07
      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
      B138-11 (GRF) - Body ground Power switch on (IG) Below 1 V
      B138-12 (GRFG) - Body ground Power switch on (IG) Below 1 V
      B138-7 (GSN) - Body ground Power switch on (IG) Below 1 V
      B138-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      B138-10 (GCS) - Body ground Power switch on (IG) Below 1 V
      B138-9 (GCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    4. Turn the power switch off.

    5. Connect the low voltage connector from the inverter with converter assembly.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. CHECK GENERATOR RESOLVER


    1. Disconnect the low voltage connector B138 from the inverter with converter assembly.

    2. A003U17E07
      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 (Check for Open)
      Tester Connection Switch Condition Specified Condition
      B138-11 (GRF) - B138-12 (GRFG) Power switch off 7.1 to 21.6 Ω
      B138-7 (GSN) - B138-8 (GSNG) Power switch off 13.7 to 34.5 Ω
      B138-10 (GCS) - B138-9 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      B138-11 (GRF) or B138-12 (GRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B138-7 (GSN) or B138-8 (GSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B138-10 (GCS) or B138-9 (GCSG) - Body ground and other terminals Power switch off 10 kΩ or higher

    3. Connect the inverter with converter assembly connector.


    NG

    Click here

    OK

  9. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector B138 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. A003U17E08
      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
      B138-1 (MRF) - Body ground Power switch on (IG) Below 1 V
      B138-2 (MRFG) - Body ground Power switch on (IG) Below 1 V
      B138-3 (MSN) - Body ground Power switch on (IG) Below 1 V
      B138-4 (MSNG) - Body ground Power switch on (IG) Below 1 V
      B138-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      B138-5 (MCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    4. Turn the power switch off.

    5. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  10. CHECK MOTOR RESOLVER


    1. Disconnect the low voltage connector B138 from the inverter with converter assembly.

    2. A003U17E08
      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 (Check for Open)
      Tester Connection Switch Condition Specified Condition
      B138-1 (MRF) - B138-2 (MRFG) Power switch off 7.1 to 21.6 Ω
      B138-3 (MSN) - B138-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      B138-6 (MCS) - B138-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      B138-1 (MRF) or B138-2 (MRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B138-3 (MSN) or B138-4 (MSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B138-6 (MCS) or B138-5 (MCSG) - Body ground and other terminals Power switch off 10 kΩ or higher

    3. Connect the inverter with converter assembly connector.


    NG

    Click here

    OK

  11. CHECK INVERTER WITH CONVERTER 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. A003UIY

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

    3. A003RUEE02

      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
      8.0 N*m (82 kgf*cm, 71 in.*lbf)
      Bolt B
      9.2 N*m (94 kgf*cm, 81 in.*lbf)

      Note

      Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Disconnect the generator cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts 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 inverter with converter assembly.

    7. Install the inverter terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  12. CHECK INVERTER WITH CONVERTER 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. A003UIY

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

    3. A003UDIE02

      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
      Bolt A
      8.0 N*m (82 kgf*cm, 71 in.*lbf)
      Bolt B
      9.2 N*m (94 kgf*cm, 81 in.*lbf)

      Note

      Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Disconnect the motor cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts 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

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

    7. Install the inverter terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  13. 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. A003UIY

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

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

    4. A003UOGE05
      Text in Illustration
      *1 Generator Cable
      *2 Shield Ground

      Check MG1 for an interphase short using a milliohmmeter.


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

        Tech Tips

        If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        Y1-1 (W) - Y1-2 (U) Power switch off 89.5 to 98.9 mΩ
        Y1-2 (U) - Y1-3 (V) Power switch off 89.5 to 98.9 mΩ
        Y1-3 (V) - Y1-1 (W) Power switch off 89.5 to 98.9 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at 20°C (68°F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. 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
      Y1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Y1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      Y1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter terminal cover.


    NG

    Click here

    OK

  14. 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. A003UIY

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

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

    4. A003S65E06
      Text in Illustration
      *1 Motor Cable
      *2 Shield Ground

      Check MG2 for an interphase short using a milliohmmeter.


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

        Tech Tips

        If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        X1-1 (W) - X1-2 (U) Power switch off 152.6 to 169.0 mΩ
        X1-2 (U) - X1-3 (V) Power switch off 157.6 to 174.0 mΩ
        X1-3 (V) - X1-1 (W) Power switch off 151.6 to 168.0 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at 20°C (68°F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. 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
      X1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      X1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      X1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter terminal cover.


    NG

    Click here

    OK

  15. CHECK FUSE (PCU)


    1. A003TUUE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 PCU Fuse

      Remove the PCU fuse from the engine room junction block assembly.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      PCU fuse terminals Always Below 1 Ω

    3. Install the PCU fuse.


    NG

    Click here

    OK

  16. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)

    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 connector A105 from the inverter with converter assembly.

    3. A003UMIE21
      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
      A105-28 (GND1) - Body ground Power switch off Below 1 Ω
      A105-27 (GND2) - Body ground Power switch off Below 1 Ω

    4. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A105-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A105-9 (+B2) - Body ground Power switch on (IG) 11 to 14 V

    6. Turn the power switch off.

    7. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

  17. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect connector A105 from the inverter with converter assembly.

    3. Disconnect connector A99 from the power management control ECU.

    4. A003S2AE04
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A105-8 (HTM+) - A99-24 (HTM+) Power switch off Below 1 Ω
      A105-18 (HTM-) - A99-25 (HTM-) Power switch off Below 1 Ω
      A105-7 (MTH+) - A99-30 (MTH+) Power switch off Below 1 Ω
      A105-17 (MTH-) - A99-29 (MTH-) Power switch off Below 1 Ω
      A105-6 (REQ+) - A99-33 (REQ+) Power switch off Below 1 Ω
      A105-16 (REQ-) - A99-32 (REQ-) Power switch off Below 1 Ω
      A105-5 (CLK+) - A99-21 (CLK+) Power switch off Below 1 Ω
      A105-15 (CLK-) - A99-20 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A105-8 (HTM+) or A99-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A105-18 (HTM-) or A99-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A105-7 (MTH+) or A99-30 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A105-17 (MTH-) or A99-29 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A105-6 (REQ+) or A99-33 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A105-16 (REQ-) or A99-32 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A105-5 (CLK+) or A99-21 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A105-15 (CLK-) or A99-20 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A105-8 (HTM+) or A99-24 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A105-18 (HTM-) or A99-25 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A105-7 (MTH+) or A99-30 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A105-17 (MTH-) or A99-29 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A105-6 (REQ+) or A99-33 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A105-16 (REQ-) or A99-32 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A105-5 (CLK+) or A99-21 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A105-15 (CLK-) or A99-20 (CLK-) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the power management control ECU and inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.

    8. Connect the power management control ECU connector.

    9. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  18. CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect connector A99 from the power management control ECU.

    2. A003RUAE04
      Text in Illustration
      *a

      Component without harness connected

      (Power Management Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A99-24 (HTM+) - A99-25 (HTM-) Power switch off 80 to 170 Ω
      A99-30 (MTH+) - A99-29 (MTH-) Power switch off 80 to 170 Ω
      A99-33 (REQ+) - A99-32 (REQ-) Power switch off 80 to 170 Ω
      A99-21 (CLK+) - A99-20 (CLK-) Power switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A003SU4

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  20. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A003RVY

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

  21. 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

  22. CHECK INVERTER WATER PUMP ASSEMBLY


    1. Perform a road test and check that DTCs are not stored.

      OK
      DTCs are not stored.

    NG

    REPLACE INVERTER WATER PUMP ASSEMBLY Click here

    OK

    COMPLETED

  23. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A003SU4

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  24. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)


    1. Disconnect the low voltage connector B138 from the inverter with converter assembly.

    2. A003UZYE04
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Generator Resolver)
      *b

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      Disconnect the generator resolver connector.

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      B132-1 (GRF) - B138-11 (GRF) Power switch off Below 1 Ω
      B132-5 (GRFG) - B138-12 (GRFG) Power switch off Below 1 Ω
      B132-2 (GSN) - B138-7 (GSN) Power switch off Below 1 Ω
      B132-6 (GSNG) - B138-8 (GSNG) Power switch off Below 1 Ω
      B132-3 (GCS) - B138-10 (GCS) Power switch off Below 1 Ω
      B132-7 (GCSG) - B138-9 (GCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      B132-1 (GRF) or B138-11 (GRF) - Body ground and other terminals Power switch off 10 kΩ or higher
      B132-5 (GRFG) or B138-12 (GRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B132-2 (GSN) or B138-7 (GSN) - Body ground and other terminals Power switch off 10 kΩ or higher
      B132-6 (GSNG) or B138-8 (GSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B132-3 (GCS) or B138-10 (GCS) - Body ground and other terminals Power switch off 10 kΩ or higher
      B132-7 (GCSG) or B138-9 (GCSG) - Body ground and other terminals Power switch off 10 kΩ or higher

      Tech Tips

      The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    4. Connect the generator resolver connector.

    5. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  25. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A003RVY

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  26. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)


    1. Disconnect the low voltage connector B138 from the inverter with converter assembly.

    2. A003TSFE05
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Motor Resolver)
      *b

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      Disconnect the motor resolver connector.

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      B129-3 (MRF) - B138-1 (MRF) Power switch off Below 1 Ω
      B129-6 (MRFG) - B138-2 (MRFG) Power switch off Below 1 Ω
      B129-1 (MSN) - B138-3 (MSN) Power switch off Below 1 Ω
      B129-4 (MSNG) - B138-4 (MSNG) Power switch off Below 1 Ω
      B129-2 (MCS) - B138-6 (MCS) Power switch off Below 1 Ω
      B129-5 (MCSG) - B138-5 (MCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      B129-3 (MRF) or B138-1 (MRF) - Body ground and other terminals Power switch off 10 kΩ or higher
      B129-6 (MRFG) or B138-2 (MRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B129-1 (MSN) or B138-3 (MSN) - Body ground and other terminals Power switch off 10 kΩ or higher
      B129-4 (MSNG) or B138-4 (MSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      B129-2 (MCS) or B138-6 (MCS) - Body ground and other terminals Power switch off 10 kΩ or higher
      B129-5 (MCSG) or B138-5 (MCSG) - Body ground and other terminals Power switch off 10 kΩ or higher

      Tech Tips

      The motor resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    4. Connect the motor resolver connector.

    5. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  27. 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. A003SU9E01

      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 transaxle assembly.

    5. Check for arc marks at the bolts 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 transaxle assembly.

    7. Install the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  28. 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. A003TGAE03
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shielded Ground
      *3

      Generator Cable

      (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
      Y1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Y1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      Y1-3 (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 Switch Condition Specified Condition
      Y1-1 (W) - Y2-3 (W) Power switch off Below 1 Ω
      Y1-2 (U) - Y2-2 (U) Power switch off Below 1 Ω
      Y1-3 (V) - Y2-1 (V) Power switch off Below 1 Ω
      Y1-1 (W) - Y2-2 (U) Power switch off 100 MΩ or higher
      Y1-2 (U) - Y2-1 (V) Power switch off 100 MΩ or higher
      Y1-3 (V) - Y2-3 (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

  29. 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. A003SNC

      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 transaxle assembly.

    4. Check for arc marks at the bolts 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 transaxle assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  30. 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. A003TBQE04
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2 Shielded Ground
      *3

      Motor Cable

      (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
      X1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      X1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      X1-3 (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 Switch Condition Specified Condition
      X1-1 (W) - X2-1 (W) Power switch off Below 1 Ω
      X1-2 (U) - X2-3 (U) Power switch off Below 1 Ω
      X1-3 (V) - X2-2 (V) Power switch off Below 1 Ω
      X1-1 (W) - X2-3 (U) Power switch off 100 MΩ or higher
      X1-2 (U) - X2-2 (V) Power switch off 100 MΩ or higher
      X1-3 (V) - X2-1 (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

  31. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU 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 connector A105 from the inverter with converter assembly.

    3. A003UMIE22
      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
      A105-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A105-9 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  32. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT

    REPLACE FUSE (PCU)

  33. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (PCU)