HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A08-264

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

DESCRIPTION

The hybrid vehicle converter (DC/DC converter) converts the DC 201.6 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 201.6 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 hybrid vehicle converter controls the output voltage in order to keep a constant voltage at the terminals of the auxiliary battery.

The power management control ECU (HV CPU) uses the NODD signal line to transmit a stop command to the hybrid vehicle 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 hybrid vehicle converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the power management control ECU (HV CPU) monitors the operation of the hybrid vehicle converter and alerts the driver if it detects a malfunction.

A003UTSE02
DTC No. INF Code DTC Detection Condition Trouble Area
P0A08 264 DC/DC converter malfunction

  • Wire harness or connector

  • Inverter water pump assembly

  • Inverter cooling system

  • Hybrid vehicle transaxle assembly

  • Generator cable

  • Motor cable

  • Frame wire

  • Inverter with converter assembly

  • Fusible link block assembly (MAIN)

  • Fuse (DC/DC-S, IGCT, IGCT No. 2)

  • Fusible link block assembly (DC/DC)

WIRING DIAGRAM

A003UOAE02

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 P0A08-264 only is output. A
      Any of the following 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 Click here

    A

  2. CHECK FUSE (IGCT NO. 2)


    1. Disconnect the cable from the negative auxiliary battery terminal.

    2. Remove the IGCT NO. 2 fuse from the engine room junction block assembly.

    3. A003UPGE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 IGCT NO. 2 Fuse

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      IGCT NO. 2 fuse terminals Always Below 1 Ω

    4. Install the IGCT NO. 2 fuse.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 2 FUSE) Click here

    OK

  3. CHECK FUSE (DC/DC-S)


    1. A003S5NE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 DC/DC-S Fuse

      Remove the DC/DC-S 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
      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

  4. CHECK FUSE (IGCT)


    1. A003TBKE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 IGCT Fuse

      Remove the IGCT 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
      IGCT fuse terminals Always Below 1 Ω

    3. Install the IGCT fuse.


    NG

    CHECK ENGINE ROOM JUNCTION BLOCK (IGCT RELAY, IGCT FUSE, IGCT NO. 2 FUSE) Click here

    OK

  5. CHECK FUSIBLE LINK (DC/DC)


    1. A003SXUE04

      Disconnect connector 1E 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
      1E-1 - 1F-1 (AMD) Always Below 1 Ω

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

      OK
      The fusible link is installed securely.

    4. Connect the engine room junction block assembly connector.


    NG

    REPLACE FUSIBLE LINK (DC/DC)

    OK

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


    1. Check the connections of the power management control ECU connectors.

      A003TI1E01
      Text in Illustration
      *A for LHD *B for RHD
      OK
      The connectors are connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  7. 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

  8. 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. A003UIY

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

    3. A003RYIE02
      Text in Illustration
      *1 Three-phase AC Cable for MG1
      *2 Three-phase AC Cable for MG2

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      Y1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      Y1-2 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      Y1-3 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      X1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      X1-2 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      X1-3 (V) - Body ground and shield ground Power switch off 1 MΩ or higher

      Tech Tips

      Perform this inspection while the three-phase AC cable for MG1 and for MG2 are connected.

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


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) Click here

    OK

  9. CHECK ENGINE ROOM 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. A003TKQ

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

      Torque
      T=8.3 N*m {85 kgf*cm, 73 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

  10. CHECK TERMINAL VOLTAGE (AMD TERMINAL VOLTAGE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. A003TKQE01

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      1F-1 - Body ground Power switch off 11 to 14 V

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  11. CHECK HARNESS AND CONNECTOR (ENGINE ROOM JUNCTION BLOCK - 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. Turn the power switch on (IG).

      Tech Tips

      Turning the power switch on (IG) with the service grip removed causes interlock switch system DTC P0A0D-350 to be output.

    4. A003UMIE17
      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
      A105-1 (IGCT) - Body ground Power switch on (IG) 11 to 14 V
      A105-11 (S) - Body ground

    5. Turn the power switch off.

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  12. CHECK 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 connector A105 from the inverter with converter assembly.

    3. A003UMIE18
      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
      A105-12 (NODD) - Body ground Power switch off 120 to 140 kΩ

    4. Connect the inverter with converter assembly connector.


    NG

    INSPECT POWER MANAGEMENT CONTROL ECU Click here

    OK

  13. 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. 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.

    4. A003UWPE02
      A003V01E02

      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 Switch 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)

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

      Standard Voltage
      Tester Connection Switch 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.)

      		 13 to 15 V

    6. Turn the power switch off.


    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    OK

  14. 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

  15. CHECK COOLANT HOSE


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


    NG

    CORRECT THE PROBLEM

    OK

  16. 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

  17. 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

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

  18. 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. A003RUEE01
      Text in Illustration
      *1 Three-phase AC Cables for MG1

      Disconnect the three-phase AC cables for MG1 from the inverter with converter assembly.

    4. A003UOGE05
      Text in Illustration
      *1 Three-phase AC Cables for MG1
      *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 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

    5. Connect the three-phase AC cables for MG1 to the inverter with converter assembly.

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


    NG

    Click here

    OK

  19. 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. A003UDIE01
      Text in Illustration
      *1 Three-phase AC Cables for MG2

      Disconnect the three-phase AC cables for MG2 from the inverter with converter assembly.

    4. A003S65E06
      Text in Illustration
      *1 Three-phase AC Cables for MG2
      *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 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

    5. Connect the three-phase AC cables for MG2 to the inverter with converter assembly.

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


    NG

    Click here

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

  20. INSPECT POWER MANAGEMENT CONTROL ECU


    1. A003UPBE11
      Text in Illustration
      *a

      Component without harness connected

      (Power Management Control ECU)

      Disconnect all the connectors from the power management control ECU.

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A98-21 (NODD) - E111-6 (E1) Power switch off 120 to 140 kΩ

    3. Connect the power management control ECU connectors.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  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 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

  24. 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

  25. 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

  26. 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

  27. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 2 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. A003UPGE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 IGCT NO. 2 Fuse

      Remove the IGCT NO. 2 fuse from the engine room junction block assembly.

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

      A003SVPE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly *2 IGCT NO. 2 Fuse
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 - -
      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A105-1 (IGCT) or 2 (IGCT NO. 2 fuse) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Install the IGCT NO. 2 fuse.

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  28. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT

    REPLACE FUSE (IGCT NO. 2)

  29. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S FUSE)


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

    2. A003S5NE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 DC/DC-S Fuse

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

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

      A003S2KE02
      Text in Illustration
      *1 Engine Room Junction Block Assembly *2 DC/DC-S Fuse
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 - -
      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A105-11 (S) or 2 (DC/DC-S fuse) - Body ground and other terminals Power switch off 10 kΩ or higher

    4. Install the DC/DC-S fuse.

    5. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  30. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT

    REPLACE FUSE (DC/DC-S)

  31. CHECK ENGINE ROOM JUNCTION BLOCK (IGCT RELAY, IGCT FUSE, IGCT NO. 2 FUSE)


    1. A003TVHE01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 IGCT Fuse
      *3 IGCT NO. 2 Fuse
      *4 IGCT Relay

      Remove the IGCT relay, IGCT fuse and IGCT NO. 2 fuse from the engine room junction block assembly.

    2. A003RQ4E01
      Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 IGCT Relay

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

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

    3. Install the IGCT relay, IGCT fuse and IGCT NO. 2 fuse.


    NG

    REPAIR OR REPLACE ENGINE ROOM JUNCTION BLOCK Click here

    OK

    REPLACE FUSE (IGCT)

  32. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (IGCT NO. 2)

  33. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (DC/DC-S)

  34. REPAIR OR REPLACE ENGINE ROOM JUNCTION BLOCK


    NEXT

    REPLACE FUSE (IGCT)