Click here

HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A94-172

Click here
Click here
DTC Code DTC Name
P0A94-172 DC / DC Converter Performance
Click here

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 172 Boost converter fail signal detection (overcurrent by system malfunction)

  • Wire harness or connector

  • Hybrid vehicle transaxle assembly

  • Generator cable

  • Motor cable

  • Inverter with converter assembly

  • PCU fuse

  • Power management control ECU
Click here

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).

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).

    Tip:

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

Click here

PROCEDURE


  1. Click here

    CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / DTC.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      DTC P0A94-172 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
      P0AA6-526 Hybrid Battery Voltage System Isolation Fault
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      Tip:

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

      • P0A94-172 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.


  2. Click here

    CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. A003XSM

      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.
      Tip:

      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.


  3. Click here

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. A003XRBE09

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      D28-11 (GRF) - Body ground Power switch on (IG) Below 1 V
      D28-12 (GRFG) - Body ground Power switch on (IG) Below 1 V
      D28-7 (GSN) - Body ground Power switch on (IG) Below 1 V
      D28-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      D28-10 (GCS) - Body ground Power switch on (IG) Below 1 V
      D28-9 (GCSG) - Body ground Power switch on (IG) Below 1 V
      Table 1. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      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.


  4. Click here

    CHECK GENERATOR RESOLVER


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. A003XRBE09

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D28-11 (GRF) - D28-12 (GRFG) Power switch off 7.1 to 21.6 Ω
      D28-7 (GSN) - D28-8 (GSNG) Power switch off 13.7 to 34.5 Ω
      D28-10 (GCS) - D28-9 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D28-11 (GRF) or D28-12 (GRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D28-7 (GSN) or D28-8 (GSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D28-10 (GCS) or D28-9 (GCSG) - Body ground and other terminals Power switch off 10 kΩ or higher
      Table 2. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    3. Connect the inverter with converter assembly connector.


  5. Click here

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. A003XRBE10

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      D28-1 (MRF) - Body ground Power switch on (IG) Below 1 V
      D28-2 (MRFG) - Body ground Power switch on (IG) Below 1 V
      D28-3 (MSN) - Body ground Power switch on (IG) Below 1 V
      D28-4 (MSNG) - Body ground Power switch on (IG) Below 1 V
      D28-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      D28-5 (MCSG) - Body ground Power switch on (IG) Below 1 V
      Table 3. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      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.


  6. Click here

    CHECK MOTOR RESOLVER


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. A003XRBE10

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D28-1 (MRF) - D28-2 (MRFG) Power switch off 7.1 to 21.6 Ω
      D28-3 (MSN) - D28-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      D28-6 (MCS) - D28-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D28-1 (MRF) or D28-2 (MRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D28-3 (MSN) or D28-4 (MSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D28-6 (MCS) or D28-5 (MCSG) - Body ground and other terminals Power switch off 10 kΩ or higher
      Table 4. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    3. Connect the inverter with converter assembly connector.


  7. Click here

    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. A003WQ2

      Remove the inverter cover from the inverter with converter assembly.

    3. A003XVTE02

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

      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 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 cover.


  8. Click here

    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. A003WQ2

      Remove the inverter cover from the inverter with converter assembly.

    3. A003W0EE02

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

      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 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 cover.


  9. Click here

    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. A003WQ2

      Remove the inverter cover from the inverter with converter assembly.

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

    4. A003XYWE09

      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.

        Tip:

        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
        d1-1 (W) - d1-2 (U) Power switch off 89.5 to 98.9 mΩ
        d1-2 (U) - d1-3 (V) Power switch off 89.5 to 98.9 mΩ
        d1-3 (V) - d1-1 (W) Power switch off 89.5 to 98.9 mΩ
        Table 5. Text in Illustration
        *1 Generator Cable
        *2 Shield Ground
        Tip:

        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
      d1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-3 (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 cover.


  10. Click here

    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. A003WQ2

      Remove the inverter cover from the inverter with converter assembly.

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

    4. A003W2GE10

      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.

        Tip:

        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
        c1-1 (W) - c1-2 (U) Power switch off 152.6 to 169.0 mΩ
        c1-2 (U) - c1-3 (V) Power switch off 157.6 to 174.0 mΩ
        c1-3 (V) - c1-1 (W) Power switch off 151.6 to 168.0 mΩ
        Table 6. Text in Illustration
        *1 Motor Cable
        *2 Shield Ground
        Tip:

        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
      c1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      c1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      c1-3 (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 cover.


  11. Click here

    CHECK FUSE (PCU)


    1. A003V6HE01

      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
      Table 7. Text in Illustration
      *1 Engine Room Junction Block Assembly
      *2 PCU Fuse

    3. Install the PCU fuse.


  12. Click here

    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 A62 from the inverter with converter assembly.

    3. A003YOVE48

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A62-28 (GND1) - Body ground Power switch off Below 1 Ω
      A62-27 (GND2) - Body ground Power switch off Below 1 Ω
      Table 8. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    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
      A62-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A62-9 (+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.


  13. Click here

    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 A62 from the inverter with converter assembly.

    3. Disconnect connector A20 from the power management control ECU.

    4. A003XRZE10

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A62-8 (HTM+) - A20-24 (HTM+) Power switch off Below 1 Ω
      A62-18 (HTM-) - A20-25 (HTM-) Power switch off Below 1 Ω
      A62-7 (MTH+) - A20-30 (MTH+) Power switch off Below 1 Ω
      A62-17 (MTH-) - A20-29 (MTH-) Power switch off Below 1 Ω
      A62-6 (REQ+) - A20-33 (REQ+) Power switch off Below 1 Ω
      A62-16 (REQ-) - A20-32 (REQ-) Power switch off Below 1 Ω
      A62-5 (CLK+) - A20-21 (CLK+) Power switch off Below 1 Ω
      A62-15 (CLK-) - A20-20 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A62-8 (HTM+) or A20-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-18 (HTM-) or A20-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-7 (MTH+) or A20-30 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-17 (MTH-) or A20-29 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-6 (REQ+) or A20-33 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-16 (REQ-) or A20-32 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-5 (CLK+) or A20-21 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A62-15 (CLK-) or A20-20 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
      Table 9. 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)

    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
      A62-8 (HTM+) or A20-24 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A62-18 (HTM-) or A20-25 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A62-7 (MTH+) or A20-30 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A62-17 (MTH-) or A20-29 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A62-6 (REQ+) or A20-33 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A62-16 (REQ-) or A20-32 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A62-5 (CLK+) or A20-21 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A62-15 (CLK-) or A20-20 (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.


  14. Click here

    CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect connector A20 from the power management control ECU.

    2. A003X83E07

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A20-24 (HTM+) - A20-25 (HTM-) Power switch off 80 to 170 Ω
      A20-30 (MTH+) - A20-29 (MTH-) Power switch off 80 to 170 Ω
      A20-33 (REQ+) - A20-32 (REQ-) Power switch off 80 to 170 Ω
      A20-21 (CLK+) - A20-20 (CLK-) Power switch off 80 to 170 Ω
      Table 10. Text in Illustration
      *a

      Component without harness connected

      (Power Management Control ECU)

    3. Connect the power management control ECU connector.


  15. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A003YGF

      Check the connection of the generator resolver connector.

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

  16. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A003ZN3

      Check the connection of the motor resolver connector.

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

  17. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A003YGF

      Check the connection of the generator resolver connector.

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

  18. Click here

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


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. A003ZIWE05

      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
      D7-1 (GRF) - D28-11 (GRF) Power switch off Below 1 Ω
      D7-5 (GRFG) - D28-12 (GRFG) Power switch off Below 1 Ω
      D7-2 (GSN) - D28-7 (GSN) Power switch off Below 1 Ω
      D7-6 (GSNG) - D28-8 (GSNG) Power switch off Below 1 Ω
      D7-3 (GCS) - D28-10 (GCS) Power switch off Below 1 Ω
      D7-7 (GCSG) - D28-9 (GCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D7-1 (GRF) or D28-11 (GRF) - Body ground and other terminals Power switch off 10 kΩ or higher
      D7-5 (GRFG) or D28-12 (GRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D7-2 (GSN) or D28-7 (GSN) - Body ground and other terminals Power switch off 10 kΩ or higher
      D7-6 (GSNG) or D28-8 (GSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D7-3 (GCS) or D28-10 (GCS) - Body ground and other terminals Power switch off 10 kΩ or higher
      D7-7 (GCSG) or D28-9 (GCSG) - Body ground and other terminals Power switch off 10 kΩ or higher
      Table 11. 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)
      Tip:

      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.


  19. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A003ZN3

      Check the connection of the motor resolver connector.

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

  20. Click here

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


    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. A003Y42E06

      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
      D1-3 (MRF) - D28-1 (MRF) Power switch off Below 1 Ω
      D1-6 (MRFG) - D28-2 (MRFG) Power switch off Below 1 Ω
      D1-1 (MSN) - D28-3 (MSN) Power switch off Below 1 Ω
      D1-4 (MSNG) - D28-4 (MSNG) Power switch off Below 1 Ω
      D1-2 (MCS) - D28-6 (MCS) Power switch off Below 1 Ω
      D1-5 (MCSG) - D28-5 (MCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D1-3 (MRF) or D28-1 (MRF) - Body ground and other terminals Power switch off 10 kΩ or higher
      D1-6 (MRFG) or D28-2 (MRFG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D1-1 (MSN) or D28-3 (MSN) - Body ground and other terminals Power switch off 10 kΩ or higher
      D1-4 (MSNG) or D28-4 (MSNG) - Body ground and other terminals Power switch off 10 kΩ or higher
      D1-2 (MCS) or D28-6 (MCS) - Body ground and other terminals Power switch off 10 kΩ or higher
      D1-5 (MCSG) or D28-5 (MCSG) - Body ground and other terminals Power switch off 10 kΩ or higher
      Table 12. 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)
      Tip:

      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.


  21. Click here

    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. A003Z4GE01

      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
      T=20 N*m {204 kgf*cm, 15 ft.*lbf}
      Bolt B
      T=10 N*m {102 kgf*cm, 7 ft.*lbf}
      Note:

      • Make sure that the tightening torque of the bolt A is between 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.


  22. Click here

    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. A003XONE05

      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
      d1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      Table 13. Text in Illustration
      *1

      Generator Cable

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

      Generator Cable

      (Hybrid Vehicle Transaxle Assembly Side)
      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
      d1-1 (W) - d2-3 (W) Power switch off Below 1 Ω
      d1-2 (U) - d2-2 (U) Power switch off Below 1 Ω
      d1-3 (V) - d2-1 (V) Power switch off Below 1 Ω
      d1-1 (W) - d2-2 (U) Power switch off 100 MΩ or higher
      d1-2 (U) - d2-1 (V) Power switch off 100 MΩ or higher
      d1-3 (V) - d2-3 (W) Power switch off 100 MΩ or higher

    5. Install the generator cable.


  23. Click here

    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. A003Z8N

      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
      T=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.


  24. Click here

    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. A003VIIE06

      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
      c1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      c1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      c1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      Table 14. Text in Illustration
      *1

      Motor Cable

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

      Motor Cable

      (Hybrid Vehicle Transaxle Assembly Side)
      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
      c1-1 (W) - c2-1 (W) Power switch off Below 1 Ω
      c1-2 (U) - c2-3 (U) Power switch off Below 1 Ω
      c1-3 (V) - c2-2 (V) Power switch off Below 1 Ω
      c1-1 (W) - c2-3 (U) Power switch off 100 MΩ or higher
      c1-2 (U) - c2-2 (V) Power switch off 100 MΩ or higher
      c1-3 (V) - c2-1 (W) Power switch off 100 MΩ or higher

    5. Install the motor cable.


  25. Click here

    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 A62 from the inverter with converter assembly.

    3. A003YOVE49

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A62-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A62-9 (+B2) - Body ground Power switch off 10 kΩ or higher
      Table 15. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    4. Connect the inverter with converter assembly connector.


  26. Click here

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    (Click here)


  27. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR


  28. Click here

    GO TO DTC CHART (HYBRID CONTROL SYSTEM)Click here

  29. Click here

    CONNECT SECURELY

  30. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  31. Click here

    REPLACE MALFUNCTIONING PARTS

  32. Click here

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLYClick here

  33. Click here

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

  34. Click here

    REPLACE POWER MANAGEMENT CONTROL ECUClick here

  35. Click here

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTSClick here

  36. Click here

    REPLACE FUSE (PCU)

  37. Click here

    REPLACE GENERATOR CABLEClick here

  38. Click here

    REPLACE MOTOR CABLEClick here