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 288 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 288 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 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 monitors the operation of the hybrid vehicle converter and alerts the driver if it detects a malfunction.

A01FVPZE01
DTC No. INF Code DTC Detection Condition Trouble Area
P0A08 264

Either of the following conditions is met:


  • DC/DC converter malfunction

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

  • Wire harness or connector

  • Inverter cooling system

  • Hybrid vehicle transmission assembly

  • Generator cable

  • Motor cable

  • Inverter with converter assembly

  • Fuse (DC/DC-S (HV))

  • Fusible link block assembly (DC/DC)

  • Inverter bus-bar plate sub-assembly

  • Power management control ECU

WIRING DIAGRAM

A01FRHJE02
A01FRHJE03

Refer to the wiring diagram for DTC P0AA6-526 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.

Note

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

Tech Tips


  • After repair, clear the DTCs, turn the power switch off and wait for 30 seconds or more and perform the following procedure to confirm that the auxiliary battery low voltage indicated by this DTC has been repaired.


    1. Wait for 2 minutes with the shift lever in P, the power switch on (READY) and the following conditions met, then confirm that Data List item "+B" is between 13.0 and 15.0 V.

      (If charging is not performed and the electrical load increases, +B voltage may not be steady and gradually drops.)


      1. Headlight switch is in the HI position.

      2. A/C blower fan switch is in the HI position.

      3. Window defogger switch is turned on.

  • By performing the following procedure, the DC/DC converter function can be checked.


    1. Connect the AC/DC 400 A probe to the positive auxiliary battery cable.


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

      2. Turn the power switch on (READY), set the headlight switch and A/C blower fan switch in the HI position, and turn on the window defogger.

      3. Confirm that the current drawn from the auxiliary battery is 0 A or lower and the auxiliary battery voltage is between 13.0 and 15.0 V.

  • This DTC is stored when the power switch is on (READY), the auxiliary battery voltage is 11 V or less and operation of the DC/DC converter is suspended due to a malfunction. Therefore, this DTC may be also stored when a part other than the DC/DC converter is malfunctioning or depending on user operation.

    Malfunction cases to store DTC P0A08-264
    Malfunction Case Remarks Inspection Step
    Fuse is blown. (DC/ DC-S (HV), DC/DC) - 2, 5
    The connector between the auxiliary battery and DC/DC converter is not connected securely. - 4, 25
    High-voltage insulation between the inverter, generator (MG1), motor (MG2) and body ground is poor (body ground). DTC P0AA6 may be stored if the ground potential fluctuates due to a high-voltage insulation malfunction. 1
    A signal connector of the power management control ECU or inverter is not connected securely. - 3, 4
    The DC/DC converter is malfunctioning. Inspect the DC/DC converter function. 12
    Control is suspended due to overheating. (The inverter water pump with motor assembly is malfunctioning, the coolant is not sufficient, a hose is clogged, etc.)

    When the inverter is overheating, the DC/DC converter has self protection control that suspends the DC/DC converter control. As that time, this DTC may be stored.

    The suspended DC/DC converter control will return to normal by clearing the DTCs and turning the power switch off.

    		 13 to 16, 20

  • If this vehicle is used to jump start another vehicle with a discharged battery, a fuse may blow due to overcurrent or the DC/DC converter self-protection may be activated. Also, if this vehicle is jump started by a vehicle with a 24 V battery, the same malfunction may occur and this DTC may be stored. (The suspended DC/DC converter control will return to normal by clearing the DTCs and turning the power switch off.)

  • Confirm whether high electrical load equipment such as a high-capacitance audio device or electric kettle is used on the vehicle. (A fuse of the auxiliary battery may be blown due to overcurrent.)

  • If the DC/DC converter is malfunctioning, the auxiliary battery cannot be charged. Therefore, once the power switch is turned off, it may be impossible to turn it on (READY) again if the auxiliary battery is completely discharged. In this case, charge the auxiliary battery. Be careful as charging is not performed during the inspection.

  • If the power switch turns off immediately after it is turned on (READY), the auxiliary battery voltage may be low. Charge the auxiliary battery.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0A08-264 only is output. A
      Any of the following DTCs including pending DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A93-346 Inverter Cooling System Performance
      P0A94-547, 548, 549 DC / DC Converter Performance
      P0AA6-526, 613 Hybrid Battery Voltage System Isolation Fault
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P3004-131, 803 High Voltage Power Resource
      P314A-828 Inverter Coolant Pump Speed Signal

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. CHECK FUSE (DC/DC-S (HV))


    1. A01FQMZE01
      Text in Illustration
      *1 No. 1 Junction Block Assembly
      *2 DC/DC-S (HV) Fuse

      Remove the DC/DC-S (HV) fuse from the No. 1 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 (HV) fuse terminals Always Below 1 Ω

    3. Install the DC/DC-S (HV) fuse.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 1 JUNCTION BLOCK ASSEMBLY) Click here

    OK

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


    1. A01FQC6E01
      Text in Illustration
      *A for LHD
      *B for RHD

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

      OK
      The connectors are connected securely and there are no contact pressure problems.

    NG

    CONNECT SECURELY

    OK

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

    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. Check the connector connections and contact pressure of the low voltage connectors of the inverter with converter assembly Click here.

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector cannot be pulled out.

      A01FRBVE01
      Text in Illustration
      *A for LHD *B for RHD
      OK
      The connectors are connected securely and there are no contact pressure 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

  5. CHECK FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)


    1. Check the fusible link block assembly (DC/DC) in the No. 1 engine room relay block and junction block assembly for improper installation.

      OK
      The fusible link is installed securely.

    2. Remove the fusible link block assembly from the No. 1 engine room relay block and junction block assembly.

    3. A01FRZUE01
      Text in Illustration
      *1 Fusible Link Block Assembly

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Fusible link block assembly (DC/DC) 1 - 2 Always Below 1 Ω

    4. Install the fusible link block assembly.


    NG

    REPLACE FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)

    OK

  6. CHECK CABLE AND WIRE HARNESS

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01FRI1E01
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. A01FV5DE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. A01FR1LE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Generator Cable
      *2 Motor Cable

      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
      for LHD
      Tester Connection Switch Condition Specified Condition
      v1-3 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      v1-1 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      u1-3 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      u1-2 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      u1-1 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      v1-3 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      u3-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      u3-2 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      u3-3 (U) - Body ground and shield ground Power switch off 1 MΩ or higher

      Tech Tips

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

    5. Install the inverter terminal cover.


    NG

    CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1) Click here

    OK

  7. CHECK AMD TERMINAL VOLTAGE

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A01FQWDE02
      Text in Illustration
      *A for LHD
      *B for RHD

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

      Standard Voltage
      for LHD
      Tester Connection Switch Condition Specified Condition
      A - Body ground Power switch off Same as auxiliary battery voltage
      for RHD
      Tester Connection Switch Condition Specified Condition
      1K-1 (AMD) - Body ground Power switch off Same as auxiliary battery voltage

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


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. CHECK 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. A01FQE3E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Check that the bolt for the AMD terminal (inverter with converter assembly side and No. 1 engine room relay block and junction block assembly side) is tightened to the specified torque, the AMD terminal (inverter with converter assembly side and No. 1 engine room relay block and junction block assembly side) is connected securely, and there is no contact problem.

      Torque
      T=18 N*m {184 kgf*cm, 13 ft.*lbf} (Inverter with converter assembly side)
      T=11.0 N*m {107 kgf*cm, 8 ft.*lbf} (No. 1 engine room relay block and junction block assembly side)
      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

  9. CHECK INVERTER BUS-BAR PLATE SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the inverter bus-bar plate sub-assembly from the AMD terminal (inverter with converter assembly side and No. 1 engine room relay block and junction block assembly side).

    3. A01FSXWE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Inverter Bus-Bar Plate Sub-assembly

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

      Standard Resistance
      for LHD
      Tester Connection Condition Specified Condition
      A - E1-1 (AMD) Always Below 1 Ω
      for RHD
      Tester Connection Condition Specified Condition
      E1-1 (AMD) - 1K-1 (AMD) Always Below 1 Ω

    4. Connect the inverter bus-bar plate sub-assembly.


    NG

    REPLACE INVERTER BUS-BAR PLATE SUB-ASSEMBLY Click here

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

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

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

    4. A01FUEDE06
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Condition Specified Condition
      A39-3 (S) - Body ground Always Same as auxiliary battery voltage
      for RHD
      Tester Connection Condition Specified Condition
      A75-3 (S) - Body ground Always Same as auxiliary battery voltage

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

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  11. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

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

    3. A01FUEDE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A39-5 (NODD) - Body ground Power switch off 110 to 150 kΩ
      for RHD
      Tester Connection Switch Condition Specified Condition
      A75-5 (NODD) - Body ground Power switch off 110 to 150 kΩ

    4. Connect the inverter with converter assembly connector.


    NG

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

    OK

  12. CHECK DC/DC CONVERTER FUNCTION


    1. A01FSJ6E02

      Connect the AC/DC 400 A probe to the positive auxiliary battery line.

    2. Install the service plug grip.

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

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

      Tech Tips

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

    5. A01FRE3E02

      Measure the current flowing from the auxiliary battery with the power switch on (READY), the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.

      Standard Current
      Item Condition Specified Condition
      Current flowing from auxiliary battery

      Power switch on (READY)

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

      0 A or less

      (no current from auxiliary battery)

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

      Standard Voltage
      Item Condition Specified Condition
      Auxiliary battery voltage

      Power switch on (READY)

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

      		 13 to 15 V

    7. Turn the power switch off.


    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    OK

  13. CHECK QUANTITY OF HV COOLANT


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

    2. Check for HV coolant leaks.

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

      Note

      The inverter water pump with motor assembly has a protection function that activates when there is an HV coolant leak. Therefore, it is not necessary to replace the inverter water pump with motor assembly unless the cause of the HV coolant leak is the inverter water pump with motor assembly.

      Tech Tips

      After repairing the HV coolant leaks and adding coolant, perform the "Activate the (Inverter) 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 HV COOLANT LEAK AND ADD HV COOLANT

    A

  14. CHECK COOLANT HOSE


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


    NG

    CORRECT THE PROBLEM

    OK

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


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Electric Cooling Fan.

    4. Perform the "Control the Electric Cooling Fan" Active Test.

      OK
      The cooling fan rotates.

    5. Turn the power switch off.


    NG

    CHECK COOLING FAN SYSTEM Click here

    OK

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


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Read the freeze frame data Ambient Temperature using the GTS.

    5. Check if the freeze frame data Ambient Temperature is below freezing.

      Result
      Result Proceed to
      Ambient Temperature value is above freezing temperature of the HV coolant. A
      Ambient Temperature value is below freezing temperature of the HV coolant. B

      Tech Tips


      • HV coolant (SLLC) with a 30% concentration freezes at -15°C (5°F) and HV coolant (SLLC) with a 50% concentration freezes at -35°C (-31°F).

      • If the HV coolant freezes in the HV radiator or HV water pump, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be stored.

      • A DTC is stored when the HV water pump impeller cannot rotate due to freezing of the HV coolant.

      • If a DTC is stored 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 stored.

    6. Turn the power switch off.


    B

    Click here

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY

  17. CHECK HYBRID VEHICLE TRANSMISSION 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. A01FRI1E01
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. A01FV5DE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. A01FTL0E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Generator Cable

      Disconnect the generator cable from the inverter with converter assembly.

    5. A01FSH3E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a Generator Cable (Inverter with Converter Assembly Side)

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

      Note

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

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      v1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable.

    7. Install the inverter terminal cover.


    NG

    Click here

    OK

  18. CHECK HYBRID VEHICLE TRANSMISSION 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. A01FRI1E01
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. A01FV5DE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. A01FR8FE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Motor Cable

      Disconnect the motor cable from the inverter with converter assembly.

    5. A01FUB2E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a Motor Cable (Inverter with Converter Assembly Side)

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

      Note

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

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the motor cable.

    7. Install the inverter terminal cover.


    NG

    Click here

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY

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


    1. A01FR8YE38
      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
      A35-23 (NODD) - N91-6 (E1) Power switch off 110 to 150 kΩ

    3. Connect the power management control ECU connectors.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  20. REPLACE HV COOLANT


    1. Replace the HV coolant with coolant having an appropriate concentration (appropriate freeze point) for the vehicle usage conditions Click here.


    NEXT

    COMPLETED

  21. CHECK HYBRID VEHICLE TRANSMISSION 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 hybrid vehicle transmission assembly Click here.

    3. A01FTSA

      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
      T=8.0 N*m (82 kgf*cm, 71 in.*lbf)

      Note

      Make sure that the tightening torque of the bolt 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 hybrid vehicle transmission assembly.

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

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the generator cable to the hybrid vehicle transmission assembly.

    7. Install the hybrid vehicle transmission assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  22. 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 Click here.

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

      A01FVLBE01
      Text in Illustration
      *A for LHD *B for RHD
      *1 Shield ground - -
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      		 *b

      Generator Cable

      (Hybrid Vehicle Transmission Assembly Side)

      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
      for LHD
      Tester Connection Switch Condition Specified Condition
      v1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminals of the generator cable with insulating tape to prevent them from coming into contact with the body ground.

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

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      v1-3 (W) - v2-1 (W) Power switch off Below 1 Ω
      v1-2 (V) - v2-2 (V) Power switch off Below 1 Ω
      v1-1 (U) - v2-3 (U) Power switch off Below 1 Ω
      v1-3 (W) - v2-3 (U) Power switch off 100 MΩ or higher
      v1-2 (V) - v2-1 (W) Power switch off 100 MΩ or higher
      v1-1 (U) - v2-2 (V) Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v1-1 (W) - v2-1 (W) Power switch off Below 1 Ω
      v1-2 (V) - v2-2 (V) Power switch off Below 1 Ω
      v1-3 (U) - v2-3 (U) Power switch off Below 1 Ω
      v1-1 (W) - v2-3 (U) Power switch off 100 MΩ or higher
      v1-2 (V) - v2-1 (W) Power switch off 100 MΩ or higher
      v1-3 (U) - v2-2 (V) Power switch off 100 MΩ or higher

    5. Install the generator cable.


    NG

    REPLACE GENERATOR CABLE Click here

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  23. CHECK HYBRID VEHICLE TRANSMISSION 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. Remove the hybrid vehicle transmission assembly Click here.

    3. A01FQUD

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

      Note

      Make sure that the tightening torque of the bolt 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 hybrid vehicle transmission assembly.

    5. Check for arc marks at the terminals for the motor cable.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the motor cable to the hybrid vehicle transmission assembly.

    7. Install the hybrid vehicle transmission assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  24. 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 Click here.

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

      A01FQROE01
      Text in Illustration
      *A for LHD *B for RHD
      *1 Shield ground - -
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

      		 *b

      Motor Cable

      (Hybrid Vehicle Transmission Assembly Side)

      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
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminals of the motor cable with insulating tape to prevent them from coming into contact with the body ground.

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

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - u2-3 (W) Power switch off Below 1 Ω
      u1-2 (V) - u2-2 (V) Power switch off Below 1 Ω
      u1-1 (U) - u2-1 (U) Power switch off Below 1 Ω
      u1-3 (W) - u2-1 (U) Power switch off 100 MΩ or higher
      u1-2 (V) - u2-3 (W) Power switch off 100 MΩ or higher
      u1-1 (U) - u2-2 (V) Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - u2-3 (W) Power switch off Below 1 Ω
      u3-2 (V) - u2-2 (V) Power switch off Below 1 Ω
      u3-3 (U) - u2-1 (U) Power switch off Below 1 Ω
      u3-1 (W) - u2-1 (U) Power switch off 100 MΩ or higher
      u3-2 (V) - u2-3 (W) Power switch off 100 MΩ or higher
      u3-3 (U) - u2-2 (V) Power switch off 100 MΩ or higher

    5. Install the motor cable.


    NG

    REPLACE MOTOR CABLE Click here

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  25. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 1 JUNCTION BLOCK ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

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

    3. Remove the DC/DC-S (HV) fuse from the No. 1 junction block assembly.

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

      A01FRL9E01
      Text in Illustration
      *A for LHD *B for RHD
      *1 No. 1 Junction Block Assembly *2 DC/DC-S (HV) Fuse
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 - -
      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      A39-3 (S) or 2 (DC/DC-S (HV) fuse) - Body ground and other terminals Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A75-3 (S) or 2 (DC/DC-S (HV) fuse) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Install the DC/DC-S (HV) fuse.

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  26. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

    REPLACE FUSE (DC/DC-S (HV))

  27. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (DC/DC-S (HV))