HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A09-591

DESCRIPTION

The hybrid vehicle converter (DC/DC converter) controls output voltage (12 V) based on duty ratio signals sent from the power management control ECU (HV CPU) .

INSPECTION PROCEDURE

PROCEDURE

1. Click here

   CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)

   
   
   1. 

      Check the connections of the power management control ECU connectors.

      Table 1. Text in Illustration

      *1

      for LHD

      *2

      for RHD

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

   
   
   • OKClick here
   • NGClick here
2. Click here

   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.

      

      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.

   
   
   • OKClick here
   • NGClick here
3. Click here

   CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

   
   

   1. Turn the power switch on (IG).

   2. 

      Connect an oscilloscope between the power management control ECU terminals specified in the table below, and measure the waveform.

      Item	Content
      Terminal	A80-11 (VLO) - F97-6 (E1)
      Equipment Setting	5V/DIV., 50ms/DIV.
      Condition	Power switch on (IG)

      Table 2. Text in Illustration

      *1	Component with harness connected (Power Management Control ECU)

      OK
      The waveform appears as shown in the illustration.

      Tip:
      

      • Perform this inspection with the power management control ECU connector connected.

   3. Turn the power switch off.

   
   
   • OKClick here
   • NGClick here
4. Click here

   CLEAR DTC

   
   

   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. Clear DTCs and freeze frame data.

   
   
   • NEXTClick here
5. Click here

   CHECK DTC OUTPUT (HV)

   
   

   1. Turn the power switch on (READY).

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

   3. Check if DTCs are output.

      Result
      Result Proceed to DTC P0A09-591 is not output. A DTC P0A09-591 is output again. for LHD B for RHD C

   4. Turn the power switch off.

   
   
   • AClick here
   • BClick here
   • CClick here
6. Click here

   CHECK FOR INTERMITTENT PROBLEMS

   
   

   1. Check for intermittent problems (Click here).

      Result
      Result Proceed to OK (for LHD) A OK (for RHD) B NG C

   
   
   • AClick here
   • BClick here
   • CClick here
7. Click here

   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 the A79 connector from the inverter with converter assembly.

   3. 

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition A79-4 (VLO) - Body ground Power switch off 370 to 430 kΩ

      Table 3. Text in Illustration

      *1	Front view of wire harness connector (to Inverter with Converter Assembly)

   4. Connect the inverter with converter assembly connector.

   
   
   • OKClick here
   • NGClick here
8. Click here

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

   
   

   1. Disconnect the A79 connector from the inverter with converter assembly.

   2. Disconnect the A80 connector from the power management control ECU.

   3. 

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition A79-4 (VLO) - A80-11 (VLO) Power switch off Below 1 Ω A79-4 (VLO) or A80-11 (VLO) - Body ground and other terminals Power switch off 10 kΩ or higher

      Table 4. Text in Illustration

      *1	Front view of wire harness connector (to Inverter with Converter Assembly)
      *2	Rear view of wire harness connector (to Power Management Control ECU)

      Result
      Result Proceed to OK (for LHD) A OK (for RHD) B NG C

   4. Connect the inverter with converter assembly connector.

   5. Connect the power management control ECU connector.

   
   
   • AClick here
   • BClick here
   • CClick here
9. Click here

   CONNECT SECURELY

10. Click here

    REPLACE POWER MANAGEMENT CONTROL ECU (for LHD)Click here

11. Click here

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

12. Click here

    REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here

13. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

14. Click here

    REPLACE POWER MANAGEMENT CONTROL ECU (for RHD)Click here