| DTC Code | DTC Name |
|---|---|
| P0A94-127 | DC / DC Converter Performance |
DESCRIPTION
For a description of the boost converter Click here.
If a malfunction occurs in the boost converter, the MG ECU detects it and transmits this information to the power management control ECU.
| DTC No. | INF Code | DTC Detection Condition | Trouble Area |
|---|---|---|---|
| P0A94 | 127 | Boost converter overvoltage signal detection (overvoltage due to system malfunction) |
|
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.
CAUTION / NOTICE / HINT
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 the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.
Turn the power switch on (READY) and wait for 5 seconds or more.
With the engine stopped and park (P) selected, depress the accelerator pedal to start the engine.
PROCEDURE
CHECK DTC OUTPUT (HYBRID CONTROL)
Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
Check if DTCs are output.
| Result | ||||||
|---|---|---|---|---|---|---|
|
| DTC No. | Relevant Diagnosis |
|---|---|
| P31AB-123 | Hybrid Battery Cell Low Voltage |
Tech Tips
P0A94-127 may be output due to a malfunction which causes the DTC in the table above to be output. In this case, first troubleshoot the output DTC in the table above. Then, perform a reproduction test to check that no DTCs are output.
Turn the power switch off.
| B |
|
GO TO DTC CHART (P31AB-123) Click here |
| A |
|
CHECK DTC OUTPUT (HYBRID CONTROL)
Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
Check if DTCs are output.
| Result | ||||||
|---|---|---|---|---|---|---|
|
| 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 |
| P0A94-172, 442, 547, 548, 549, 553, 554, 555, 556, 557, 564, 585, 587, 589, 590 | DC / DC Converter Performance |
| P0AA6-526 | Hybrid Battery Voltage System Isolation Fault |
| P0ADB-227 | Hybrid Battery Positive Contactor Control Circuit Low |
| P0ADC-226 | Hybrid Battery Positive Contactor Control Circuit High |
| P0ADF-229 | Hybrid Battery Negative Contactor Control Circuit Low |
| P0AE0-228 | Hybrid Battery Negative Contactor Control Circuit High |
| P0C76-523 | Hybrid Battery System Discharge Time Too Long |
| P3004-131, 803 | High Voltage Power Resource |
Tech Tips
*1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
P0A94-127 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.
Turn the power switch off.
| B |
|
GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here |
| A |
|
CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
CAUTION:
Be sure to wear insulated gloves.
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.
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 |
|
CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)
CAUTION:
Be sure to wear insulated gloves.
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.
Disconnect the D29 inverter with converter assembly connector.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).
| *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 | |||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
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.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Turn the power switch off.
Reconnect the D29 inverter with converter assembly connector.
| NG |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR |
| OK |
|
CHECK GENERATOR RESOLVER
CAUTION:
Be sure to wear insulated gloves.
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.
Disconnect the D29 inverter with converter assembly connector.
| *a | Front view of wire harness connector (to Inverter with Converter Assembly) |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance (Check for Open) | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| Standard Resistance (Check for Short) | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Reconnect the D29 inverter with converter assembly connector.
| NG |
|
CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here |
| OK |
|
CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)
CAUTION:
Be sure to wear insulated gloves.
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.
Disconnect the D29 inverter with converter assembly connector.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).
| *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 | |||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
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.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Turn the power switch off.
Reconnect the D29 inverter with converter assembly connector.
| NG |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR |
| OK |
|
CHECK MOTOR RESOLVER
CAUTION:
Be sure to wear insulated gloves.
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.
Disconnect the D29 inverter with converter assembly connector.
| *a | Front view of wire harness connector (to Inverter with Converter Assembly) |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance (Check for Open) | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| Standard Resistance (Check for Short) | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Reconnect the D29 inverter with converter assembly connector.
| NG |
|
CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here |
| OK |
|
CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the inverter cover from the inverter with converter assembly.
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).
Disconnect the generator cable from the inverter with converter assembly.
Check for arc marks at the bolts and terminals for the generator cable.
| Result | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
|||||||||||||||
Connect the generator cable to the inverter with converter assembly.
Install the inverter cover.
| B |
|
REPLACE MALFUNCTIONING PARTS |
| C |
|
CONNECT SECURELY |
| A |
|
CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the inverter cover from the inverter with converter assembly.
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).
Disconnect the motor cable from the inverter with converter assembly.
Check for arc marks at the bolts and terminals for the motor cable.
| Result | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
|||||||||||||||
Connect the motor cable to the inverter with converter assembly.
Install the inverter cover.
| B |
|
REPLACE MALFUNCTIONING PARTS |
| C |
|
CONNECT SECURELY |
| A |
|
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the inverter cover from the inverter with converter assembly.
Disconnect the generator cable and motor cable from the inverter with converter assembly.
| *1 | Generator Cable (Inverter with Converter Assembly Side) |
| *2 | Shield Ground |
Check MG1 for an interphase short using a milliohmmeter.
Using a milliohmmeter, measure the resistance according to the value(s) in the table below.
Tech Tips
If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.
| Standard Resistance | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Tech Tips
To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).
R20 = Rt / {1 + 0.00393 X (T - 20)}
The calculation is based on the following:
R20: Resistance at 20°C (68°F) (mΩ)
Rt: Measured resistance (mΩ)
T: Temperature when the resistance is measured (°C)
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 | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Connect the generator cable and motor cable.
Install the inverter cover.
| NG |
|
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) Click here |
| OK |
|
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the inverter cover from the inverter with converter assembly.
Disconnect the generator cable and motor cable from the inverter with converter assembly.
| *1 | Motor Cable (Inverter with Converter Assembly Side) |
| *2 | Shield Ground |
Check MG2 for an interphase short using a milliohmmeter.
Using a milliohmmeter, measure the resistance according to the value(s) in the table below.
Tech Tips
If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.
| Standard Resistance | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Tech Tips
To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).
R20 = Rt / {1 + 0.00393 X (T - 20)}
The calculation is based on the following:
R20: Resistance at 20°C (68°F) (mΩ)
Rt: Measured resistance (mΩ)
T: Temperature when the resistance is measured (°C)
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 | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Connect the generator cable and motor cable.
Install the inverter cover.
| NG |
|
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) Click here |
| OK |
|
CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH VOLTAGE CONNECTOR CONNECTION CONDITION)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the inverter cover from the inverter with converter assembly.
Check that the bolts for the frame wire are tightened to the specified torque, the frame wire 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).
Disconnect the frame wire from the inverter with converter assembly.
Check for arc marks at the bolts and terminals for the frame wire.
| Result | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
|||||||||||||||
Connect the frame wire to the inverter with converter assembly.
Install the inverter cover.
| B |
|
REPLACE MALFUNCTIONING PARTS |
| C |
|
CONNECT SECURELY |
| A |
|
CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)
CAUTION:
Be sure to wear insulated gloves.
Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.
| OK |
|---|
| Dirt or foreign objects have not entered the connection, and there is no evidence of contamination. |
| NG |
|
REPLACE SERVICE PLUG GRIP Click here |
| OK |
|
INSPECT SERVICE PLUG GRIP
| *1 | Service plug grip |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | ||||||
|---|---|---|---|---|---|---|
|
| NG |
|
REPLACE SERVICE PLUG GRIP Click here |
| OK |
|
CHECK FRAME WIRE
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the No. 2 hybrid battery shield sub-assembly Click here.
| *a | Frame Wire Connection Condition (Hybrid Battery Junction Block Assembly) |
Disconnect the frame wire from the hybrid battery junction block assembly.
Remove the inverter cover from the inverter with converter assembly.
Disconnect the frame wire from the inverter with converter assembly.
| *1 | Frame Wire (Inverter with Converter Assembly Side) |
| *2 | Frame Wire (Hybrid Battery Junction Block Assembly Side) |
| *3 | Shield Ground |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | |||||||||
|---|---|---|---|---|---|---|---|---|---|
|
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 | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Connect the frame wire to the hybrid battery junction block assembly.
Connect the frame wire to the inverter with converter assembly.
Install the inverter cover.
Install the No. 2 hybrid battery shield sub-assembly.
| NG |
|
REPLACE FRAME WIRE Click here |
| OK |
|
INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the hybrid battery junction block assembly Click here.
| *a | Component without harness connected (Hybrid Battery Junction Block Assembly) |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | |||||||||
|---|---|---|---|---|---|---|---|---|---|
|
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | ||||||
|---|---|---|---|---|---|---|
|
Install the hybrid battery junction block assembly.
| NG |
|
REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here |
| OK |
|
INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the hybrid battery junction block assembly Click here.
| *a | Component without harness connected (Hybrid Battery Junction Block Assembly) |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | |||||||||
|---|---|---|---|---|---|---|---|---|---|
|
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | ||||||
|---|---|---|---|---|---|---|
|
Install the hybrid battery junction block assembly.
| NG |
|
REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here |
| OK |
|
CHECK FUSE (PCU)
| *1 | Engine Room Relay Block and Junction Block Assembly |
| *2 | PCU fuse |
Remove the PCU fuse from the engine room relay block and junction block assembly.
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | ||||||
|---|---|---|---|---|---|---|
|
Install the PCU fuse.
| NG |
|
CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) Click here |
| OK |
|
CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)
CAUTION:
Be sure to wear insulated gloves.
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.
Disconnect the A59 inverter with converter assembly connector.
| *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 | |||||||||
|---|---|---|---|---|---|---|---|---|---|
|
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).
Measure the voltage according to the value(s) in the table below.
| Standard Voltage | |||||||||
|---|---|---|---|---|---|---|---|---|---|
|
Note
Turning the power switch on (IG) with the inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.
Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Reconnect the A59 inverter with converter assembly connector.
| NG |
|
REPAIR OR REPLACE POWER SOURCE CIRCUIT |
| OK |
|
CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - POWER MANAGEMENT CONTROL ECU)
CAUTION:
Be sure to wear insulated gloves.
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.
Disconnect the A59 inverter with converter assembly connector.
Disconnect the A22 power management control ECU connector.
Measure the resistance according to the value(s) in the table below.
| Standard Resistance (Check for Open) | |||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| Standard Resistance (Check for Short) | |||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| *a | Front view of wire harness connector (to Inverter with Converter Assembly) |
| *b | Rear view of wire harness connector (to Power Management Control ECU) |
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).
Measure the voltage according to the value(s) in the table below.
| Standard Voltage | |||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
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.
Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Reconnect the A22 power management control ECU connector.
Reconnect the A59 inverter with converter assembly connector.
| NG |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR |
| OK |
|
CHECK POWER MANAGEMENT CONTROL ECU
Disconnect the A22 power management control ECU connector.
| *a | Component without harness connected (Power Management Control ECU) |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Reconnect the A22 power management control ECU connector.
| NG |
|
REPLACE POWER MANAGEMENT CONTROL ECU Click here |
| OK |
|
CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
Check the connection of the generator resolver connector.
| OK |
|---|
| The connector is connected securely and there are no contact problems. |
| NG |
|
CONNECT SECURELY |
| OK |
|
CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
Check the connection of the motor resolver connector.
| OK |
|---|
| The connector is connected securely and there are no contact problems. |
| OK |
|
REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here |
| NG |
|
CONNECT SECURELY |
CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
Check the connection of the generator resolver connector.
| OK |
|---|
| The connector is connected securely and there are no contact problems. |
| NG |
|
CONNECT SECURELY |
| OK |
|
INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)
Disconnect the D7 generator resolver connector.
| *a | Component without harness connected (Generator Resolver (Hybrid Vehicle Transaxle Assembly)) |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance (Check for Open) | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| Standard Resistance (Check for Short) | |||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Tech Tips
The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.
Connect the D7 generator resolver connector.
| OK |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR |
| NG |
|
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here |
CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
Check the connection of the motor resolver connector.
| OK |
|---|
| The connector is connected securely and there are no contact problems. |
| NG |
|
CONNECT SECURELY |
| OK |
|
INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)
Disconnect the D1 motor resolver connector.
| *a | Component without harness connected (Motor Resolver (Hybrid Vehicle Transaxle Assembly)) |
Measure the resistance according to the value(s) in the table below.
| Standard Resistance (Check for Open) | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
| Standard Resistance (Check for Short) | |||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Tech Tips
The motor resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.
Connect the D1 motor resolver connector.
| OK |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR |
| NG |
|
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here |
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the inverter with converter assembly.
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).
Disconnect the generator cable from the hybrid vehicle transaxle assembly.
Check for arc marks at the bolts and terminals for the generator cable.
| Result | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
|||||||||||||||
Connect the generator cable to the hybrid vehicle transaxle assembly.
Install the inverter with converter assembly.
| B |
|
REPLACE MALFUNCTIONING PARTS |
| C |
|
CONNECT SECURELY |
| A |
|
CHECK GENERATOR CABLE
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the generator cable.
| *1 | Generator Cable (Inverter with Converter Assembly Side) |
| *2 | Generator Cable (Hybrid Vehicle Transaxle Assembly Side) |
| *3 | Shield ground |
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 | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Note
Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | |||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Install the generator cable.
| OK |
|
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here |
| NG |
|
REPLACE GENERATOR CABLE Click here |
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)
CAUTION:
Be sure to wear insulated gloves.
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.
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).
Disconnect the motor cable from the hybrid vehicle transaxle assembly.
Check for arc marks at the bolts and terminals for the motor cable.
| Result | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
|||||||||||||||
Connect the motor cable to the hybrid vehicle transaxle assembly.
| B |
|
REPLACE MALFUNCTIONING PARTS |
| C |
|
CONNECT SECURELY |
| A |
|
CHECK MOTOR CABLE
CAUTION:
Be sure to wear insulated gloves.
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.
Remove the motor cable.
| *1 | Motor Cable (Inverter with Converter Assembly Side) |
| *2 | Motor Cable (Hybrid Vehicle Transaxle Assembly Side) |
| *3 | Shield ground |
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 | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Note
Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground
Measure the resistance according to the value(s) in the table below.
| Standard Resistance | |||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Install the motor cable.
| OK |
|
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here |
| NG |
|
REPLACE MOTOR CABLE Click here |
CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)
CAUTION:
Be sure to wear insulated gloves.
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.
Disconnect the A59 inverter with converter assembly connector.
| *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 | |||||||||
|---|---|---|---|---|---|---|---|---|---|
|
Reconnect the A59 inverter with converter assembly connector.
| NG |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR Click here |
| OK |
|
REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS
Refer to replace inverter with converter assembly parts Click here.
| NEXT |
|
REPLACE FUSE (PCU) |
REPAIR OR REPLACE HARNESS OR CONNECTOR
| NEXT |
|
REPLACE FUSE (PCU) |