HYBRID CONTROL SYSTEM, Diagnostic DTC:P0CA3-442

DTC Code DTC Name
P0CA3-442 DC/DC Converter Step Up Voltage Performance

DTC SUMMARY

  1. MALFUNCTION DESCRIPTION

    This DTC indicates that it has been detected that the VH voltage cannot be boosted as commanded due to malfunction of the boost converter system. The cause of this malfunction may be one of the following:

    • Internal inverter malfunction

    • Inverter with converter assembly internal circuit malfunction

    • Inverter low-voltage circuit malfunction

    • The connectors are not connected properly

DESCRIPTION

The boost converter boosts the 244.8 V DC from the HV battery to a maximum of approximately 650 V DC. The inverter converts the voltage that has been boosted by the boost converter into alternating current, which is used for driving generator (MG1) and motor (MG2). When a motor or generator operates as a generator, the alternating current that it creates is converted into direct current by the inverter. Then the boost converter drops this voltage to direct current of approximately 244.8 V in order to charge the HV battery.

A105188E13

The MG ECU uses a voltage sensor (VL) that is built into the boost converter to detect the high voltage before it is boosted. It also uses a voltage sensor (VH) that is built into the inverter to detect the high voltage after it is boosted. Based on the voltage before and after it is boosted, the MG ECU controls the operation of the boost converter to boost the voltage to the target voltage.

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P0CA3-442

DC/DC Converter Step Up Voltage Performance

Abnormal voltage execution value:

Boosting cannot be performed as requested due to a boost converter system malfunction.

(1 trip detection logic)

  • Wire harness or connector

  • Inverter with converter assembly

Comes on

Master Warning Light:

Comes on
Tip:

With the vehicle stopped, apply the parking brake and turn the power switch on (READY).

With the shift lever in P, depress the brake pedal firmly, and quickly and fully depress the accelerator pedal.

Immediately after the accelerator pedal is fully depressed, "VH-Voltage after boosting" will be between 400 and 650 V.

Table 1. Related Data List

DTC No.

Data List

P0CA3-442

VH-Voltage after Boosting

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

    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 hereClick hereClick hereClick here

Tip:

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.

  1. Turn the power switch on (READY).

  2. With the engine stopped and the shift lever in P, depress the accelerator pedal to start the engine.

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 for DTCs.

      Powertrain > Hybrid Control > Trouble Codes

      Result

      Result

      Proceed to

      P0CA3-442 only is output, or DTCs except the ones in the table below are also output.

      A

      Any of the following DTCs are also output.

      B

      Malfunction Content

      Relevant DTC

      Microcomputer malfunction

      P0A1A-151, 166, 658, 791

      Generator Control Module

      P0A1B-198, 786, 794

      Drive Motor "A" Control Module

      P0A1D (all INF codes)*

      Hybrid Powertrain Control Module

      P1C2A-155

      Generator A/D Converter Circuit

      P1C2B-192

      Drive Motor "A" A/D Converter Circuit

      P1CA6-156

      Generator Control Module Malfunction

      P1CA7-193

      Drive Motor Control Module Malfunction

      P1CAC-200

      Generator Position Sensor Angle Malfunction

      P1CAD-168

      Drive Motor "A" Position Sensor Angle Malfunction

      P1CAF-792

      Generator Position Sensor REF Signal Cycle Malfunction

      P1CB0-795

      Drive Motor "A" Position Sensor REF Signal Cycle Malfunction

      P1CB2-793

      Generator Position Sensor REF Signal Stop Malfunction

      P1CB3-796

      Drive Motor "A" Position Sensor REF Signal Stop Malfunction

      P3133-659

      Communication Error from Generator to Drive Motor "A"

      P3134-661

      Communication Error from Drive Motor "A" to Generator

      Power source circuit malfunction

      P06B0-163

      Sensor Power Supply "A" Circuit / Open

      P06D6-511

      Sensor Reference Voltage "F" Circuit / Open

      P06E6-164

      Sensor Power Supply "C" Circuit / Open

      P1C73-512

      Sensor Standard Voltage "F" Circuit / Open

      Sensor and actuator circuit malfunction

      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

      P0A45-669

      Drive Motor "B" Position Sensor Circuit

      P0A46-671

      Drive Motor "B" Position Sensor Circuit Range / Performance

      P0A47-670

      Drive Motor "B" 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

      P0BEA-290

      Drive Motor "A" Phase V Current Sensor Circuit Range / Performance

      P0BEE-298

      Drive Motor "A" Phase W Current Sensor Circuit Range / Performance

      P0BF6-683

      Drive Motor "B" Phase V Current Sensor Circuit Range / Performance

      P0BFA-685

      Drive Motor "B" Phase W Current Sensor Circuit Range / Performance

      P0E05-328

      Generator Phase V Current Sensor Circuit Range / Performance

      P0E09-336

      Generator Phase W Current Sensor Circuit Range / Performance

      P1C3C-294

      Drive Motor "A" Phase V Current Sensor Correlation

      P1C3D-302

      Drive Motor "A" Phase W Current Sensor Correlation

      P1C3E-333

      Generator Phase V Current Sensor Correlation

      P1C3F-341

      Generator Phase W Current Sensor Correlation

      P1C4A-288

      Drive Motor "A" Phase V Current Sensor Sub Circuit Range / Performance

      P1C4F-296

      Drive Motor "A" Phase W Current Sensor Sub Circuit Range / Performance

      P1C54-326

      Generator Phase V Current Sensor Sub Circuit Range / Performance

      P1C59-334

      Generator Phase W Current Sensor Sub Circuit Range / Performance

      P1C6D-501

      Drive Motor "A" Phase V Current Sensor Offset Range / Performance

      P1C6E-502

      Drive Motor "A" Phase W Current Sensor Offset Range / Performance

      P1C6F-688

      Drive Motor "B" Phase V Current Sensor Offset Range / Performance

      P1C70-689

      Drive Motor "B" Phase W Current Sensor Offset Range / Performance

      P1C71-515

      Generator Phase V Current Sensor Offset Range / Performance

      P1C72-516

      Generator Phase W Current Sensor Offset Range / Performance

      P33C1-684

      Drive Motor "B" Phase V Current Sensor Sub Circuit Range / Performance

      P33C6-686

      Drive Motor "B" Phase W Current Sensor Sub Circuit Range / Performance

      P33D8-677

      Drive Motor "B" Phase V Current Sensor Correlation

      P33D9-678

      Drive Motor "A" Phase W Current Sensor Correlation

      System malfunction

      P0A1A-517, 809

      Generator Control Module

      P0A1B-503, 505, 547, 554, 806

      Drive Motor "A" Control Module

      P0A1C-693, 812

      Drive Motor "B" Control Module

      P0A40-504, 506, 549, 556, 808

      Drive Motor "A" Position Sensor Circuit Range / Performance

      P0A46-695, 814

      Drive Motor "B" Position Sensor Circuit Range / Performance

      P0A4C-518, 811

      Generator Position Sensor Circuit Range / Performance

      P0A78-279, 287, 548, 555, 807

      Drive Motor "A" Inverter Performance

      P0A79-694, 716, 813

      Drive Motor "B" Inverter Performance

      P0A7A-325, 810

      Generator Inverter Performance

      P0A90-509

      Drive Motor "A" Performance

      P0A92-521

      Hybrid Generator Performance

      P0C76-523

      Hybrid Battery System Discharge Time Too Long

      P0D2E-586

      Drive Motor "A" Inverter Voltage Sensor Circuit Range / Performance

      P0D2F-266

      Drive Motor "A" Inverter Voltage Sensor Circuit Low

      P0D30-267

      Drive Motor "A" Inverter Voltage Sensor Circuit High

      P0E32-585

      DC/DC Converter Voltage Sensor "A" Range / Performance

      P0E33-589

      DC/DC Converter Voltage Sensor "A" Low

      P0E34-590

      DC/DC Converter Voltage Sensor "A" High

      P1C2D-587

      Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      Tip:

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

      • P0CA3-442 may be output as a result of the malfunction indicated by the DTCs above.

        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    5. Turn the power switch off.

    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM)

    Click hereClick hereClick here

    A

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

    Click here

    Result

    Result

    Proceed to

    OK

    A

    NG (The connector is not connected securely.)

    B

    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)

    C
    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR