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DTC    P0A94-553    DC / DC Converter Performance

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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
553
Boost converter fail signal detection (boost converter overheating)
  1. Wire harness or connector
  2. Inverter cooling system
  3. Hybrid vehicle transaxle assembly
  4. Generator cable
  5. Motor cable
  6. Inverter with converter assembly
  7. Cooling fan circuit
  8. PCU fuse
  9. Power management control ECU

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).

INSPECTION PROCEDURE

CAUTION:
  1. 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.
  2. After disconnecting 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.

NOTICE:
After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

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

1.CHECK DTC OUTPUT (HV)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

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

  1. Check if DTCs are output.

    Result:
    Result
    		Proceed to
    DTC P0A94-553 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
    P0C73-776
    		Motor Electronics Coolant Pump "A" Control Performance
    P0C76-523
    		Hybrid Battery System Discharge Time Too Long
    P314A-828
    		Inverter Coolant Pump Speed Signal

    HINT:
    1. *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
    2. P0A94-553 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. After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

  1. Turn the power switch off.



B
GO TO DTC CHART (Click here)
A


2.CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
A214648

CAUTION:
Be sure to wear insulated gloves.

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

    NOTICE:
    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.

NOTICE:
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.

  1. 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.

    HINT:
    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


3.CHECK QUANTITY OF HV COOLANT

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

  1. Check for 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
    Coolant leaks are evident.
    		C

    HINT:
    After repairing the coolant leaks and adding coolant, perform the "Activate the 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 COOLANT LEAK AND ADD COOLANT
A


4.CHECK COOLANT HOSE

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



NG
CORRECT THE PROBLEM
OK


5.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE ELECTRIC COOLING FAN)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

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

  1. Clear DTCs and freeze frame data.

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

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

    OK:
    The cooling fan rotates.

  1. Turn the power switch off.



NG
CHECK COOLING FAN SYSTEM (Click here)
OK


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

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Read the freeze frame data Ambient Temperature using the intelligent tester.

  1. 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

    HINT:
    1. 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).
    2. If the HV coolant freezes in the HV radiator or inverter water pump assembly, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be set.
    3. A DTC is set when the water pump impeller cannot rotate due to freezing of the HV coolant.
    4. If a DTC is set 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 set.

  1. Turn the power switch off.



B
Go to step 21
A


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

CAUTION:
Be sure to wear insulated gloves.

  1. Disconnect the low voltage connector D29 from the inverter with converter assembly.

  1. Turn the power switch on (IG).



    A217747E01

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    D29-11 (GRF) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-12 (GRFG) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-7 (GSN) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-8 (GSNG) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-10 (GCS) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-9 (GCSG) - Body ground
    		Power switch on (IG)
    		Below 1 V

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

    NOTICE:
    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.

  1. Turn the power switch off.

  1. Connect the low voltage connector from the inverter with converter assembly.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


8.CHECK GENERATOR RESOLVER

  1. Disconnect the low voltage connector D29 from the inverter with converter assembly.



    A217747E01

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

    Standard Resistance (Check for Open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    D29-11 (GRF) - D29-12 (GRFG)
    		Power switch off
    		7.1 to 21.6 Ω
    D29-7 (GSN) - D29-8 (GSNG)
    		Power switch off
    		13.7 to 34.5 Ω
    D29-10 (GCS) - D29-9 (GCSG)
    		Power switch off
    		12.8 to 32.4 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    D29-11 (GRF) or D29-12 (GRFG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D29-7 (GSN) or D29-8 (GSNG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D29-10 (GCS) or D29-9 (GCSG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher

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

  1. Connect the inverter with converter assembly connector.



NG
Go to step 22
OK


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

CAUTION:
Be sure to wear insulated gloves.

  1. Disconnect the low voltage connector D29 from the inverter with converter assembly.

  1. Turn the power switch on (IG).



    A217747E02

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    D29-1 (MRF) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-2 (MRFG) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-3 (MSN) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-4 (MSNG) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-6 (MCS) - Body ground
    		Power switch on (IG)
    		Below 1 V
    D29-5 (MCSG) - Body ground
    		Power switch on (IG)
    		Below 1 V

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

    NOTICE:
    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.

  1. Turn the power switch off.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


10.CHECK MOTOR RESOLVER

  1. Disconnect the low voltage connector D29 from the inverter with converter assembly.



    A217747E02

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

    Standard Resistance (Check for Open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    D29-1 (MRF) - D29-2 (MRFG)
    		Power switch off
    		7.1 to 21.6 Ω
    D29-3 (MSN) - D29-4 (MSNG)
    		Power switch off
    		13.7 to 34.5 Ω
    D29-6 (MCS) - D29-5 (MCSG)
    		Power switch off
    		12.8 to 32.4 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    D29-1 (MRF) or D29-2 (MRFG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D29-3 (MSN) or D29-4 (MSNG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D29-6 (MCS) or D29-5 (MCSG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher

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

  1. Connect the inverter with converter assembly connector.



NG
Go to step 24
OK


11.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.

    NOTICE:
    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.



    A209686

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



    A215643E02

  1. 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:
    8.0 N*m (82 kgf*cm, 71 in.*lbf)
    Bolt B:
    9.2 N*m (94 kgf*cm, 81 ft.*lbf)

    NOTICE:
    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).

  1. Disconnect the generator cable from the inverter with converter assembly.

  1. 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

  1. Connect the generator cable to the inverter with converter assembly.

  1. Install the inverter terminal cover.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


12.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.

    NOTICE:
    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.



    A209686

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



    A215644E02

  1. 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:
    8.0 N*m (82 kgf*cm, 71 in.*lbf)
    Bolt B:
    9.2 N*m (94 kgf*cm, 81 ft.*lbf)

    NOTICE:
    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).

  1. Disconnect the motor cable from the inverter with converter assembly.

  1. 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

  1. Connect the motor cable to the inverter with converter assembly.

  1. Install the inverter terminal cover.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


13.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

CAUTION:
Be sure to wear insulated gloves.

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

    NOTICE:
    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.



    A209686

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

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



    A215629E02

  1. 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.

      HINT:
      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
      f1-1 (W) - f1-2 (U)
      		Power switch off
      		89.5 to 98.9mΩ
      f1-2 (U) - f1-3 (V)
      		Power switch off
      		89.5 to 98.9mΩ
      f1-3 (V) - f1-1 (W)
      		Power switch off
      		89.5 to 98.9mΩ

      Text in Illustration 
      *1
      		Generator Cable
      *2
      		Shield Ground

      HINT:
      To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68° F).
      1. R20 = Rt / {1 + 0.00393 X (T - 20)}
      The calculation is based on the following:
      1. R20: Resistance at 20°C (68° F) (mΩ)
      2. Rt: Measured resistance (mΩ)
      3. T: Temperature when the resistance is measured (° C)

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

    NOTICE:
    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
    f1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    f1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    f1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

  1. Connect the generator cable and motor cable.

  1. Install the inverter terminal cover.



NG
Go to step 26
OK


14.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)

CAUTION:
Be sure to wear insulated gloves.

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

    NOTICE:
    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.



    A209686

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

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



    A215630E01

  1. 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.

      HINT:
      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
      e1-1 (W) - e1-2 (U)
      		Power switch off
      		152.6 to 169.0 mΩ
      e1-2 (U) - e1-3 (V)
      		Power switch off
      		157.6 to 174.0 mΩ
      e1-3 (V) - e1-1 (W)
      		Power switch off
      		151.6 to 168.0 mΩ

      Text in Illustration 
      *1
      		Motor Cable
      *2
      		Shield Ground

      HINT:
      To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68° F).
      1. R20 = Rt / {1 + 0.00393 X (T - 20)}
      The calculation is based on the following:
      1. R20: Resistance at 20°C (68° F) (mΩ)
      2. Rt: Measured resistance (mΩ)
      3. T: Temperature when the resistance is measured (° C)

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

    NOTICE:
    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
    e1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    e1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    e1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

  1. Connect the generator cable and motor cable.

  1. Install the inverter terminal cover.



NG
Go to step 28
OK


15.CHECK FUSE (PCU)


    A216622E01

  1. Remove the PCU fuse from the engine room junction block assembly.

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

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    PCU fuse terminal
    		Always
    		Below 1Ω

    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		PCU fuse

  1. Install the PCU fuse.



NG
Go to step 30
OK


16.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.

    NOTICE:
    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.

  1. Disconnect connector A59 from inverter with converter assembly.



    A215725E01

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A59-28 (GND1) - Body ground
    		Power switch off
    		Below 1 Ω
    A59-27 (GND2) - Body ground
    		Power switch off
    		Below 1 Ω

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

  1. Turn the power switch on (IG).

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A59-10 (+B) - Body ground
    		Power switch on (IG)
    		Same as auxiliary battery voltage
    A59-9 (+B2) - Body ground
    		Power switch on (IG)
    		Same as auxiliary battery voltage

    NOTICE:
    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.

  1. Turn the power switch off.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE POWER SOURCE CIRCUIT
OK


17.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.

    NOTICE:
    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.

  1. Turn the power switch off.

  1. Disconnect connector A59 from the inverter with converter assembly.

  1. Disconnect connector A22 from the power management control ECU.



    A216755E03

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

    Standard Resistance (Check for open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A22-24 (HTM+) - A59-8 (HTM+)
    		Power switch off
    		Below 1 Ω
    A22-25 (HTM-) - A59-18 (HTM-)
    		Power switch off
    		Below 1 Ω
    A22-30 (MTH+) - A59-7 (MTH+)
    		Power switch off
    		Below 1 Ω
    A22-29 (MTH-) - A59-17 (MTH-)
    		Power switch off
    		Below 1 Ω
    A22-33 (REQ+) - A59-6 (REQ+)
    		Power switch off
    		Below 1 Ω
    A22-32 (REQ-) - A59-16 (REQ-)
    		Power switch off
    		Below 1 Ω
    A22-21 (CLK+) - A59-5 (CLK+)
    		Power switch off
    		Below 1 Ω
    A22-20 (CLK-) - A59-15 (CLK-)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A22-24 (HTM+) or A59-8 (HTM+) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A22-25 (HTM-) or A59-18 (HTM-) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A22-30 (MTH+) or A59-7 (MTH+) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A22-29 (MTH-) or A59-17 (MTH-) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A22-33 (REQ+) or A59-6 (REQ+) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A22-32 (REQ-) or A59-16 (REQ-) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A22-21 (CLK+) or A59-5 (CLK+) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A22-20 (CLK-) or A59-15 (CLK-) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

    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)

  1. Turn the power switch on (IG).

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A22-24 (HTM+) or A59-8 (HTM+) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A22-25 (HTM-) or A59-18 (HTM-) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A22-30 (MTH+) or A59-7 (MTH+) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A22-29 (MTH-) or A59-17 (MTH-) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A22-33 (REQ+) or A59-6 (REQ+) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A22-32 (REQ-) or A59-16 (REQ-) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A22-21 (CLK+) or A59-5 (CLK+) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A22-20 (CLK-) or A59-15 (CLK-) - Body ground
    		Power switch on (IG)
    		Below 1 V

    NOTICE:
    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.

  1. Turn the power switch off.

  1. Connect the power management control ECU connector.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


18.CHECK POWER MANAGEMENT CONTROL ECU

  1. Disconnect connector A22 from the power management control ECU.



    A234460E01

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A22-24 (HTM+) - A22-25 (HTM-)
    		Power switch off
    		80 to 170 Ω
    A22-30 (MTH+) - A22-29 (MTH-)
    		Power switch off
    		80 to 170 Ω
    A22-33 (REQ+) - A22-32 (REQ-)
    		Power switch off
    		80 to 170 Ω
    A22-21 (CLK+) - A22-20 (CLK-)
    		Power switch off
    		80 to 170 Ω

    Text in Illustration 
    *1
    		Component without harness connected
    (Power Management Control ECU)

  1. Connect the power management control ECU connector.



NG
REPLACE POWER MANAGEMENT CONTROL ECU (Click here)
OK


19.CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    A217042

  1. Check the connection of the generator resolver connector.

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



NG
CONNECT SECURELY
OK


20.CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    A217043

  1. Check the connection of the motor resolver connector.

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



NG
CONNECT SECURELY
OK

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)  

21.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 

22.CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    A217042

  1. Check the connection of the generator resolver connector.

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



NG
CONNECT SECURELY
OK


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

  1. Disconnect the low voltage connector D29 from the inverter with converter assembly.



    A217748E01

  1. Disconnect the generator resolver connector.

  1. 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) - D29-11 (GRF)
    		Power switch off
    		Below 1 Ω
    D7-5 (GRFG) - D29-12 (GRFG)
    		Power switch off
    		Below 1 Ω
    D7-2 (GSN) - D29-7 (GSN)
    		Power switch off
    		Below 1 Ω
    D7-6 (GSNG) - D29-8 (GSNG)
    		Power switch off
    		Below 1 Ω
    D7-3 (GCS) - D29-10 (GCS)
    		Power switch off
    		Below 1 Ω
    D7-7 (GCSG) - D29-9 (GCSG)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    D7-1 (GRF) or D29-11 (GRF) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D7-5 (GRFG) or D29-12 (GRFG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D7-2 (GSN) or D29-7 (GSN) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D7-6 (GSNG) or D29-8 (GSNG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D7-3 (GCS) or D29-10 (GCS) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D7-7 (GCSG) or D29-9 (GCSG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher

    Text in Illustration 
    *1
    		Front view of wire harness connector
    (to Generator Resolver)
    *2
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

    HINT:
    The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

  1. Connect the generator resolver connector.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)  

24.CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    A217043

  1. Check the connection of the motor resolver connector.

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



NG
CONNECT SECURELY
OK


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

  1. Disconnect the low voltage connector D29 from the inverter with converter assembly.



    A217749E01

  1. Disconnect the motor resolver connector.

  1. 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) - D29-1 (MRF)
    		Power switch off
    		Below 1 Ω
    D1-6 (MRFG) - D29-2 (MRFG)
    		Power switch off
    		Below 1 Ω
    D1-1 (MSN) - D29-3 (MSN)
    		Power switch off
    		Below 1 Ω
    D1-4 (MSNG) - D29-4 (MSNG)
    		Power switch off
    		Below 1 Ω
    D1-2 (MCS) - D29-6 (MCS)
    		Power switch off
    		Below 1 Ω
    D1-5 (MCSG) - D29-5 (MCSG)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    D1-3 (MRF) or D29-1 (MRF) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D1-6 (MRFG) or D29-2 (MRFG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D1-1 (MSN) or D29-3 (MSN) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D1-4 (MSNG) or D29-4 (MSNG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D1-2 (MCS) or D29-6 (MCS) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher
    D1-5 (MCSG) or D29-5 (MCSG) - Body ground and other terminals
    		Power switch off
    		1 MΩ or higher

    Text in Illustration 
    *1
    		Front view of wire harness connector
    (to Motor Resolver)
    *2
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

    HINT:
    The motor resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

  1. Connect the motor resolver connector.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)  

26.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.

    NOTICE:
    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.

  1. Remove the inverter with converter assembly.



    A217462E01

  1. 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}

    NOTICE:
    1. 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).
    2. 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).

  1. Disconnect the generator cable from the hybrid transaxle assembly.

  1. 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

  1. Connect the generator cable to the hybrid transaxle assembly.

  1. Install the inverter with converter assembly.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


27.CHECK GENERATOR CABLE

CAUTION:
Be sure to wear insulated gloves.

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

    NOTICE:
    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.

  1. Remove the generator cable.



    A217727E01

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

    NOTICE:
    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
    f1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    f1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    f1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

    Text in Illustration 
    *1
    		Generator Cable
    (Inverter with Converter Assembly Side)
    *2
    		Shielded ground
    *3
    		Generator Cable
    (Hybrid Vehicle Transaxle Assembly Side)

    NOTICE:
    Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    f1-2 (U) - f2-2 (U)
    		Power switch off
    		Below 1 Ω
    f1-3 (V) - f2-1 (V)
    		Power switch off
    		Below 1 Ω
    f1-1 (W) - f2-3 (W)
    		Power switch off
    		Below 1 Ω
    f1-2 (U) - f2-1 (V)
    		Power switch off
    		100 MΩ or higher
    f1-3 (V) - f2-3 (W)
    		Power switch off
    		100 MΩ or higher
    f1-1 (W) - f2-2 (U)
    		Power switch off
    		100 MΩ or higher

  1. Install the generator cable.



NG
REPLACE GENERATOR CABLE (Click here)
OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)  

28.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.

    NOTICE:
    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.



    A217463

  1. 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}

    NOTICE:
    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).

  1. Disconnect the motor cable from the hybrid transaxle assembly.

  1. 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

  1. Connect the motor cable to the hybrid transaxle assembly.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


29.CHECK MOTOR CABLE

CAUTION:
Be sure to wear insulated gloves.

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

    NOTICE:
    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.

  1. Remove the motor cable.



    A217728E01

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

    NOTICE:
    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
    e1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    e1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    e1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

    Text in Illustration 
    *1
    		Motor Cable
    (Inverter with Converter Assembly Side)
    *2
    		Shielded ground
    *3
    		Motor Cable
    (Hybrid Vehicle Transaxle Assembly Side)

    NOTICE:
    Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    e1-2 (U) - e2-3 (U)
    		Power switch off
    		Below 1 Ω
    e1-3 (V) - e2-2 (V)
    		Power switch off
    		Below 1 Ω
    e1-1 (W) - e2-1 (W)
    		Power switch off
    		Below 1 Ω
    e1-2 (U) - e2-2 (V)
    		Power switch off
    		100 MΩ or higher
    e1-3 (V) - e2-1 (W)
    		Power switch off
    		100 MΩ or higher
    e1-1 (W) - e2-3 (U)
    		Power switch off
    		100 MΩ or higher

  1. Install the motor cable.



NG
REPLACE MOTOR CABLE (Click here)
OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)  

30.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.

    NOTICE:
    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.

  1. Disconnect connector A59 from the inverter with converter assembly.



    A215725E09

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A59-10 (+B) - Body ground
    		Power switch off
    		10 kΩ or higher
    A59-9 (+B2) - Body ground
    		Power switch off
    		10 kΩ or higher

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

  1. Connect the inverter with converter assembly connector.



NG
Go to step 32
OK


31.REPLACE INVERTER WITH CONVERTER ASSEMBLY

  1. Replace the inverter with converter assembly (Click here).


NEXT

REPLACE FUSE (PCU) 

32.REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT

REPLACE FUSE (PCU)