DTC    P0A94-127    DC / DC Converter Performance

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DESCRIPTION

WIRING DIAGRAM

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.
   

HINT:

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

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. Check if DTCs are output.
   

   Result:

   Result	Proceed to
   DTC P0A94-127 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
   P0A94-172, 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
   P3004-803	Power Cable Malfunction

   HINT:

   1. *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      
   2. 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.
      

5. Turn the power switch off.
   

B	GO TO DTC CHART (Click here)

A

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.

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.
   

   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

CAUTION:

Be sure to wear insulated gloves.

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

2. Turn the power switch on (IG).
   

3. 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.

4. Turn the power switch off.
   

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

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

2. 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)

3. Connect the inverter with converter assembly connector.
   

NG	Go to step 24

OK

CAUTION:

Be sure to wear insulated gloves.

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

2. Turn the power switch on (IG).
   

3. 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.

4. Turn the power switch off.
   

5. Connect the inverter with converter assembly connector.
   

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

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

2. 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)

3. Connect the inverter with converter assembly connector.
   

NG	Go to step 26

OK

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.

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

3. 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).

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

5. 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

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

7. Install the inverter terminal cover.
   

B	REPLACE MALFUNCTIONING PARTS
C	CONNECT SECURELY

A

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.

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

3. 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).

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

5. 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

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

7. Install the inverter terminal cover.
   

B	REPLACE MALFUNCTIONING PARTS
C	CONNECT SECURELY

A

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.

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

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

4. 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)
         

5. 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

6. Connect the generator cable and motor cable.
   

7. Install the inverter terminal cover.
   

NG	Go to step 28

OK

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.

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

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

4. 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)
         

5. 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

6. Connect the generator cable and motor cable.
   

7. Install the inverter terminal cover.
   

NG	Go to step 30

OK

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.

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

3. 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:

   T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
   

   NOTICE:

   Make sure that the tightening torque of the bolts is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

4. Disconnect the frame wire from the inverter with converter assembly.
   

5. Check for arc marks at the bolts for the frame wire.
   

   Result:

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

6. Connect the frame wire to the inverter with converter assembly.
   

7. Install the inverter terminal cover.
   

B	REPLACE MALFUNCTIONING PARTS
C	CONNECT SECURELY

A

CAUTION:

Be sure to wear insulated gloves.

1. 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

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Service plug grip terminals	Always	Below 1 Ω

   Text in Illustration 

   *1	Service plug grip

NG	REPLACE SERVICE PLUG GRIP (Click here)

OK

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.

2. Remove the upper hybrid battery cover sub-assembly (Click here).
   

3. Check the connection between the frame wire T4, T3 and the hybrid battery junction block.
   

Torque:

9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

4. Check for arc marks on the terminals of the frame wire.
   

   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

5. Install the upper hybrid battery cover sub-assembly (Click here).
   

B	REPLACE MALFUNCTIONING PARTS
C	CONNECT SECURELY

A

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.

2. Disconnect the frame wire from the hybrid battery junction block.
   

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

4. Disconnect the frame wire from the inverter with converter assembly.
   

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

   Standard Resistance:

   Tester Connection	Switch Condition	Specified Condition
   T4-1 - T1-2 (CBI) (Positive terminal)	Power switch off	Below 1 Ω
   T3-1 - T1-1 (CEI) (Negative terminal)	Power switch off	Below 1 Ω

   Text in Illustration 

   *1	Frame Wire (Inverter with Converter Assembly Side)
   *2	Frame Wire (Hybrid Battery Junction Block Side)

6. 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
   T4-1 - Body ground and shielded ground	Power switch off	10 MΩ or higher
   T3-1 - Body ground and shielded ground	Power switch off	10 MΩor higher
   T3-1 - T4-1	Power switch off	10 MΩ or higher

7. Connect the frame wire to the hybrid battery junction block.
   

8. Connect the frame wire to the inverter with converter assembly.
   

9. Install the inverter terminal cover.
   

NG	REPLACE FRAME WIRE (Click here)

OK

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.

2. Remove the hybrid battery junction block.
   

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   h2 - T4	Auxiliary battery voltage is not applied between terminals c3-4 (SMRB) and c3-2 (GND)	10 kΩ or higher
   h2 - T4	Auxiliary battery voltage is applied between terminals c3-4 (SMRB) and c3-2 (GND)	Below 1 Ω

   Text in Illustration 

   *1	Hybrid Battery Junction Block

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   c3-4 (SMRB) - c3-2 (GND)	-40 to 80°C (-40 to 176°F)	19.0 to 35.5 Ω

5. Install the hybrid battery junction block.
   

NG	REPLACE HYBRID BATTERY JUNCTION BLOCK (Click here)

OK

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.

2. Remove the hybrid battery junction block.
   

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   k2 - T3	Auxiliary battery voltage is not applied between terminals c3-1 (SMRG) and c3-2 (GND)	10 kΩ or higher
   k2 - T3	Auxiliary battery voltage is applied between terminals c3-1 (SMRG) and c3-2 (GND)	Below 1 Ω

   Text in Illustration 

   *1	Hybrid Battery Junction Block

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   c3-1 (SMRG) - c3-2 (GND)	-40 to 80°C (-40 to 176°F)	19.0 to 35.5 Ω

5. Install the hybrid battery junction block.
   

NG	REPLACE HYBRID BATTERY JUNCTION BLOCK (Click here)

OK

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

2. 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

3. Install the PCU fuse.
   

NG	Go to step 32

OK

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.

2. Disconnect connector A59 from 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
   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)

4. Turn the power switch on (IG).
   

5. 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.

6. Turn the power switch off.
   

7. Connect the inverter with converter assembly connector.
   

NG	REPAIR OR REPLACE POWER SOURCE CIRCUIT

OK

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.

2. Turn the power switch off.
   

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

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

5. 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)

6. Turn the power switch on (IG).
   

7. 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.

8. Turn the power switch off.
   

9. Connect the power management control ECU connector.
   

10. Connect the inverter with converter assembly connector.
    

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

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

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

   Standard Resistance:

   Tester Connection	Switch Condition	Specified Condition
   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)

3. Connect the power management control ECU connector.
   

NG	REPLACE POWER MANAGEMENT CONTROL ECU (Click here)

OK

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

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)

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

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

2. Disconnect the generator resolver connector.
   

3. 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.

4. Connect the generator resolver connector.
   

5. Connect the inverter with converter assembly connector.
   

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)

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

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

2. Disconnect the motor resolver connector.
   

3. 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.

4. Connect the motor resolver connector.
   

5. Connect the inverter with converter assembly connector.
   

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)

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.

2. Remove the inverter with converter assembly.
   

3. 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).
      

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

5. 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

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

7. Install the inverter with converter assembly.
   

B	REPLACE MALFUNCTIONING PARTS
C	CONNECT SECURELY

A

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.

2. Remove the generator cable.
   

3. 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

4. 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

5. Install the generator cable.
   

NG	REPLACE GENERATOR CABLE (Click here)

OK
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)

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.

2. 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).

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

4. 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

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

B	REPLACE MALFUNCTIONING PARTS
C	CONNECT SECURELY

A

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.

2. Remove the motor cable.
   

3. 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

4. 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

5. Install the motor cable.
   

NG	REPLACE MOTOR CABLE (Click here)

OK
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)

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.

2. Disconnect connector A59 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
   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)

4. Connect the inverter with converter assembly connector.
   

NG	Go to step 34

OK

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

NEXT
REPLACE FUSE (PCU)

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REPLACE FUSE (PCU)