DTC    P0A08-264    DC / DC Converter Status Circuit

for Preparation Click here


DESCRIPTION

The hybrid vehicle converter (DC/DC converter) converts the DC 201.6 V of the HV battery into DC 12 V in order to supply power to areas such as the vehicle's lighting, audio, and ECU systems. In addition, it charges the auxiliary battery. A transistor bridge circuit initially converts DC 201.6 V into alternating current, and a transformer lowers its voltage. Then, it is rectified and smoothed (into DC) and converted into DC 12 V. The hybrid vehicle converter controls the output voltage in order to keep a constant voltage at the terminals of the auxiliary battery.
The power management control ECU (HV CPU) uses the NODD signal line to transmit a stop command to the hybrid vehicle converter and receive signals indicating the normal or abnormal condition of the 12 V charging system. If the vehicle is being driven with an inoperative hybrid vehicle converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the power management control ECU (HV CPU) monitors the operation of the hybrid vehicle converter and alerts the driver if it detects a malfunction.

A217225E05


DTC No.
INF Code
DTC Detection Condition
Trouble Area
P0A08
264
DC/DC converter malfunction
  1. Wire harness or connector
  2. Inverter water pump assembly
  3. Inverter cooling system
  4. Hybrid vehicle transaxle assembly
  5. Generator cable
  6. Motor cable
  7. Frame wire
  8. Inverter with converter assembly
  9. Fusible link block assembly (MAIN)
  10. Fuse (DC/DC-S, IGCT, IGCT No. 2)
  11. Fusible link block assembly (DC/DC)
  12. Power management control ECU

WIRING DIAGRAM


A217226E03


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 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).

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

NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work (Click here).

1.CHECK DTC OUTPUT (HYBRID CONTROL)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Enter the following menus: Powertrain / Hybrid Control / DTC.

  1. Check if DTCs are output.

    Result:
    Result
    		Proceed to
    DTC P0A08-264 only is output.
    		A
    Any of the following DTCs are also output.
    		B


    DTC No.
    		Relevant Diagnosis
    P0A93-346
    		Inverter Cooling System Performance
    P0A94-547, 548, 549
    		DC / DC Converter Performance
    P0AA6-526, 613
    		Hybrid Battery Voltage System Isolation Fault
    P0ADB-227
    		Hybrid Battery Positive Contactor Control Circuit Low
    P0ADF-229
    		Hybrid Battery Negative Contactor Control Circuit Low
    P0AE6-225
    		Hybrid Battery Precharge Contactor Control Circuit Low
    P0C73-776
    		Motor Electronics Coolant Pump "A" Control Performance
    P3004-131, 803
    		Power Cable Malfunction
    P314A-828
    		Inverter Coolant Pump Speed Signal

  1. Turn the power switch off.



B
GO TO DTC CHART (HYBRID CONTROL SYSTEM) (Click here)
A


2.CHECK FUSE (IGCT NO. 2)

  1. Disconnect the cable from the negative auxiliary battery terminal.

  1. Remove the IGCT No. 2 fuse from the engine room junction block assembly.



    A248214E01

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

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    IGCT No. 2 fuse terminals
    		Always
    		Below 1 Ω

    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		IGCT No. 2 Fuse

  1. Install the IGCT No. 2 fuse.



NG
Go to step 27
OK


3.CHECK FUSE (DC/DC-S)


    A248215E01

  1. Remove the DC/DC-S 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
    DC/DC-S fuse terminals
    		Always
    		Below 1 Ω

    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		DC/DC-S Fuse

  1. Install the DC/DC-S fuse.



NG
Go to step 29
OK


4.CHECK FUSE (IGCT)


    A248216E01

  1. Remove the IGCT 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
    IGCT fuse terminals
    		Always
    		Below 1 Ω

    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		IGCT Fuse

  1. Install the IGCT fuse.



NG
Go to step 31
OK


5.CHECK FUSIBLE LINK (DC/DC)


    A216616E06

  1. Disconnect connector 1E 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
    1E-1 - B1-1 (AMD)
    		Always
    		Below 1 Ω

  1. Check the fusible links (DC/DC) in the engine room junction block assembly for improper installation.

    OK:
    The fusible link is installed securely.

  1. Connect the engine room junction block assembly connector.



NG
REPLACE FUSIBLE LINK (DC/DC)
OK


6.CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)


  1. Check the connections of the power management control ECU connectors.


    A237663E01


    Text in Illustration 
    *A
    		for LHD
    		*B
    		for RHD

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



NG
CONNECT SECURELY
OK


7.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


8.CHECK CABLE AND WIRE HARNESS

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 cover from the inverter with converter assembly.



    A217177E03

  1. Using a megohmmeter set to 500 V, measure the insulation 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
    d1-1 (W) - Body ground and shield ground
    		Power switch off
    		1 MΩ or higher
    d1-2 (U) - Body ground and shield ground
    		Power switch off
    		1 MΩ or higher
    d1-3 (V) - Body ground and shield ground
    		Power switch off
    		1 MΩ or higher
    c1-1 (W) - Body ground and shield ground
    		Power switch off
    		1 MΩ or higher
    c1-2 (U) - Body ground and shield ground
    		Power switch off
    		1 MΩ or higher
    c1-3 (V) - Body ground and shield ground
    		Power switch off
    		1 MΩ or higher

    Text in Illustration  
    *1
    		Three-phase AC Cable for MG1
    *2
    		Three-phase AC Cable for MG2

    HINT:
    Perform this inspection while the three-phase AC cable for MG1 and for MG2 are connected.

  1. Install the inverter cover to the inverter with converter assembly.



NG
Go to step 18
OK


9.CHECK ENGINE ROOM JUNCTION BLOCK ASSEMBLY (AMD TERMINAL 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.



    A216630

  1. Check that the bolt for the AMD terminal is tightened to the specified torque, the AMD terminal is connected securely, and there is no contact problem.

    Torque:
    T=8.3 N*m {85 kgf*cm, 73 in.*lbf }

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



B
CONNECT SECURELY

C
REPLACE MALFUNCTIONING PARTS
A


10.CHECK TERMINAL VOLTAGE (AMD TERMINAL VOLTAGE)

CAUTION:
Be sure to wear insulated gloves.



    A216630E01

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    1F-1 - Body ground
    		Power switch off
    		11 to 14 V



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


11.CHECK HARNESS AND CONNECTOR (ENGINE ROOM JUNCTION BLOCK - 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. Disconnect connector A62 from the inverter with converter assembly.



    A215725E46

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-11 (S) - Body ground
    		Always
    		11 to 14 V

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

  1. Turn the power switch on (IG).

    HINT:
    Turning the power switch on (IG) with the service grip removed causes interlock switch system DTC P0A0D-350 to be output.

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-1 (IGCT) - Body ground
    		Power switch on (IG)
    		11 to 14 V

    NOTICE:
    Turning the power switch on (IG) with the inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

  1. Turn the power switch off.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


12.CHECK POWER MANAGEMENT CONTROL ECU

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 A62 from the inverter with converter assembly.



    A215725E45

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-12 (NODD) - Body ground
    		Power switch off
    		120 to 140 kΩ

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

  1. Connect the inverter with converter assembly connector.



NG
Go to step 20
OK


13.CHECK DC/DC CONVERTER FUNCTION

HINT:
The current at the AMD terminal cannot be measured directly because of space limitations. Measure the current flowing at the auxiliary battery instead.

  1. Connect the AC/DC 400 A probe to the positive auxiliary battery line.

  1. Install the service plug grip.

  1. Turn the power switch on (READY) and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.



    A174427E02
    A174428E02

  1. Measure the current flowing from the auxiliary battery with the power switch on (READY), the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.

    Standard Current:
    Item
    		Switch Condition
    		Specified Condition
    Current flowing from auxiliary battery
    		Power switch on (READY)
    (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)
    		0 A or less
    (no current from auxiliary battery)

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    Auxiliary battery voltage
    		Power switch on (READY)
    (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)
    		13 to 15 V

  1. Turn the power switch off.



NG
REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)
OK


14.CHECK QUANTITY OF HV COOLANT

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

  1. Check for coolant leaks.
    Result 
    Result
    		Proceed to
    Coolant leaks are not evident. A sufficient amount of coolant remains in the inverter reserve tank.
    		A
    Coolant leaks are not evident. No coolant remains in the inverter reserve tank.
    		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


15.CHECK COOLANT HOSE

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



NG
CORRECT THE PROBLEM
OK


16.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 / 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


17.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 inverter water pump assembly 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

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)  

18.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 cover from the inverter with converter assembly.



    A215643E01

  1. Disconnect the three-phase AC cables for MG1 from the inverter with converter assembly.
    Text in Illustration 
    *1
    		Three-phase AC Cables for MG1



    A215629E09

  1. Using a megohmmeter set to 500 V, measure the insulation 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
    d1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

    Text in Illustration 
    *1
    		Three-phase AC Cables for MG1
    *2
    		Shield Ground

  1. Connect the three-phase AC cables for MG1 to the inverter with converter assembly.

  1. Install the inverter cover to the inverter with converter assembly.



NG
Go to step 23
OK


19.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 cover from the inverter with converter assembly.



    A215644E01

  1. Disconnect the three-phase AC cables for MG2 from the inverter with converter assembly.
    Text in Illustration 
    *1
    		Three-phase AC Cables for MG2



    A215630E10

  1. Using a megohmmeter set to 500 V, measure the insulation 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
    c1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

    Text in Illustration 
    *1
    		Three-phase AC Cables for MG2
    *2
    		Shield Ground

  1. Connect the three-phase AC cables for MG2 to the inverter with converter assembly.

  1. Install the inverter cover to the inverter with converter assembly.



NG
Go to step 25
OK

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)  

20.INSPECT POWER MANAGEMENT CONTROL ECU


    A204442E26

  1. Disconnect all the connectors from the power management control ECU.

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A19-21 (NODD) - H3-6 (E1)
    		Power switch off
    		120 to 140 kΩ

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

  1. Connect the power management control ECU connectors.



NG
REPLACE POWER MANAGEMENT CONTROL ECU (Click here)
OK

REPAIR OR REPLACE HARNESS OR CONNECTOR 

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


22.CHECK INVERTER WATER PUMP ASSEMBLY

  1. Perform a road test and check that DTCs are not stored.

    OK:
    DTCs are not stored.



NG
REPLACE INVERTER WATER PUMP ASSEMBLY (Click here)
OK

COMPLETED 

23.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


24.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.



    A217727E05

  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
    d1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-3 (V) - 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
    d1-1 (W) - d2-3 (W)
    		Power switch off
    		Below 1 Ω
    d1-2 (U) - d2-2 (U)
    		Power switch off
    		Below 1 Ω
    d1-3 (V) - d2-1 (V)
    		Power switch off
    		Below 1 Ω
    d1-1 (W) - d2-2 (U)
    		Power switch off
    		100 MΩ or higher
    d1-2 (U) - d2-1 (V)
    		Power switch off
    		100 MΩ or higher
    d1-3 (V) - d2-3 (W)
    		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)  

25.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


26.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.



    A217728E06

  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
    c1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-3 (V) - 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
    c1-1 (W) - c2-1 (W)
    		Power switch off
    		Below 1 Ω
    c1-2 (U) - c2-3 (U)
    		Power switch off
    		Below 1 Ω
    c1-3 (V) - c2-2 (V)
    		Power switch off
    		Below 1 Ω
    c1-1 (W) - c2-3 (U)
    		Power switch off
    		100 MΩ or higher
    c1-2 (U) - c2-2 (V)
    		Power switch off
    		100 MΩ or higher
    c1-3 (V) - c2-1 (W)
    		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)  

27.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 2 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 A62 from the inverter with converter assembly.



    A248214E01

  1. Remove the IGCT No. 2 fuse from the engine room junction block assembly.
    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		IGCT No. 2 Fuse



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


    A248217E01


    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    		*2
    		IGCT No. 2 Fuse
    *a
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)
    		-
    		-

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-1 (IGCT) or 2 (IGCT No. 2 fuse) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

  1. Install the IGCT No. 2 fuse.

  1. Connect the inverter with converter assembly connector.



NG
Go to step 32
OK


28.REPLACE INVERTER WITH CONVERTER ASSEMBLY

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


NEXT

REPLACE FUSE (IGCT NO. 2) 

29.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S FUSE)

  1. Disconnect connector A62 from the inverter with converter assembly.



    A248215E01

  1. Remove the DC/DC-S fuse from the engine room junction block assembly.
    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		DC/DC-S Fuse



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


    A248218E01


    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    		*2
    		DC/DC-S Fuse
    *a
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)
    		-
    		-

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-11 (S) or 2 (DC/DC-S fuse) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

  1. Install the DC/DC-S fuse.

  1. Connect the inverter with converter assembly connector.



NG
Go to step 33
OK


30.REPLACE INVERTER WITH CONVERTER ASSEMBLY

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


NEXT

REPLACE FUSE (DC/DC-S) 

31.CHECK ENGINE ROOM JUNCTION BLOCK ASSEMBLY (IGCT RELAY, IGCT FUSE, IGCT NO. 2 FUSE)


    A248219E01

  1. Remove the IGCT relay, IGCT fuse and IGCT No. 2 fuse from the engine room junction block assembly.
    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		IGCT Fuse
    *3
    		IGCT No. 2 Fuse
    *4
    		IGCT Relay



    A248220E01

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

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    3 (IGCT relay block) - Body ground and other terminals
    		Always
    		10 kΩ or higher
    5 (IGCT relay block) - Body ground and other terminals
    		Always
    		10 kΩ or higher

    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		IGCT Relay

  1. Install the IGCT relay, IGCT fuse and IGCT No. 2 fuse.



NG
Go to step 34
OK

REPLACE FUSE (IGCT) 

32.REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT

REPLACE FUSE (IGCT NO. 2) 

33.REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT

REPLACE FUSE (DC/DC-S) 

34.REPAIR OR REPLACE ENGINE ROOM JUNCTION BLOCK ASSEMBLY

NEXT

REPLACE FUSE (IGCT)