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DTC P0A08-264: DC / DC Converter Status Circuit [08/2013 - ]: Procedure

WARNING: This page is about a different car, the 2014 Lexus ES 300h. However, it is still accessible from the selected car via links, so may be relevant.
  1. CHECK DTC OUTPUT (HYBRID CONTROL) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check for DTCs.

      Result

      Result Proceed to
      P0A08-264 only is output, or DTCs except the ones in the table below are also output. A
      Any of the following DTCs including pending 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 High Voltage Power Resource
      P314A-828 Inverter Coolant Pump Speed Signal
    5. Turn the power switch off.

    B → See step   28 

    A: Go to next step 

  2. CHECK FUSE (DC/DC-S) 
    1. Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.
      GTY323323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 Relay Block and Junction Block Assembly
      *2 DC/DC-S Fuse
    3. Install the DC/DC-S fuse.

    NG → See step   25 

    OK: Go to next step 

  3. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR) See step   3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  4. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) See step   4 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  5. CHECK FUSIBLE LINK BLOCK ASSEMBLY (DC/DC) 
    1. Check the fusible link block assembly (DC/DC) in the engine room relay block and junction block assembly for improper installation.

      OK

      The fusible link is installed securely.

    2. Remove the fusible link block assembly from the engine room relay block and junction block assembly.
    3. Measure the resistance according to the value(s) in the table below.
      GTY320983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      Fusible link block assembly (DC/DC) 1 - 2 Always Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Fusible Link Block Assembly
    4. Install the fusible link block assembly.

    NG → REPLACE FUSIBLE LINK BLOCK ASSEMBLY (DC/DC) 

    OK: Go to next step 

  6. CHECK CABLE AND WIRE HARNESS 
    WARNING:

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY376457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
      GTY382173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance

      Tester Connection Condition Specified Condition
      d1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      d1-2 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      d1-3 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      e1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      e1-2 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      e1-3 (U) - Body ground and shield ground Power switch off 1 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 Generator Cable
      *2 Motor Cable

      HINT: 

      Perform this inspection while the generator cable and motor cable are connected.

    4. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).

    NG → See step   17 

    OK: Go to next step 

  7. CHECK AMD TERMINAL VOLTAGE (ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Connect the cable to the negative (-) auxiliary battery terminal.
    2. Measure the voltage according to the value(s) in the table below.
      GTY316363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Condition Specified Condition
      1K-1 (AMD) - Body ground Power switch off Same as auxiliary battery voltage
    3. Disconnect the cable from the negative (-) auxiliary battery terminal.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  8. CHECK AMD TERMINAL CONNECTION CONDITION 
    WARNING:

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Check that the bolt for the AMD terminal (inverter with converter assembly side and engine room relay block and junction block assembly side) is tightened to the specified torque, the AMD terminal (inverter with converter assembly side and engine room relay block and junction block assembly side) is connected securely, and there is no contact problem.
      GTY315085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque

      T = 18 N*m {184 kgf*cm, 13ft.*lbf } (Inverter with converter assembly side)

      T = 8.0 N*m {82 kgf*cm, 71in.*lbf } (Engine room relay block and junction block assembly side)

      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: Go to next step 

  9. CHECK NO. 3 ENGINE ROOM WIRE 
    WARNING:

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Disconnect No. 3 engine room wire from the AMD terminal (inverter with converter assembly side and engine room relay block and junction block assembly side).
    3. Measure the resistance according to the value(s) in the table below.
      GTY403658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      B1-1 (AMD) - 1K-1 (AMD) Always Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 No. 3 Engine Room Wire
    4. Connect No. 3 engine room wire.

    NG → REPLACE NO. 3 ENGINE ROOM WIRE 

    OK: Go to next step 

  10. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S FUSE, DC/DC IGCT FUSE) 
    WARNING:

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Disconnect the A13 inverter with converter assembly connector.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Measure the voltage according to the value(s) in the table below.
      GTY316513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Condition Specified Condition
      A13-3 (S) - Body ground Always Same as auxiliary battery voltage
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    5. Turn the power switch on (IG).
    6. Measure the voltage according to the value(s) in the table below.
      GTY316515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Condition Specified Condition
      A13-1 (IGCT) - Body ground Power switch on (IG) Same as auxiliary battery voltage
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
      NOTE:

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

    7. Turn the power switch off.
    8. Disconnect the cable from the negative (-) auxiliary battery terminal.
    9. Reconnect the A13 inverter with converter assembly connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  11. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU) 
    WARNING:

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Disconnect the A13 inverter with converter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.
      GTY320113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      A13-5 (NODD) - Body ground Power switch off 110 to 150 kΩ
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Reconnect the A13 inverter with converter assembly connector.

    NG → See step   19 

    OK: Go to next step 

  12. 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.
      GTY288327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the service plug grip.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. 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.

      HINT: 

      If the power switch turns off immediately after it is turned on (READY), auxiliary battery voltage may be low. Recharge the auxiliary battery and perform this procedure again.

    5. 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.
      GTY285281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Current

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

      Standard Voltage

      Item 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
    7. Turn the power switch off.

    NG → See step   31 

    OK: Go to next step 

  13. CHECK QUANTITY OF HV COOLANT See step   3 

    B → ADD HV COOLANT 

    C → INSPECT FOR HV COOLANT LEAK AND ADD HV COOLANT 

    A: Go to next step 

  14. CHECK COOLANT HOSE See step   4 

    NG → CORRECT THE PROBLEM 

    OK: Go to next step 

  15. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE ELECTRIC COOLING FAN) See step   5 

    NG → See step   32 

    OK: Go to next step 

  16. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Read the freeze frame data Ambient Temperature using the Techstream.
    5. 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: 

      • 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).
      • If the HV coolant freezes in the HV radiator or HV water pump, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be stored.
      • A DTC is stored when the water pump impeller cannot rotate due to freezing of the HV coolant.
      • If a DTC is stored 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 stored.
    6. Turn the power switch off.

    B → See step   20 

    A → See step   31 

  17. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) 
    WARNING:

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Remove the upper inverter cover (generator cable side) from the inverter with converter assembly.
      GTY376459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the generator cable from the inverter with converter assembly.
      GTY315277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Generator Cable
    4. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
      GTY379942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance

      Tester Connection Condition Specified Condition
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 Shield Ground
      *a Generator Cable (Inverter with Converter Assembly Side)
    5. Connect the generator cable.
    6. Install the upper inverter cover.

    NG → See step   21 

    OK: Go to next step 

  18. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) 
    WARNING:

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Remove the upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY376395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the motor cable from the inverter with converter assembly.
      GTY320250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Motor Cable
    4. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
      GTY379577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance

      Tester Connection Condition Specified Condition
      d1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 Shield Ground
      *a Motor Cable (Inverter with Converter Assembly Side)
    5. Connect the motor cable.
    6. Install the upper inverter cover.

    NG → See step   23 

    OK → See step   31 

  19. INSPECT POWER MANAGEMENT CONTROL ECU (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU) 
    1. Disconnect the A31, A33, H1 and H2 power management control ECU connectors.
      GTY416642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      A31-21 (NODD) - H1-6 (E1) Power switch off 110 to 150 kΩ
      TEXT IN ILLUSTRATION

      *a Component without harness connected
      (Power Management Control ECU)
    3. Reconnect the A31, A33, H1 and H2 power management control ECU connectors.

    NG → See step   30 

    OK → REPAIR OR REPLACE HARNESS OR CONNECTOR 

  20. REPLACE HV COOLANT See step   7 

    NEXT → COMPLETED 

  21. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 26 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  22. CHECK GENERATOR CABLE. Refer to  PROCEDURE - Step 27 

    NG → See step   33 

    OK → See step   29 

  23. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 28 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  24. CHECK MOTOR CABLE. Refer to  PROCEDURE - Step 29 

    NG → See step   34 

    OK → See step   29 

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

    Be sure to wear insulated gloves.

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

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Disconnect the A13 inverter with converter assembly connector.
    3. Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.
      GTY323323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block and Junction Block Assembly
      *2 DC/DC-S Fuse
    4. Measure the resistance according to the value(s) in the table below.
      GTY321064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      A13-3 (S) or 2 (DC/DC-S fuse) - Body ground and other terminals Power switch off 10 kΩ or higher
    5. Install the DC/DC-S fuse.
    6. Reconnect the A13 inverter with converter assembly connector.

    NG → See step   27 

    OK: Go to next step 

  26. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to COMPONENTS [08/2013 - ]

    NEXT → REPLACE FUSE (DC/DC-S) 

  27. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT → REPLACE FUSE (DC/DC-S) 

  28. GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2013 - ] 
  29. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [08/2013 - ] 
  30. REPLACE POWER MANAGEMENT CONTROL ECU. Refer to  COMPONENTS [08/2013 - ] 
  31. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS [08/2013 - ] 
  32. CHECK COOLING FAN SYSTEM. Refer to  Cooling Fan Circuit [08/2013 - ] 
  33. REPLACE GENERATOR CABLE. Refer to  COMPONENTS [08/2013 - ] 
  34. REPLACE MOTOR CABLE. Refer to  COMPONENTS [08/2013 - ] 
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