DTC P1CCC-96: DC/DC Converter Enable Component Internal Failure [12/2023 - ]: Procedure

Pre-procedure1

• None.

• Check for DTCs.

  Powertrain > Hybrid Control > Trouble Codes 

  Powertrain > Motor Generator > Trouble Codes 

  Result

  Result	Proceed to
  P1CCC-96 only is output, or DTCs except the ones in the table below are also output.	A
  DTCs of hybrid control system in the table below are output.	B
  DTCs of motor generator control system in the tables below are output.	C

  TABLE 1
  
  

  Malfunction Content	System	Relevant DTC
  Insulation Malfunction	Hybrid control system	P1C7C-49	Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure
  		P1C7D-49	Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure
  		P1C7E-49	Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure
  		P1C7F-49	Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure
  		P1C80-49	Hybrid/EV Battery Voltage System Isolation (Rear Motor Area) Internal Electronic Failure
  High Voltage Circuit Malfunction	Hybrid control system	P0AA6-49	Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure
  		P0AD9-11	Hybrid/EV Battery Positive Contactor Circuit Short to Ground
  		P0ADD-11	Hybrid/EV Battery Negative Contactor Circuit Short to Ground
  		P0AE4-11	Hybrid/EV Battery Precharge Contactor Circuit Short to Ground
  		P1C84-49	High Voltage Power Resource Circuit Short during Ready ON
  		P3004-49	High Voltage Power Resource Circuit Short during Pre-Charge
  System Malfunction	Hybrid control system	P0A93-00	Inverter "A" Cooling System Performance
  		P0C73-96	Motor Electronics Coolant Pump "A" Component Internal Failure
  		P314A-31	Motor Electronics Coolant Pump "A" No Signal
  		P1F32-00	DC/DC Converter Cooling System Performance
  	Motor generator control system	P0E57-17	DC/DC Converter Voltage Sensor "A"(VL) Circuit Voltage Above Threshold

  HINT: 

  P1CCC-96 may be output as a result of the malfunction indicated by the DTCs above.

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

Post-procedure1

• Turn the ignition switch off.

Result: 

B 

GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [12/2023 - ] 

Result: 

C 

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [12/2023 - ] 

Result: 

A 

See step  2

Refer to PROCEDURE - Step 1

Result

Result: 

NG 

CONNECT SECURELY 

Result: 

OK 

See step  3

1. Check the connection condition of the DC/DC converter assembly connectors and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

   HINT: 

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [09/2023 - ]

   OK

   - The connector is connected securely.

   - The terminals are not deformed and are connected securely.

   - No water or foreign matter in the connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Result

   Result	Proceed to
   OK	A
   NG (The connector is not connected securely.)	B
   NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

Result: 

B 

CONNECT SECURELY 

Result: 

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

A 

See step  4

Pre-procedure1

• Remove the DC/DC fuse from the No. 1 luggage room relay block and No. 1 junction block assembly.

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

  Standard Resistance

  Tester Connection	Condition	Specified Condition
  DC/DC fuse	Always	Below 1 Ω

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Install the DC/DC fuse.

Result: 

NG 

REPLACE FUSE (DC/DC) 

Result: 

OK 

See step  5

Pre-procedure1

• Connect the cable to the negative (-) auxiliary battery terminal.

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

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  Standard Voltage

  Tester Connection	Condition	Specified Condition	Result
  I55-1 (AMD) - Body ground	Ignition switch off	11 to 14 V	V

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Disconnect the cable from the negative (-) auxiliary battery terminal.

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

OK 

See step  6

Pre-procedure1

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

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

• Check for arc marks on the terminals for the AMD terminal (DC/DC converter assembly side).

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  *1	AMD Terminal (DC/DC Converter Assembly Side)

• Check the connection of the AMD terminal (DC/DC converter assembly side).

  Torque

  T = 11.5 N*m (117 kgf*cm, 8 ft.*lbf) (DC/DC Converter Assembly Side)

  Result

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

Post-procedure1

• None.

Result: 

B 

CONNECT SECURELY 

Result: 

C 

REPLACE MALFUNCTIONING PARTS 

Result: 

A 

See step  7

1. Check the connection condition of the No. 1 junction block assembly connectors and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

   HINT: 

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [09/2023 - ]

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   - The connector is connected securely.

   - The terminals are not deformed and are connected securely.

   - No water or foreign matter in the connector.

   Result

   Result	Proceed to
   OK	A
   NG (The connector is not connected securely.)	B
   NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

Result: 

B 

CONNECT SECURELY 

Result: 

C 

REPLACE MALFUNCTIONING PARTS 

Result: 

A 

See step  8

1. Check the connection condition of the DC/DC converter assembly connectors and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

   HINT: 

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [09/2023 - ]

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   - The connector is connected securely.

   - The terminals are not deformed and are connected securely.

   - No water or foreign matter in the connector.

   Result

   Result	Proceed to
   OK	A
   NG (The connector is not connected securely.)	B
   NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

Result: 

B 

CONNECT SECURELY 

Result: 

C 

REPLACE MALFUNCTIONING PARTS 

Result: 

A 

See step  9

Pre-procedure1

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

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

• Disconnect the No. 1 high voltage socket inverter wire connector from the DC/DC converter assembly.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

• Disconnect the No. 1 high voltage socket inverter wire connector from the No. 1 junction block assembly.

  HINT: 

  Make sure that no foreign matter has entered or contaminated the No. 1 high voltage socket inverter wire connector.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

• Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
  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.
  • Be sure to inspect with connecting the tester probes to the tips of the terminal.

  Standard Resistance

  Tester Connection	Condition	Specified Condition	Result
  c7-2 (CEP) - c6-1 (CEP)	Ignition switch off	Below 1 Ω	Ω
  c7-1 (CBP) - c6-2 (CBP)	Ignition switch off	Below 1 Ω	Ω

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  *1	Shield Ground
  *a	No. 1 High Voltage Socket Inverter Wire (No. 1 Junction Block Assembly Side)
  *b	No. 1 High Voltage Socket Inverter Wire (DC/DC Converter Assembly Side)

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Reconnect the No. 1 high voltage socket inverter wire connector.

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

OK 

See step  10

See step  10

Result

Result: 

NG 

REPLACE NO. 1 JUNCTION BLOCK ASSEMBLY. Refer to  REMOVAL [12/2023 - ] 

Result: 

OK 

See step  11

Pre-procedure1

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

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

• Disconnect the DC/DC converter assembly connector.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  Standard Resistance

  Tester Connection	Condition	Specified Condition	Result
  I49-5 (NODD) - Body ground	Ignition switch off	110 to 150 kΩ	kΩ

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Reconnect the DC/DC converter assembly connector.

Result: 

NG 

See step  14

Result: 

OK 

See step  12

1. Check that the DC/DC converter assembly is free from detachments or damage of the cooling system parts.

   OK

   - The No. 1 DC/DC converter intake duct and DC/DC converter cooling exhaust duct are free from detachments or damage

   - The DC/DC converter cooling blower assembly is not damaged

   Result

   Result	Proceed to
   OK	A
   NG (The duct is loose)	B
   NG (The DC/DC converter cooling blower assembly is damaged)	C

Result: 

B 

CONNECT SECURELY 

Result: 

C 

REPLACE MALFUNCTIONING PARTS 

Result: 

A 

See step  13

HINT: 

The current at the AMD terminal cannot be measured directly because of space limitations.

Measure the current flowing at the auxiliary battery instead.

Pre-procedure1

• Connect the AC/DC 400 A probe of the tester to the positive (+) auxiliary battery cable.
  NOTE:

  Check the probe is installed in the direction as shown in the illustration

• Install the service plug grip.
• Connect the cable to the negative (-) auxiliary battery terminal.
• Turn the ignition switch to ON (READY) and leave the vehicle as it is until the electric current flowing to the auxiliary battery becomes 10 A or less.

  HINT: 

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

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

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  *a	Probe Direction
  *b	Current Flowing to Auxiliary Battery

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  *a	Probe Direction
  *b	Current Flowing from Auxiliary Battery

  Standard Current

  Item	Condition	Specified Condition
  Current flowing from auxiliary battery	Ignition 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)

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

  Standard Voltage

  Item	Condition	Specified Condition
  Auxiliary battery voltage	Ignition switch ON (READY) (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)	12.5 to 15 V

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Turn the ignition switch off.

Result: 

OK 

USE SIMULATION METHOD TO CHECK. Refer to  HOW TO PROCEED WITH TROUBLESHOOTING [09/2023 - ] 

Result: 

NG 

See step  15

Pre-procedure1

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

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

• Disconnect the DC/DC converter assembly connector.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

• Disconnect the hybrid vehicle control ECU assembly connector.

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

  Standard Resistance

  Tester Connection	Condition	Specified Condition	Result
  I49-5 (NODD) - B88-47 (NODD)	Ignition switch off	Below 1 Ω	Ω
  I49-5 (NODD) or B88-47 (NODD) - Body ground and other terminals	Ignition switch off	10 kΩ or higher	kΩ

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Reconnect the hybrid vehicle control ECU assembly connector.
• Reconnect the DC/DC converter assembly connector.

Result: 

OK 

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY. Refer to  REMOVAL [12/2023 - ] 

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Pre-procedure1

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

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

• Disconnect the No. 1 high voltage socket inverter wire connector from the DC/DC converter assembly.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

• Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
  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.
  • Be sure to inspect with connecting the tester probes to the tips of the terminal.

  Standard Resistance

  Tester Connection	Condition	Specified Condition	Result
  c6-1 (CEP) - Body ground and shield ground	Ignition switch off	1 MΩ or higher	MΩ
  c6-2 (CBP) - Body ground and shield ground	Ignition switch off	1 MΩ or higher	MΩ

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  *1	Shield Ground
  *a	No. 1 High Voltage Socket Inverter Wire (DC/DC Converter Assembly Side)

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Reconnect the No. 1 high voltage socket inverter wire connector.

Result: 

OK 

REPLACE DC/DC CONVERTER ASSEMBLY. Refer to  REMOVAL [12/2023 - ] 

Result: 

NG 

REPLACE MALFUNCTIONING PARTS