DTC P1CCC-49: DC/DC Converter Internal Electronic Failure [09/2023 - ]: Procedure
- CHECK DTC OUTPUT (HYBRID CONTROL)
Pre-procedure1
- None.
- Check for DTCs.
Powertrain > Hybrid Control > Trouble Codes
Result
Result Proceed to P1CCC-49 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 TABLE 1Malfunction 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 Abort Pre-Charge TABLE 2Malfunction Content System Relevant DTC Communication system malfunction Hybrid control system U01BD-87 Lost Communication with DC/DC Converter Control Module "C" HINT:
P1CCC-96 may be output as a result of the malfunction indicated by the DTCs above.
- The chart above is listed in inspection order of priority.
- 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 [09/2023 - ]
Result:
A
See step 2
- CHECK AMD TERMINAL VOLTAGE WARNING:
Be sure to wear insulated gloves.
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.
- Connect the cable to the negative (-) auxiliary battery terminal.
- Measure the voltage according to the value(s) in the table below.
Standard Voltage
Tester Connection Condition Specified Condition 1G-1 - Body ground Ignition switch off Same as auxiliary battery voltage *1 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side)
- Measure the voltage according to the value(s) in the table below.
Standard Voltage
Tester Connection Condition Specified Condition C48-1 (AMD) - Body ground Ignition switch off Same as auxiliary battery voltage *1 AMD Terminal (EV Converter Assembly Side) Result
Proceed to OK NG
Post-procedure1
- Disconnect the cable from the negative (-) auxiliary battery terminal.
Result:
NG
See step 16
Result:
OK
See step 3
- Check that the service plug grip is not installed.
- CHECK AMD TERMINAL CONNECTION CONDITION WARNING:
Be sure to wear insulated gloves.
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. Refer to DIAGNOSTIC TROUBLE CODE CHART [09/2023 - ] because this may cause a malfunction.
- Check that the nuts for the AMD terminal are tightened to the specified torque, the AMD terminal is connected securely, and there are no contact problems.
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 *1 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side) *1 AMD Terminal (EV Converter Assembly Side)
Post-procedure1
- None.
Result:
B
CONNECT SECURELY
Result:
C
REPLACE MALFUNCTIONING PARTS
Result:
A
See step 4
- Check that the service plug grip is not installed.
- CHECK CONNECTOR CONNECTION CONDITION (EV CONVERTER ASSEMBLY CONNECTOR) WARNING:
Be sure to wear insulated gloves.
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 the connection condition of the EV converter assembly connector 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.
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
Post-procedure1
- None.
Result:
B
CONNECT SECURELY
Result:
C
REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
A
See step 5
- Check that the service plug grip is not installed.
- CHECK HARNESS AND CONNECTOR (EV CONVERTER ASSEMBLY - BODY GROUND) WARNING:
Be sure to wear insulated gloves.
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.
- Measure the resistance according to the value(s) in the table below.
Standard Resistance
Tester Connection Condition Specified Condition Result C49-1 (PGND) - Body ground Ignition switch off Below 1 Ω Ω C50-1 (PGND) - Body ground Ignition switch off Below 1 Ω Ω Result
Proceed to OK NG
Post-procedure1
- None.
Result:
NG
See step 11
Result:
OK
See step 6
- Check that the service plug grip is not installed.
- CHECK HARNESS AND CONNECTOR (EV CONVERTER ASSEMBLY POWER SOURCE CIRCUIT) WARNING:
Be sure to wear insulated gloves.
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 EV converter assembly connector.
- Connect the cable to the negative (-) auxiliary battery terminal.
- Turn the ignition switch to ON.
- Measure the voltage according to the value(s) in the table below.
Standard Voltage
Tester Connection Condition Specified Condition C47-3 (IGCT) - Body ground Ignition switch ON Same as auxiliary battery voltage NOTE:Turning the ignition switch to ON with the EV converter assembly removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.
Result
Proceed to OK NG
Post-procedure1
- Turn the ignition switch off.
- Disconnect the cable from the negative (-) auxiliary battery terminal.
- Reconnect the EV converter assembly connector.
Result:
NG
See step 14
Result:
OK
See step 7
- Check that the service plug grip is not installed.
- CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR)
Refer to PROCEDURE - Step 1
Result
Proceed to OK NG Result:
NG
CONNECT SECURELY
Result:
OK
See step 8
- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - EV CONVERTER ASSEMBLY)
Pre-procedure1
- Disconnect the hybrid vehicle control ECU assembly connector.
- Disconnect the EV converter assembly connector.
- Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open)
Tester Connection Condition Specified Condition Result D44-9 (CA4H) - C47-5 (CANH) Ignition switch off Below 1 Ω Ω D44-22 (CA4L) - C47-4 (CANL) Ignition switch off Below 1 Ω Ω Standard Resistance (Check for Short)
Tester Connection Condition Specified Condition Result D44-9 (CA4H) or C47-5 (CANH) - Body ground and other terminals Ignition switch off 10 kΩ or higher kΩ D44-22 (CA4L) or C47-4 (CANL) - Body ground and other terminals Ignition switch off 10 kΩ or higher kΩ Result
Proceed to OK NG
Post-procedure1
- Reconnect the EV converter assembly connector.
- Reconnect the hybrid vehicle control ECU assembly connector.
Result:
NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
OK
See step 9
- INSPECT HYBRID VEHICLE CONTROL ECU ASSEMBLY
Pre-procedure1
- Disconnect the hybrid vehicle control ECU assembly connector.
- Measure the resistance according to the value(s) in the table below.
*a Component without harness connected
(Hybrid Vehicle Control ECU Assembly)- - Standard Resistance
Tester Connection Condition Specified Condition Result D44-9 (CA4H) - D44-22 (CA4L) Ignition switch off 80 to 170 Ω Ω Result
Proceed to OK NG
Post-procedure1
- Reconnect the hybrid vehicle control ECU assembly connector.
Result:
NG
REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY. Refer to REMOVAL [09/2023 - 12/2023] , or refer to REMOVAL [12/2023 - ]
Result:
OK
See step 10
- 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.
Pre-procedure1
- Connect the AC/DC 400 A probe of the tester to the positive (+) auxiliary battery cable.
- 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 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 ON (READY), the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.
*a Probe Direction *b Current Flowing to Auxiliary Battery *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 15.3 V Result
Proceed to OK NG
Post-procedure1
- Turn the ignition switch off.
Result:
OK
REPLACE EV CONVERTER ASSEMBLY. Refer to REMOVAL [09/2023 - ]
Result:
NG
See step 12
- CHECK CONNECTOR CONNECTION CONDITION (EV CONVERTER ASSEMBLY CONNECTOR) WARNING:
Be sure to wear insulated gloves.
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 the connection condition of the body ground terminal.
HINT:
Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [09/2023 - ]
OK
The terminal is connected securely and there are no contact problems.
Result
Result Proceed to OK A NG (The connector is not connected securely.) B
Post-procedure1
- None.
Result:
A
REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
B
CONNECT SECURELY
- Check that the service plug grip is not installed.
- CHECK EV CONVERTER ASSEMBLY WARNING:
Be sure to wear insulated gloves.
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.
- Remove the EV converter assembly from the transaxle with motor and inverter assembly.
HINT:
- Refer to REMOVAL [09/2023 - ]
- Make sure that no foreign matter, coolant or water enters the EV converter assembly.
- Using a megohmmeter set to 500 V, measure the 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.
Standard Resistance
Tester Connection Condition Specified Condition Result 1 (CBI) - Body ground Ignition switch off 10 MΩ or higher MΩ 2 (CEI) - Body ground Ignition switch off 10 MΩ or higher MΩ *a Component without harness connected
(EV Converter Assembly)Result
Proceed to OK NG
Post-procedure1
- None.
Result:
NG
REPLACE EV CONVERTER ASSEMBLY. Refer to REMOVAL [09/2023 - ]
Result:
OK
See step 13
- Check that the service plug grip is not installed.
- CHECK MOTOR HIGH-VOLTAGE CIRCUIT
Refer to Motor High-voltage Circuit [09/2023 - ]
Result
Proceed to NEXT Result:
NEXT
REPLACE EV CONVERTER ASSEMBLY. Refer to REMOVAL [09/2023 - ]
- CHECK FUSE (IGCT NO. 2)
Pre-procedure1
- Remove the IGCT NO. 2 fuse from the No. 2 engine room relay block and No. 2 junction block assembly.
- Measure the resistance according to the value(s) in the table below.
Standard Resistance
Tester Connection Condition Specified Condition Result IGCT NO. 2 fuse Always Below 1 Ω Ω Result
Proceed to OK NG
Post-procedure1
- Install the IGCT NO. 2 fuse.
Result:
NG
REPLACE FUSE (IGCT NO. 2)
Result:
OK
See step 15
- CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - EV CONVERTER ASSEMBLY)
Pre-procedure1
- Remove the IGCT NO. 1 relay from the No. 1 engine room relay block and No. 1 junction block assembly.
- Disconnect the EV converter assembly connector.
- Measure the resistance according to the value(s) in the table below.
Standard Resistance (Check for Open)
Tester Connection Condition Specified Condition Result C47-3 (IGCT) - 5 (IGCT NO. 1 relay holder) Ignition switch off Below 1 Ω Ω Standard Resistance (Check for Short)
Tester Connection Condition Specified Condition Result C47-3 (IGCT) or 5 (IGCT NO. 1 relay holder) - Body ground and other terminals Ignition switch off 10 kΩ or higher kΩ Result
Proceed to OK NG
Post-procedure1
- Install the IGCT NO. 1 relay.
- Reconnect the EV converter assembly connector.
Result:
OK
REPAIR OR REPLACE ECU POWER SOURCE CIRCUIT. Refer to ECU Power Source Circuit [09/2023 - ]
Result:
NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
- CHECK AMD TERMINAL CONNECTION CONDITION WARNING:
Be sure to wear insulated gloves.
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 that the nuts for the AMD terminal are tightened to the specified torque, the AMD terminal is connected securely, and there are no contact problems.
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 *1 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side) *1 AMD Terminal (EV Converter Assembly Side)
Post-procedure1
- None.
Result:
B
CONNECT SECURELY
Result:
C
REPLACE MALFUNCTIONING PARTS
Result:
A
See step 17
- Check that the service plug grip is not installed.
- CHECK HARNESS AND CONNECTOR (NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY - EV CONVERTER ASSEMBLY)
Pre-procedure1
- Disconnect the AMD connector from the No. 1 engine room relay block and No. 1 junction block assembly.
*1 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side)
- Measure the resistance according to the value(s) in the table below.
Standard Resistance
Tester Connection Condition Specified Condition Result C48-1 (AMD) or 1G-1 - Body ground and other terminals Ignition switch off 10 kΩ or higher kΩ Result
Proceed to OK NG
Post-procedure1
- Reconnect the AMD connector.
Result:
NG
See step 19
Result:
OK
See step 18
- Disconnect the AMD connector from the No. 1 engine room relay block and No. 1 junction block assembly.
- CHECK FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)
Pre-procedure1
- Check the fusible link block assembly (DC/DC) for improper installation.
OK
The fusible link block assembly is installed securely.
- Remove the fusible link block assembly from the No. 1 engine 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 Result 1G-1 - 1A-1 Always Below 1 Ω Ω Result
Proceed to OK NG *1 Fusible Link Block Assembly
Post-procedure1
- Install the fusible link block assembly.
Result:
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY BATTERY - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
Result:
NG
REPLACE FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)
- Check the fusible link block assembly (DC/DC) for improper installation.
- CHECK EV CONVERTER ASSEMBLY WARNING:
Be sure to wear insulated gloves.
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 AMD connector from the EV converter assembly.
*1 AMD Terminal (EV Converter Assembly Side)
- Measure the resistance according to the value(s) in the table below.
Standard Resistance
Tester Connection Condition Specified Condition Result C48-1 (AMD) - Body ground and other terminals Ignition switch off 10 MΩ or higher MΩ Result
Proceed to OK NG
Post-procedure1
- Connect the AMD connector from the EV converter assembly.
Result:
NG
See step 21
Result:
OK
See step 20
- Check that the service plug grip is not installed.
- CHECK FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)
Pre-procedure1
- Check the fusible link block assembly (DC/DC) for improper installation.
OK
The fusible link block assembly is installed securely.
- Remove the fusible link block assembly from the No. 1 engine 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 Result 1G-1 - 1A-1 Always Below 1 Ω Ω *1 Fusible Link Block Assembly Result
Proceed to OK NG
Post-procedure1
- Install the fusible link block assembly.
Result:
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY BATTERY - NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY)
Result:
NG
REPLACE FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)
- Check the fusible link block assembly (DC/DC) for improper installation.
- CHECK FUSIBLE LINK BLOCK ASSEMBLY (DC/DC)
Pre-procedure1
- Check the fusible link block assembly (DC/DC) for improper installation.
OK
The fusible link block assembly is installed securely.
- Remove the fusible link block assembly from the No. 1 engine 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 Result 1G-1 - 1A-1 Always Below 1 Ω Ω Result
Proceed to OK NG *1 Fusible Link Block Assembly
Post-procedure1
- Install the fusible link block assembly.
Result:
OK
REPLACE EV CONVERTER ASSEMBLY. Refer to REMOVAL [09/2023 - ]
Result:
NG
See step 22
- Check the fusible link block assembly (DC/DC) for improper installation.
- REPLACE FUSIBLE LINK BLOCK ASSEMBLY
Result
Proceed to NEXT Result:
NEXT
REPLACE EV CONVERTER ASSEMBLY. Refer to REMOVAL [09/2023 - ]