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DTC P1CCC-49: DC/DC Converter Internal Electronic Failure [09/2023 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus TX 500h. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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 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 Abort Pre-Charge
      TABLE 2

      Malfunction 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.

      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: 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [09/2023 - ] 

    Result: 

    See step  2

  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
      GTY1230852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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
      GTY1236775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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

  3. 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
      GTY1230852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side)
      GTY1236775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 AMD Terminal (EV Converter Assembly Side)

    Post-procedure1

    • None.

    Result: 

    CONNECT SECURELY 

    Result: 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    See step  4

  4. 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.

      GTY1198223Courtesy 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

    Post-procedure1

    • None.

    Result: 

    CONNECT SECURELY 

    Result: 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    See step  5

  5. 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.
      GTY1228599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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

  6. 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.
      GTY1198223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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

  7. 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

  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.
      GTY1198223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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
      D44-22 (CA4L) or C47-4 (CANL) - Body ground and other terminals Ignition switch off 10 kΩ or higher

      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

  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.
      GTY1237226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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

  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.
      GTY434149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Probe Direction
      *b Current Flowing to Auxiliary Battery
      GTY430831Courtesy 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 15.3 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

  11. 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.

      GTY1228599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B

    Post-procedure1

    • None.

    Result: 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    CONNECT SECURELY 

  12. 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
      2 (CEI) - Body ground Ignition switch off 10 MΩ or higher
      GTY1132357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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

  13. 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 - ] 

  14. 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

  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.
      GTY1198223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • 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

      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 

  16. 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
      GTY1230852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side)
      GTY1236775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 AMD Terminal (EV Converter Assembly Side)

    Post-procedure1

    • None.

    Result: 

    CONNECT SECURELY 

    Result: 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    See step  17

  17. 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.
      GTY1230852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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

      Result

      Proceed to
      OK
      NG

    Post-procedure1

    • Reconnect the AMD connector.

    Result: 

    NG 

    See step  19

    Result: 

    OK 

    See step  18

  18. 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
      GTY1234501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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) 

  19. 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.
      GTY1236775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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

      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

  20. 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
      GTY1234501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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) 

  21. 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
      GTY1234501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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

  22. REPLACE FUSIBLE LINK BLOCK ASSEMBLY 

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    REPLACE EV CONVERTER ASSEMBLY. Refer to  REMOVAL [09/2023 - ]