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Home >> Toyota >> 2006 >> Prius >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> P112 Hybrid Vehicle Control - DTC P0A94 - P3226, U0100 - U0146 >> DTC P0A94-557 DC / DC Converter Performance >> Inspection Procedure

Inspection Procedure

CAUTION:
  • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system.
  • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:

At least 5 minutes are required to discharge the high-voltage condenser inside the inverter.

  1. READ OUTPUT DTC (HV ECU) 
    1. Connect the intelligent tester to the DLC3.
    2. Turn the power switch ON (IG).
    3. Turn the intelligent tester ON.
    4. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
    5. Read DTCs.

      Result: DTC listed in the table below is output 

      DTC CHART

      DTC No. INF Code Detection Item
      P0A94  551 or 552 DC / DC Converter Malfunction

    YES : GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE 

    NO : GO TO NEXT STEP 

  2. CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Turn the power switch OFF.
    2. Remove the service plug grip (See REMOVAL ).
      NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
    3. Remove the inverter cover (see REMOVAL ).
    4. Check the connection condition of the I9 and I10 inverter connectors.

      OK : Connectors have been connected securely and there is no poor connection. 

    5. Reinstall the inverter cover (see INSTALLATION ).
    6. Reinstall the service plug grip (See INSTALLATION ).

    NG : CONNECT SECURELY 

    Fig 1: Identifying I9 And I10 Inverter Connectors
    G04473561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  3. READ OUTPUT DTC (HV ECU) 
    1. Connect the intelligent tester to the DLC3.
    2. Turn the power switch ON (IG).

      HINT:

      DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.

    3. Turn the intelligent tester ON.
    4. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
    5. Read DTCs.

      Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output 

    NO : REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    YES : GO TO NEXT STEP 

  4. INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Turn the power switch OFF.
    2. Remove the service plug grip (See REMOVAL ).
      NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
    3. Remove the inverter cover (see REMOVAL ).
    4. Turn the power switch ON (IG).

      HINT:

      DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.

    5. Measure the voltage between the terminals of the inverter connector.

      Standard voltage 

      TERMINALS VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      IGCT (I9-1) - GND1 (I9-2) 8 V or more
    6. Turn the power switch OFF.
    7. Reinstall the inverter cover (see INSTALLATION ).
    8. Reinstall the service plug grip (See INSTALLATION ).

    NG : REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Fig 2: Identifying Inverter Connector
    G04473562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : REPLACE INVERTER WITH CONVERTER ASSEMBLY 

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