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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 P0A94-587 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: 

      RESULT REFERENCE

      Display (DTC Output) Proceed to
      Only DTC P0A94 (INF 587) A
      DTCs P0A94 (INF 587), and P0A1F (INF 129) (HV battery voltage circuit malfunction) B
      DTCs P0A94 (INF 587), and P0A94 (INF 442) (Abnormal voltage execution value) C
      DTCs P0A94 (INF 587), and P0A94 (INF 585) (Boost converter voltage (VL) sensor performance problem) D
      DTCs other than above E

    B : GO TO DTC P0A1F-129 

    C : Go to step   4 

    D : GO TO DTC P0A94-585 

    E : AFTER PERFORMING "CHECK HARNESS AND CONNECTOR" PROCEDURE, GO TO RELEVANT  DIAGNOSTIC TROUBLE CODE CHART 

    A : GO TO NEXT STEP 

  2. READ OUTPUT DTC (HV BATTERY) 
    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 BATTERY / DTC INFO / TROUBLE CODES.
    5. Read DTCs.

      Result: DTCs are output 

    YES : GO TO RELEVANT  DIAGNOSTIC TROUBLE CODE CHART 

    NO : GO TO NEXT STEP 

  3. INSPECT SERVICE PLUG GRIP 
    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. Measure the resistance between the terminals of the service plug grip.

      Standard resistance: Below 1 Ω 

      Fig 1: Identifying Terminals Of The Service Plug Grip
      G04473579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reinstall the service plug grip (See INSTALLATION ).

    NG : Go to step   6 

    OK : GO TO NEXT STEP 

  4. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) 
    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. Disconnect the H16 HV control ECU connector.
    4. Remove the inverter cover (see REMOVAL ).
      Fig 2: Disconnecting H16 HV Control ECU Connector
      G04473580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the I10 inverter connector.
    6. 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.

    7. Measure the voltage between the terminals of the HV control ECU connector and body ground.

      Standard voltage 

      TERMINALS VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      VL (H16-30) - Body ground Below 1 V
      GCNV (H16-8) - Body ground Below 1 V
    8. Turn the power switch OFF.
    9. Measure the resistance between the wire harness side connectors.

      Standard resistance (Check for open) 

      Fig 3: Disconnecting I10 Inverter Connector
      G04473581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      VL (H16-30) - VL (I10-15) Below 1 Ω
      GCNV (H16-8) - GCNV (I10-32) Below 1 Ω

      Standard resistance (Check for short) 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      VL (H16-30) or VL (I10-15) - Body ground 10 kΩ or higher
      GCNV (H16-8) or GCNV (I10-32) - Body ground 10 kΩ or higher
    10. Reconnect the inverter connector.
    11. Reconnect the HV control ECU connector.
    12. Reinstall the inverter cover (see INSTALLATION ).
    13. Reinstall the service plug grip (See INSTALLATION ).

    NG : REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK : GO TO NEXT STEP 

  5. CHECK OUTPUT DTC 
    1. Proceed to A if only DTC P0A94 (INF 587) is output as a result of DTC reading in the "READ OUTPUT DTC" procedure.
    2. Proceed to B if DTCs P0A94 (INF 587) and P0A94 (INF 442) are output as a result of DTC reading in the "READ OUTPUT DTC" procedure.

    B : REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    A : REPLACE INVERTER WITH CONVERTER ASSEMBLY AND BATTERY ECU ASSEMBLY 

  6. INSPECT HIGH VOLTAGE FUSE 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Remove the high voltage fuse (See REMOVAL ).

      HINT:

      The high voltage fuse is enclosed in the service plug grip.

    2. Measure the resistance between the terminals of the high voltage fuse.

      Standard resistance: Below 1 Ω 

    3. Reinstall the high voltage fuse (See INSTALLATION ).

    NG : REPLACE HIGH VOLTAGE FUSE 

    Fig 4: Identifying High Voltage Fuse
    G04473582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : REPLACE SERVICE PLUG GRIP 

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