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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 P0A94-588 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. 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 1: Disconnecting H16 HV Control ECU Connector
      G04473584Courtesy 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 terminal of the HV control ECU connector and body ground.

      Standard voltage 

      TERMINALS VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      CPWM (H16-10) - 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.
      Fig 2: Disconnecting I10 Inverter Connector
      G04473585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance (Check for open) 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      CPWM (H16-10) - CPWM (I10-13) Below 1 Ω
      GCNV (H16-8) - GCNV (I10-32) Below 1 Ω

      Standard resistance (Check for short) 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      CPWM (H16-10) or CPWM (I10-13) - 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 : REPLACE INVERTER WITH CONVERTER ASSEMBLY 

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