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Home >> Toyota >> 2012 >> Highlander Hybrid >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Vehicle Control System (Diagnostic Codes (P0A7A-122 - P0AC0-817) (Hybrid) >> Hybrid Control System >> DTC P0A94-127: DC / DC Converter Performance >> Procedure

DTC P0A94-127: DC / DC Converter Performance: Procedure

  1. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      DTC P0A94-127 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1C (all INF codes)*1 Drive Motor "B" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-671 Drive Motor "B" Position Sensor Circuit Range / Performance
      P0A47-670 Drive Motor "B" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A69 (all INF codes)*1 Drive Motor "B" Phase V Current
      P0A6C (all INF codes)*1 Drive Motor "B" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-113, 118, 119, 120, 128, 266, 267, 279, 284, 286, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-136, 692, 693, 694, 695, 696, 704, 712, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A91-702 Drive Motor "B" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-124, 125, 126, 169, 170, 171, 172, 442, 547, 548, 549, 553, 554, 555, 556, 557, 564, 585, 587, 589, 590 DC / DC Converter Performance
      P0AA6-526 Hybrid Battery Voltage System Isolation Fault
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 Power Cable Malfunction

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A94-127 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.
    5. Turn the ignition switch off.

    B → See step   40 

    A: Go to next step 

  2. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR). Refer to  PROCEDURE - Step 2 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  3. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER). Refer to  PROCEDURE - Step 3 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  4. CHECK GENERATOR RESOLVER. Refer to  PROCEDURE - Step 4 

    NG → See step   28 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER). Refer to  PROCEDURE - Step 5 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  6. CHECK MOTOR RESOLVER. Refer to  PROCEDURE - Step 6 

    NG → See step   30 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - REAR MOTOR RESOLVER). Refer to  PROCEDURE - Step 7 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  8. CHECK REAR MOTOR RESOLVER. Refer to  PROCEDURE - Step 8 

    NG → See step   32 

    OK: Go to next step 

  9. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 9 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  10. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 10 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  11. CHECK INVERTER WITH CONVERTER ASSEMBLY (REAR MOTOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 12 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  12. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1). Refer to  PROCEDURE - Step 11 

    NG → See step   41 

    OK: Go to next step 

  13. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2). Refer to  PROCEDURE - Step 12 

    NG → See step   41 

    OK: Go to next step 

  14. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (MGR). Refer to  PROCEDURE - Step 15 

    NG → See step   34 

    OK: Go to next step 

  15. CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH VOLTAGE CONNECTOR CONNECTION CONDITION). Refer to  PROCEDURE - Step 16 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  16. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION). Refer to  PROCEDURE - Step 17 

    NG → See step   42 

    OK: Go to next step 

  17. INSPECT SERVICE PLUG GRIP. Refer to  PROCEDURE - Step 18 

    NG → See step   42 

    OK: Go to next step 

  18. CHECK NO. 3 WIRE FRAME. Refer to  PROCEDURE - Step 20 

    NG → See step   43 

    OK: Go to next step 

  19. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB). Refer to  PROCEDURE - Step 21 

    NG → See step   44 

    OK: Go to next step 

  20. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG). Refer to  PROCEDURE - Step 22 

    NG → See step   44 

    OK: Go to next step 

  21. CHECK FUSE (PCU). Refer to  PROCEDURE - Step 13 

    NG → See step   37 

    OK: Go to next step 

  22. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT). Refer to  PROCEDURE - Step 14 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  23. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER). Refer to  PROCEDURE - Step 15 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  24. CHECK HYBRID VEHICLE CONTROL ECU. Refer to  PROCEDURE - Step 16 

    NG → See step   45 

    OK: Go to next step 

  25. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 9 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  26. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 10 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  27. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 11 

    NG → CONNECT SECURELY 

    OK → See step   46 

  28. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 12 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  29. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER). Refer to  PROCEDURE - Step 13 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   41 

  30. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 14 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  31. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER). Refer to  PROCEDURE - Step 15 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   41 

  32. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 16 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  33. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - REAR MOTOR RESOLVER). Refer to  PROCEDURE - Step 17 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   48 

  34. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (REAR MOTOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 40 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  35. CHECK NO. 3 WIRE FRAME (REAR MOTOR CABLE). Refer to  PROCEDURE - Step 41 

    NG → See step   43 

    OK: Go to next step 

  36. CHECK EXTENSION WIRE ASSEMBLY. Refer to  PROCEDURE - Step 42 

    NG → See step   47 

    OK → See step   48 

  37. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE). Refer to  PROCEDURE - Step 23 

    NG → See step   39 

    OK: Go to next step 

  38. REPLACE INVERTER WITH CONVERTER ASSEMBLY 
    1. Replace the inverter with converter assembly. Refer to REMOVAL .

    NEXT → REPLACE FUSE (PCU) 

  39. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT → REPLACE FUSE (PCU) 

  40. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  41. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  42. REPLACE SERVICE PLUG GRIP. Refer to  REMOVAL 
  43. REPLACE NO. 3 WIRE FRAME. Refer to  REMOVAL 
  44. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  REMOVAL 
  45. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
  46. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL 
  47. REPLACE EXTENSION WIRE ASSEMBLY. Refer to  REMOVAL 
  48. REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
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