DTC P0A08-264: DC / DC Converter Status Circuit: Procedure

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Check if DTCs are output.

   Result

   Result	Proceed to
   DTC P0A08-264 only is output.	A
   Any of the following DTCs are also output.	B

   DTC No.	Relevant Diagnosis
   P0A93-346	Inverter Cooling System Performance
   P0A94-547, 548, 549	DC / DC Converter Performance
   P0AA6-526, 613	Hybrid Battery Voltage System Isolation Fault
   P0ADB-227	Hybrid Battery Positive Contactor Control Circuit Low
   P0ADF-229	Hybrid Battery Negative Contactor Control Circuit Low
   P0AE6-225	Hybrid Battery Precharge Contactor Control Circuit Low
   P0C73-776	Motor Electronics Coolant Pump "A" Control Performance
   P3004-131, 803	Power Cable Malfunction
   P314A-828	Inverter Coolant Pump Speed Signal

5. Turn the power switch off.

B → See step   35 

A: Go to next step 

1. Remove the IGCT NO. 2 fuse from the engine room relay block and junction block assembly.
2. Measure the resistance according to the value(s) in the table below.
   Fig 1: Checking Fuse (IGCT No. 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   IGCT NO. 2 fuse terminals	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly
   *2	IGCT NO. 2 Fuse

3. Install the IGCT NO. 2 fuse.

NG → See step   27 

OK: Go to next step 

1. Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.
   Fig 2: Checking Fuse (DC/DC-S)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   DC/DC-S fuse terminals	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly
   *2	DC/DC-S Fuse

3. Install the DC/DC-S fuse.

NG → See step   29 

OK: Go to next step 

1. Remove the IGCT fuse from the engine room relay block and junction block assembly.
   Fig 3: Checking Fuse (IGCT)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   IGCT fuse terminals	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly
   *2	IGCT Fuse

3. Install the IGCT fuse.

NG → See step   31 

OK: Go to next step 

1. Disconnect connector 1E from the engine room relay block and junction block assembly.
   Fig 4: Checking Fusible Link (DC/DC)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   1F-1 (AMD) - 1E-1	Always	Below 1 Ω

3. Check the fusible links (DC/DC) in the engine room relay block and junction block assembly for improper installation.

   OK

   The fusible link is installed securely.

4. Connect the engine room relay block and junction block assembly connector.

NG → REPLACE FUSIBLE LINK BLOCK ASSEMBLY (FUSIBLE LINK(DC/DC)) 

OK: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the inverter cover from the inverter with converter assembly.
   Fig 5: Identifying Bolts And Inverter Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
   Fig 6: Identifying Insulators

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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	Switch Condition	Specified Condition
   f1-1 (W) - Body ground and shield ground	Power switch off	1 MΩ or higher
   f1-2 (U) - Body ground and shield ground	Power switch off	1 MΩ or higher
   f1-3 (V) - Body ground and shield ground	Power switch off	1 MΩ or higher
   e1-1 (W) - Body ground and shield ground	Power switch off	1 MΩ or higher
   e1-2 (U) - Body ground and shield ground	Power switch off	1 MΩ or higher
   e1-3 (V) - Body ground and shield ground	Power switch off	1 MΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Three-phase AC Cable for MG1
   *2	Three-phase AC Cable for MG2

   HINT: 

   Perform this inspection while the three-phase AC cable for MG1 and for MG2 are connected.

4. Install the inverter cover to the inverter with converter assembly.

NG → See step   18 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Check that the bolt for the AMD terminal is tightened to the specified torque, the AMD terminal is connected securely, and there is no contact problem.
   Fig 7: Identifying AMD Terminal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque

   T=8.3 N*m {85 kgf*cm, 73 in.*lbf }

   Result

   Result		Proceed to
   There are no arc marks.	The terminal is connected securely and there is no contact problem.	A
   There are no arc marks.	The terminal is not connected securely and there is a contact problem.	B
   There are arc marks.	-	C

B → CONNECT SECURELY 

C → REPLACE MALFUNCTIONING PARTS 

A: Go to next step 

1. Connect the cable to the negative (-) auxiliary battery terminal.
2. Measure the voltage according to the value(s) in the table below.
   Fig 8: Checking Terminal Voltage (AMD Terminal Voltage)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   1F-1 (AMD) - Body ground	Power switch off	11 to 14 V

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Disconnect connector A59 from the inverter with converter assembly.
3. Connect the cable to the negative (-) auxiliary battery terminal.
4. Measure the voltage according to the value(s) in the table below.
   Fig 9: Measuring Voltage Of Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   A59-11 (S) - Body ground	Always	11 to 14 V

   TEXT IN ILLUSTRATION
   
   

   *a	Front view of wire harness connector (to Inverter with Converter Assembly)

5. Turn the power switch on (IG).
6. Measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   A59-1 (IGCT) - Body ground	Power switch on (IG)	11 to 14 V

   NOTE:

   Turning the power switch on (IG) with the inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

7. Turn the power switch off.
8. Disconnect the cable from the negative (-) auxiliary battery terminal.
9. Connect the inverter with converter assembly connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Disconnect connector A59 from the inverter with converter assembly.
3. Measure the resistance according to the value(s) in the table below.
   Fig 10: Measuring Resistance Of Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A59-12 (NODD) - Body ground	Power switch off	120 to 140 kΩ

   TEXT IN ILLUSTRATION
   
   

   *a	Front view of wire harness connector (to Inverter with Converter Assembly)

4. Connect the inverter with converter assembly connector.

NG → See step   20 

OK: Go to next step 

HINT: 

The current at the AMD terminal cannot be measured directly because of space limitations. Measure the current flowing at the auxiliary battery instead.

1. Connect the AC/DC 400 A probe to the positive auxiliary battery line.
2. Install the service plug grip.
3. Connect the cable to the negative (-) auxiliary battery terminal.
4. Turn the power switch on (READY) and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.
5. Measure the current flowing from the auxiliary battery with the power switch on (READY), the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.
   Fig 11: Identifying Inverter With Converter Assembly (Operation Of DC/DC Converter)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 12: Inspecting Inverter With Converter Assembly (Operation Of DC/DC Converter)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Current

   Item	Switch Condition	Specified Condition
   Current flowing from auxiliary battery	Power 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)

6. Measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Item	Switch Condition	Specified Condition
   Auxiliary battery voltage	Power switch on (READY) (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)	13 to 15 V

7. Turn the power switch off.

NG → See step   36 

OK: Go to next step 

B → ADD HV COOLANT 

C → INSPECT FOR COOLANT LEAK AND ADD COOLANT 

A: Go to next step 

NG → CORRECT THE PROBLEM 

OK: Go to next step 

NG → See step   37 

OK: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Read the freeze frame data Ambient Temperature using the Techstream.
4. Check if the freeze frame data Ambient Temperature is below freezing.

   Result

   Result	Proceed to
   Ambient Temperature value is above freezing temperature of the HV coolant	A
   Ambient Temperature value is below freezing temperature of the HV coolant	B

   HINT: 

   • HV coolant (SLLC) with a 30% concentration freezes at -15 °C (5°F) and HV coolant (SLLC) with a 50% concentration freezes at -35°C (-31°F).
   • If the HV coolant freezes in the HV radiator or HV water pump, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be set.
   • A DTC is set when the water pump impeller cannot rotate due to freezing of the HV coolant.
   • If a DTC is set due to freezing of HV coolant, the problem cannot be reproduced. Judge whether freezing of HV coolant occurred according to the freeze point of the HV coolant, HV coolant change history and ambient temperature when the DTC was set.
5. Turn the power switch off.

B → See step   21 

A → See step   36 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the inverter cover from the inverter with converter assembly.
   Fig 13: Identifying Bolts And Inverter Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the three-phase AC cables for MG1 from the inverter with converter assembly.
   Fig 14: Identifying Three-Phase AC Cables For MG1 And Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Three-phase AC Cables for MG1

4. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
   Fig 15: Three-Phase AC Cables For MG1 Connector End View

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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	Switch Condition	Specified Condition
   f1-1 (W) - Body ground and shield ground	Power switch off	100 MΩ or higher
   f1-2 (U) - Body ground and shield ground	Power switch off	100 MΩ or higher
   f1-3 (V) - Body ground and shield ground	Power switch off	100 MΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shield Ground
   *a	Three-phase AC Cables for MG1

5. Connect the three-phase AC cables for MG1 to the inverter with converter assembly.
6. Install the inverter cover to the inverter with converter assembly.

NG → See step   23 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the inverter cover from the inverter with converter assembly.
   Fig 16: Identifying Bolts And Inverter Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the three-phase AC cables for MG2 from the inverter with converter assembly.
   Fig 17: Identifying Three-Phase AC Cables For MG2 And Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Three-phase AC Cables for MG2

4. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.
   Fig 18: Three-Phase AC Cables For MG2 Connector End View

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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	Switch Condition	Specified Condition
   e1-1 (W) - Body ground and shield ground	Power switch off	100 MΩ or higher
   e1-2 (U) - Body ground and shield ground	Power switch off	100 MΩ or higher
   e1-3 (V) - Body ground and shield ground	Power switch off	100 MΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shield Ground
   *a	Three-phase AC Cables for MG2

5. Connect the three-phase AC cables for MG2 to the inverter with converter assembly.
6. Install the inverter cover to the inverter with converter assembly.

NG → See step   25 

OK → See step   36 

1. Disconnect all the connectors from the power management control ECU.
   Fig 19: Checking Power Management Control ECU

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A21-21 (NODD) - L5-6 (E1)	Power switch off	120 to 140 kΩ

   TEXT IN ILLUSTRATION
   
   

   *a	Component without harness connected (Power Management Control ECU)

3. Connect the power management control ECU connectors.

NG → See step   39 

OK → REPAIR OR REPLACE HARNESS OR CONNECTOR 

NEXT: Go to next step 

NG → See step   40 

OK → COMPLETED 

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

NG → See step   41 

OK → See step   38 

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

NG → See step   42 

OK → See step   38 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Disconnect connector A59 from the inverter with converter assembly.
3. Remove the IGCT NO. 2 fuse from the engine room relay block and junction block assembly.
   Fig 20: Checking Fuse (IGCT No. 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly
   *2	IGCT NO. 2 Fuse

4. Measure the resistance according to the value(s) in the table below.
   Fig 21: Identifying IGCT No. 2 Fuse

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly	*2	IGCT NO. 2 Fuse
   *a	Front view of wire harness connector (to Inverter with Converter Assembly)	-	-

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A59-1 (IGCT) or 2 (IGCT NO. 2 fuse) - Body ground and other terminals	Power switch off	10 kΩ or higher

5. Install the IGCT NO. 2 fuse.
6. Connect the inverter with converter assembly connector.

NG → See step   32 

OK: Go to next step 

Refer to COMPONENTS

NEXT → REPLACE FUSE (IGCT NO. 2) 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Disconnect connector A59 from the inverter with converter assembly.
3. Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.
   Fig 22: Checking Fuse (DC/DC-S)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly
   *2	DC/DC-S Fuse

4. Measure the resistance according to the value(s) in the table below.
   Fig 23: Identifying DC/DC-S Fuse

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly	*2	DC/DC-S Fuse
   *a	Front view of wire harness connector (to Inverter with Converter Assembly)	-	-

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A59-11 (S) or 2 (DC/DC-S fuse) - Body ground and other terminals	Power switch off	10 kΩ or higher

5. Install the DC/DC-S fuse.
6. Connect the inverter with converter assembly connector.

NG → See step   33 

OK: Go to next step 

Refer to COMPONENTS

NEXT → REPLACE FUSE (DC/DC-S) 

1. Remove the IGCT relay, IGCT fuse and IGCT NO. 2 fuse from the engine room relay block and junction block assembly.
   Fig 24: Checking Engine Room Relay Block And Junction Block Assembly (IGCT Relay, IGCT Fuse, IGCT No. 2 Fuse)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly
   *2	IGCT Fuse
   *3	IGCT NO. 2 Fuse
   *4	IGCT Relay

2. Measure the resistance according to the value(s) in the table below.
   Fig 25: Identifying IGCT Relay

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   3 (IGCT relay) - Body ground and other terminals	Always	10 kΩ or higher
   5 (IGCT relay) - Body ground and other terminals	Always	10 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Relay Block and Junction Block Assembly
   *2	IGCT Relay

3. Install the IGCT relay, IGCT fuse and IGCT NO. 2 fuse.

NG → See step   34 

OK → REPLACE FUSE (IGCT) 

NEXT → REPLACE FUSE (IGCT NO. 2) 

NEXT → REPLACE FUSE (DC/DC-S) 

NEXT → REPLACE FUSE (IGCT)