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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control System - Diagnostic Codes - (Hybrid) (1 Of 8) >> Hybrid Control System >> DTC P0A08-264: DC / DC Converter Status Circuit [10/2014 - 10/2015] >> Procedure

DTC P0A08-264: DC / DC Converter Status Circuit [10/2014 - 10/2015]: Procedure

  1. CHECK DTC OUTPUT (HYBRID CONTROL) 
    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 for DTCs.

      Result

      Result Proceed to
      P0A08-264 only is output, or DTCs except the ones in the table below are also output. A
      Any of the following DTCs including pending 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 High Voltage Power Resource
      P314A-828 Inverter Coolant Pump Speed Signal
    5. Turn the power switch off.

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) 

    (Refer to DIAGNOSTIC TROUBLE CODE CHART [10/2014 - 10/2015] )

    A 

    See step  2

  2. CHECK FUSE (DC/DC-S) 
    1. Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.
      GTY607774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Engine Room Relay Block and Junction Block Assembly
      *2 DC/DC-S Fuse
    2. Measure the resistance according to the value (s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      DC/DC-S fuse terminals Always Below 1 Ω
    3. Install the DC/DC-S fuse.

    NG 

    See step  21

    OK 

    See step  3

  3. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR) 

    See step  3

    NG 

    CONNECT SECURELY 

    OK 

    See step  4

  4. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) 

    See step  4

    NG 

    CONNECT SECURELY 

    OK 

    See step  5

  5. CHECK FUSIBLE LINK BLOCK ASSEMBLY (DC/DC) 
    1. Check the fusible link block assembly (DC/DC) in the engine room relay block and junction block assembly for improper installation.

      OK

      The fusible link is installed securely.

    2. Remove the fusible link block assembly from the engine room relay block and junction block assembly.
    3. Measure the resistance according to the value (s) in the table below.
      GTY320983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fusible Link Block Assembly

      Standard Resistance

      Tester Connection Condition Specified Condition
      Fusible link block assembly (DC/DC) 1 - 2 Always Below 1 Ω
    4. Install the fusible link block assembly.

    NG 

    REPLACE FUSIBLE LINK BLOCK ASSEMBLY (DC/DC) 

    OK 

    See step  6

  6. CHECK CABLE AND WIRE HARNESS 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY376457Courtesy 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.
      GTY608798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Cable
      *2 Motor Cable
      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 Condition Specified Condition
      d1-1 (W) - Body ground and shield ground Power switch off 1 MΩ or higher
      d1-2 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      d1-3 (U) - 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 (V) - Body ground and shield ground Power switch off 1 MΩ or higher
      e1-3 (U) - Body ground and shield ground Power switch off 1 MΩ or higher

      HINT: 

      Perform this inspection while the generator cable and motor cable are connected.

    4. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).

    NG 

    See step  17

    OK 

    See step  7

  7. CHECK AMD TERMINAL VOLTAGE (ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Connect the cable to the negative (-) auxiliary battery terminal.
    2. Measure the voltage according to the value (s) in the table below.
      GTY564774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Condition Specified Condition
      1P-1 (AMD) - Body ground Power switch off Same as auxiliary battery voltage
    3. Disconnect the cable from the negative (-) auxiliary battery terminal.

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK 

    See step  8

  8. CHECK AMD TERMINAL CONNECTION CONDITION 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Check that the bolts for the AMD terminal (inverter with converter assembly side and engine room relay block and junction block assembly side) are tightened to the specified torque, the AMD terminal (inverter with converter assembly side and engine room relay block and junction block assembly side) is connected securely, and there is no contact problem.
      GTY315085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque

      T = 18 N*m {184 kgf*cm, 13ft.*lbf } (Inverter with converter assembly side)

      T = 8.0 N*m {82 kgf*cm, 71in.*lbf } (Engine room relay block and junction block assembly side)

      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 

    See step  9

  9. CHECK NO. 3 ENGINE ROOM WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Disconnect No. 3 engine room wire from the AMD terminal (inverter with converter assembly side and engine room relay block and junction block assembly side).
    3. Measure the resistance according to the value (s) in the table below.
      GTY591174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 3 Engine Room Wire

      Standard Resistance

      Tester Connection Condition Specified Condition
      X1-1 (AMD) - 1P-1 (AMD) Always Below 1 Ω
    4. Connect No. 3 engine room wire.

    NG 

    REPLACE NO. 3 ENGINE ROOM WIRE 

    OK 

    See step  10

  10. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S FUSE) 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Disconnect the A49 inverter with converter assembly connector.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Measure the voltage according to the value (s) in the table below.
      GTY567707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)

      Standard Voltage

      Tester Connection Condition Specified Condition
      A49-3 (S) - Body ground Always Same as auxiliary battery voltage
    5. Disconnect the cable from the negative (-) auxiliary battery terminal.
    6. Reconnect the A49 inverter with converter assembly connector.

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK 

    See step  11

  11. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU) 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Disconnect the A49 inverter with converter assembly connector.
    3. Measure the resistance according to the value (s) in the table below.
      GTY559558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)

      Standard Resistance

      Tester Connection Condition Specified Condition
      A49-5 (NODD) - Body ground Power switch off 110 to 150 kΩ
    4. Reconnect the A49 inverter with converter assembly connector.

    NG 

    See step  19

    OK 

    See step  12

  12. CHECK DC/DC CONVERTER FUNCTION 

    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 of the tester to the positive auxiliary battery line.
      GTY194202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      HINT: 

      If the power switch turns off immediately after it is turned on (READY), auxiliary battery voltage may be low. Recharge the auxiliary battery and perform this procedure again.

    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.
      GTY194203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Current

      Item 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 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 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    OK 

    See step  13

  13. CHECK QUANTITY OF HV COOLANT 

    See step  3

    B 

    ADD HV COOLANT 

    C 

    INSPECT FOR HV COOLANT LEAK AND ADD HV COOLANT 

    A 

    See step  14

  14. CHECK COOLANT HOSE 

    See step  4

    NG 

    CORRECT THE PROBLEM 

    OK 

    See step  15

  15. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE ELECTRIC COOLING FAN) 

    See step  5

    NG 

    CHECK COOLING FAN SYSTEM 

    (Refer to Cooling Fan Circuit [10/2014 - 10/2015] )

    OK 

    See step  16

  16. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING) 
    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. Read the freeze frame data item Ambient Temperature using the Techstream.
    5. Check if the freeze frame data item Ambient Temperature is below freezing the freezing temperature of the HV coolant.

      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 stored.
      • A DTC is stored when the water pump impeller cannot rotate due to freezing of the HV coolant.
      • If a DTC is stored 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 stored.
    6. Turn the power switch off.

    A 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    B 

    See step  20

  17. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Remove the upper inverter cover (generator cable side) from the inverter with converter assembly.
      GTY376459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the generator cable from the inverter with converter assembly.
      GTY574280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Cable
    4. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value (s) in the table below.
      GTY570085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a Generator Cable (Inverter with Converter Assembly Side)
      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 Condition Specified Condition
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
    5. Connect the generator cable.
    6. Install the upper inverter cover.

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    OK 

    See step  18

  18. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Remove the upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY376395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the motor cable from the inverter with converter assembly.
      GTY320250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Motor Cable
    4. Using a megohmmeter set to 500 V, measure the insulation resistance according to the value (s) in the table below.
      GTY593380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a Motor Cable (Inverter with Converter Assembly Side)
      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 Condition Specified Condition
      d1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
    5. Connect the motor cable.
    6. Install the upper inverter cover.

    OK 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

  19. INSPECT POWER MANAGEMENT CONTROL ECU (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU) 
    1. Disconnect the A53, A54, D104 and D105 power management control ECU connectors.
      GTY571301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Power Management Control ECU)
    2. Measure the resistance according to the value (s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      A53-21 (NODD) - D104-6 (E1) Power switch off 110 to 150 kΩ
    3. Reconnect the A53, A54, D104 and D105 power management control ECU connectors.

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NG 

    REPLACE POWER MANAGEMENT CONTROL ECU 

    (Refer to COMPONENTS [10/2014 - 10/2015] )

  20. REPLACE HV COOLANT 

    See step  7

  21. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DC/DC-S FUSE) 
    WARNING:

    Be sure to wear insulated gloves.

    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 otherwise instructed because this may cause a malfunction.

    2. Disconnect the A49 inverter with converter assembly connector.
    3. Remove the DC/DC-S fuse from the engine room relay block and junction block assembly.
      GTY584390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.
      GTY554190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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 Condition Specified Condition
      A49-3 (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. Reconnect the A49 inverter with converter assembly connector.

    NG 

    See step  23

    OK 

    See step  22

  22. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    NEXT 

    REPLACE FUSE (DC/DC-S) 

  23. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT 

    REPLACE FUSE (DC/DC-S) 

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