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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 79 (Hybrid Control System (2GR-FXS) - Diagnostic Codes (3 Of 7)) >> Hybrid Control System >> DTC P0A94-553: DC / DC Converter Performance [11/2016 - ] >> Procedure

DTC P0A94-553: DC / DC Converter Performance [11/2016 - ]: Procedure

WARNING: This page is about a different car, the 2019 Toyota Highlander, 2018 Toyota Highlander, and 2017 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  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.

      Powertrain > Hybrid Control > Trouble Codes 

      Relevant DTC
      P06B0-163 Sensor Power Supply "A" Circuit / Open
      P06D6-511 Sensor Reference Voltage "F" Circuit / Open
      P06E6-164 Sensor Power Supply "C" Circuit / Open
      P0A1A-151, 166, 517, 658, 791, 809 Generator Control Module
      P0A1B-198, 503, 505, 547, 554, 786, 794, 806 Drive Motor "A" Control Module
      P0A1C-118, 124, 169, 693, 709, 710, 713, 797, 812 Drive Motor "B" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A40-500, 504, 506, 549, 556, 808 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-120, 126, 171, 671, 695, 814 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, 518, 811 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A78-113, 128, 279, 284, 286, 287, 548, 555, 807 Drive Motor "A" Inverter Performance
      P0A79-119, 125, 136, 170, 692, 694, 696, 712, 813 Drive Motor "B" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 810 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A91-702 Drive Motor "B" Performance
      P0A92-521 Hybrid Generator Performance
      P0BEA-290 Drive Motor "A" Phase V Current Sensor Circuit Range / Performance
      P0BEE-298 Drive Motor "A" Phase W Current Sensor Circuit Range / Performance
      P0BF6-683 Drive Motor "B" Phase V Current Sensor Circuit Range / Performance
      P0BFA-685 Drive Motor "B" Phase W Current Sensor Circuit Range / Performance
      P0C19-306 Drive Motor "A" Torque Delivered Performance
      P0C1A-704 Drive Motor "B" Torque Delivered Performance
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-586 Drive Motor "A" Inverter Voltage Sensor Circuit Range / Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Voltage Sensor Circuit High
      P0E05-328 Generator Phase V Current Sensor Circuit Range / Performance
      P0E09-336 Generator Phase W Current Sensor Circuit Range / Performance
      P0E32-585 DC/DC Converter Voltage Sensor "A" Range / Performance
      P0E33-589 DC/DC Converter Voltage Sensor "A" Low
      P0E34-590 DC/DC Converter Voltage Sensor "A" High
      P0E71-344 Generator Torque Delivered Performance
      P1C2A-155 Generator A/D Converter Circuit
      P1C2B-192 Drive Motor "A" A/D Converter Circuit
      P1C2C-706 Drive Motor "B" A/D Converter Circuit
      P1C2D-587 Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294 Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302 Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333 Generator Phase V Current Sensor Correlation
      P1C3F-341 Generator Phase W Current Sensor Correlation
      P1C4A-288 Drive Motor "A" Phase V Current Sensor Sub Circuit Range / Performance
      P1C4F-296 Drive Motor "A" Phase W Current Sensor Sub Circuit Range / Performance
      P1C54-326 Generator Phase V Current Sensor Sub Circuit Range / Performance
      P1C59-334 Generator Phase W Current Sensor Sub Circuit Range / Performance
      P1C6D-501 Drive Motor "A" Phase V Current Sensor Offset Range / Performance
      P1C6E-502 Drive Motor "A" Phase W Current Sensor Offset Range / Performance
      P1C6F-688 Drive Motor "B" Phase V Current Sensor Offset Range / Performance
      P1C70-689 Drive Motor "B" Phase W Current Sensor Offset Range / Performance
      P1C71-515 Generator Phase V Current Sensor Offset Range / Performance
      P1C72-516 Generator Phase W Current Sensor Offset Range / Performance
      P1C73-512 Sensor Standard Voltage "F" Circuit / Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CA8-708 Drive Motor "B" Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAE-715 Drive Motor "B" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB1-798 Drive Motor "B" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P1CB4-799 Drive Motor "B" Position Sensor REF Signal Stop Malfunction
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      P314A-828 Inverter Coolant Pump Speed Signal
      P33C1-684 Drive Motor "B" Phase V Current Sensor Sub Circuit Range / Performance
      P33C6-686 Drive Motor "B" Phase W Current Sensor Sub Circuit Range / Performance
      P33D8-677 Drive Motor "B" Phase V Current Sensor Correlation
      P33D9-678 Drive Motor "B" Phase W Current Sensor Correlation

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A94-553 may be stored due to a malfunction which also causes DTCs in the preceding table to be stored. 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. After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.
    5. Turn the power switch off.
    Result Proceed to
    P0A94-553 only is output, or DTCs except the ones in the chart above are also output. A
    Any of the above DTCs are also output (see chart above). B

    Result: 

    B 

    Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2016 - 10/2017]  or  DIAGNOSTIC TROUBLE CODE CHART [10/2017 - ] 

    Result: 

    A 

    See step  2

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

    Refer to PROCEDURE - Step 3

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  3

  3. CHECK QUANTITY OF HV COOLANT 

    Refer to PROCEDURE - Step 3

    Result Proceed to
    No leaks are found and the HV coolant level in the inverter reserve tank assembly is above the low line. A
    No leaks are found and the HV coolant level in the inverter reserve tank assembly is below the low line. B
    HV coolant leaks are evident. C

    Result: 

    B 

    ADD HV COOLANT 

    Result: 

    C 

    INSPECT FOR HV COOLANT LEAK AND ADD HV COOLANT 

    Result: 

    A 

    See step  4

  4. CHECK COOLANT HOSE 

    Refer to PROCEDURE - Step 4

    Result: 

    NG 

    REPAIR OR REPLACE COOLANT HOSE 

    Result: 

    OK 

    See step  5

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

    Refer to PROCEDURE - Step 5

    Result: 

    NG 

    CHECK COOLING FAN SYSTEM. Refer to  Cooling Fan Circuit [11/2016 - ] 

    Result: 

    OK 

    See step  6

  6. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING) 

    Refer to PROCEDURE - Step 16

    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

    Result: 

    B 

    See step  38

    Result: 

    A 

    See step  7

  7. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) 

    Refer to PROCEDURE - Step 3 or PROCEDURE - Step 3

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  8

  8. CHECK GENERATOR RESOLVER 

    Refer to PROCEDURE - Step 4 or PROCEDURE - Step 4

    Result: 

    NG 

    See step  36

    Result: 

    OK 

    See step  9

  9. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) 

    Refer to PROCEDURE - Step 5 or PROCEDURE - Step 5

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  10

  10. CHECK MOTOR RESOLVER 

    Refer to PROCEDURE - Step 6 or PROCEDURE - Step 6

    Result: 

    NG 

    See step  34

    Result: 

    OK 

    See step  11

  11. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - REAR MOTOR RESOLVER) 

    Refer to PROCEDURE - Step 7 or PROCEDURE - Step 7

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  12

  12. CHECK REAR MOTOR RESOLVER 

    Refer to PROCEDURE - Step 8 or PROCEDURE - Step 8

    Result: 

    NG 

    See step  32

    Result: 

    OK 

    See step  13

  13. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) 

    Refer to PROCEDURE - Step 9

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

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  14

  14. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) 

    Refer to PROCEDURE - Step 10

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

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  15

  15. CHECK INVERTER WITH CONVERTER ASSEMBLY (NO. 6 FLOOR WIRE (REAR MOTOR CABLE) CONNECTION CONDITION) 

    Refer to PROCEDURE - Step 12

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

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  16

  16. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) 

    Refer to PROCEDURE - Step 11

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

    Result: 

    OK 

    See step  17

  17. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) 

    Refer to PROCEDURE - Step 12

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

    Result: 

    OK 

    See step  18

  18. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (MGR) 

    Refer to PROCEDURE - Step 15

    Result: 

    NG 

    See step  29

    Result: 

    OK 

    See step  19

  19. CHECK FUSE (PCU) 

    Refer to PROCEDURE - Step 13

    Result: 

    NG 

    See step  26

    Result: 

    OK 

    See step  20

  20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT) 

    Refer to PROCEDURE - Step 14

    Result: 

    NG 

    REPAIR OR REPLACE POWER SOURCE CIRCUIT 

    Result: 

    OK 

    See step  21

  21. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - INVERTER WITH CONVERTER ASSEMBLY) 

    Refer to PROCEDURE - Step 15

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  22

  22. CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY 

    Refer to PROCEDURE - Step 16

    Result: 

    NG 

    REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

    Result: 

    OK 

    See step  23

  23. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 9 or PROCEDURE - Step 9

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  24

  24. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 10 or PROCEDURE - Step 10

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  25

  25. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 11 or PROCEDURE - Step 12

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    A 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  26. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) 

    Refer to PROCEDURE - Step 19

    Result: 

    NG 

    See step  28

    Result: 

    OK 

    See step  27

  27. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to COMPONENTS [11/2016 - ]

    NEXT 

    REPLACE FUSE (PCU) 

  28. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT 

    REPLACE FUSE (PCU) 

  29. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (NO. 6 FLOOR WIRE (REAR MOTOR CABLE) CONNECTION CONDITION) 

    Refer to PROCEDURE - Step 33

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

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  30

  30. CHECK NO. 6 FLOOR WIRE (REAR MOTOR CABLE) 

    Refer to PROCEDURE - Step 34

    Result: 

    NG 

    REPLACE NO. 6 FLOOR WIRE. Refer to  COMPONENTS [11/2016 - ] 

    Result: 

    OK 

    See step  31

  31. CHECK EXTENSION WIRE ASSEMBLY 

    Refer to PROCEDURE - Step 35

    Result: 

    OK 

    REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

    Result: 

    NG 

    REPLACE EXTENSION WIRE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

  32. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 12 or PROCEDURE - Step 12

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  33

  33. INSPECT REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (REAR MOTOR RESOLVER) 

    Refer to PROCEDURE - Step 13 or PROCEDURE - Step 13

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    NG 

    REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

  34. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 14 or PROCEDURE - Step 14

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  35

  35. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER) 

    Refer to PROCEDURE - Step 15 or PROCEDURE - Step 15

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

  36. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 16 or PROCEDURE - Step 16

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  37

  37. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER) 

    Refer to PROCEDURE - Step 17 or PROCEDURE - Step 17

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

  38. REPLACE HV COOLANT 

    Refer to PROCEDURE - Step 7

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