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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control System (2GR-FXE) - Diagnostic Codes (1 Of 7) >> Hybrid Control System >> DTC P0A94-127: DC / DC Converter Performance [02/2014 - 11/2016] >> Procedure

DTC P0A94-127: DC / DC Converter Performance [02/2014 - 11/2016]: 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.

      Powertrain > Hybrid Control > Trouble Codes 

      Result

      Result Proceed to
      P0A94-127 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
      Relevant DTC
      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 High Voltage Power Resource

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A94-127 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.
    5. Turn the power switch off.

    Result:  2

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [02/2014 - 11/2015]  Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2015 - 11/2016] 

    Result:  1

    A 

    See step  2

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

    Refer to PROCEDURE - Step 3

    Result

    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:  3

    B 

    CONNECT SECURELY 

    Result:  4

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  3

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

    Refer to PROCEDURE - Step 3

    Result

    Proceed to
    OK
    NG

    Result:  3

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  4

  4. CHECK GENERATOR RESOLVER 

    Refer to PROCEDURE - Step 4

    Result

    Proceed to
    OK
    NG

    Result:  3

    NG 

    See step  39

    Result:  1

    OK 

    See step  5

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

    Refer to PROCEDURE - Step 5

    Result

    Proceed to
    OK
    NG

    Result:  3

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  6

  6. CHECK MOTOR RESOLVER 

    Refer to PROCEDURE - Step 6

    Result

    Proceed to
    OK
    NG

    Result:  3

    NG 

    See step  37

    Result:  1

    OK 

    See step  7

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

    Refer to PROCEDURE - Step 7

    Result

    Proceed to
    OK
    NG

    Result:  3

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  8

  8. CHECK REAR MOTOR RESOLVER 

    Refer to PROCEDURE - Step 8

    Result

    Proceed to
    OK
    NG

    Result:  3

    NG 

    See step  35

    Result:  1

    OK 

    See step  9

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

    Refer to PROCEDURE - Step 9 Refer to PROCEDURE - Step 9

    Result

    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:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  10

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

    Refer to PROCEDURE - Step 10 Refer to PROCEDURE - Step 10

    Result

    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:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  11

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

    Refer to PROCEDURE - Step 12 Refer to PROCEDURE - Step 12

    Result

    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:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  12

  12. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) 

    Refer to PROCEDURE - Step 11 Refer to PROCEDURE - Step 11

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2015]  Refer to  COMPONENTS [11/2015 - 11/2016] 

    Result:  1

    OK 

    See step  13

  13. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) 

    Refer to PROCEDURE - Step 12 Refer to PROCEDURE - Step 12

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2015]  Refer to  COMPONENTS [11/2015 - 11/2016] 

    Result:  1

    OK 

    See step  14

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

    Refer to PROCEDURE - Step 15 Refer to PROCEDURE - Step 15

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  32

    Result:  1

    OK 

    See step  15

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

    Refer to PROCEDURE - Step 16 Refer to PROCEDURE - Step 16

    Result

    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:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  16

  16. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION) 

    Refer to PROCEDURE - Step 17 Refer to PROCEDURE - Step 17

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE SERVICE PLUG GRIP. Refer to  COMPONENTS [02/2014 - ] 

    Result:  1

    OK 

    See step  17

  17. INSPECT SERVICE PLUG GRIP 

    Refer to PROCEDURE - Step 18 Refer to PROCEDURE - Step 18

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE SERVICE PLUG GRIP. Refer to  COMPONENTS [02/2014 - ] 

    Result:  1

    OK 

    See step  18

  18. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (NO. 6 FLOOR WIRE CONNECTION CONDITION) 

    Refer to PROCEDURE - Step 19 Refer to PROCEDURE - Step 19

    Result

    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:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  19

  19. CHECK NO. 6 FLOOR WIRE 

    Refer to PROCEDURE - Step 20 Refer to PROCEDURE - Step 20

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE NO. 6 FLOOR WIRE. Refer to  COMPONENTS [02/2014 - 11/2016] 

    Result:  1

    OK 

    See step  20

  20. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB) 

    Refer to PROCEDURE - Step 21 Refer to PROCEDURE - Step 21

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  COMPONENTS [02/2014 - ] 

    Result:  1

    OK 

    See step  21

  21. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRG) 

    Refer to PROCEDURE - Step 22 Refer to PROCEDURE - Step 22

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  COMPONENTS [02/2014 - ] 

    Result:  1

    OK 

    See step  22

  22. CHECK FUSE (PCU) 

    Refer to PROCEDURE - Step 13 Refer to PROCEDURE - Step 13

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  29

    Result:  1

    OK 

    See step  23

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

    Refer to PROCEDURE - Step 14 Refer to PROCEDURE - Step 14

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE POWER SOURCE CIRCUIT 

    Result:  1

    OK 

    See step  24

  24. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) 

    Refer to PROCEDURE - Step 15 Refer to PROCEDURE - Step 15

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  25

  25. CHECK POWER MANAGEMENT CONTROL ECU 

    Refer to PROCEDURE - Step 16 Refer to PROCEDURE - Step 16

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE POWER MANAGEMENT CONTROL ECU. Refer to  COMPONENTS [02/2014 - 11/2016] 

    Result:  1

    OK 

    See step  26

  26. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 9

    Result

    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:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  27

  27. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 10

    Result

    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:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  4

    A 

    See step  28

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

    Refer to PROCEDURE - Step 11

    Result

    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:  4

    A 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2016] 

    Result:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

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

    Refer to PROCEDURE - Step 19 Refer to PROCEDURE - Step 19

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  31

    Result:  1

    OK 

    See step  30

  30. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to COMPONENTS [02/2014 - 11/2016]

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    REPLACE FUSE (PCU) 

  31. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    REPLACE FUSE (PCU) 

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

    Refer to PROCEDURE - Step 33 Refer to PROCEDURE - Step 33

    Result

    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:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  33

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

    Refer to PROCEDURE - Step 34 Refer to PROCEDURE - Step 34

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE NO. 6 FLOOR WIRE. Refer to  COMPONENTS [02/2014 - 11/2016] 

    Result:  1

    OK 

    See step  34

  34. CHECK EXTENSION WIRE ASSEMBLY 

    Refer to PROCEDURE - Step 35 Refer to PROCEDURE - Step 35

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2016] 

    Result:  2

    NG 

    REPLACE EXTENSION WIRE ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2016] 

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

    Refer to PROCEDURE - Step 12

    Result

    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:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  36

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

    Refer to PROCEDURE - Step 13

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  2

    NG 

    REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2016] 

  37. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 14

    Result

    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:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  38

  38. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER) 

    Refer to PROCEDURE - Step 15

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2015]  Refer to  COMPONENTS [11/2015 - 11/2016] 

  39. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 16

    Result

    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:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  40

  40. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER) 

    Refer to PROCEDURE - Step 17

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2015]  Refer to  COMPONENTS [11/2015 - 11/2016] 

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