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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 P0A94-557: DC / DC Converter Performance [02/2014 - 11/2016] >> Procedure

DTC P0A94-557: 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
      P0A94-557 only is output, or DTCs except the ones in the table below are also output. A
      Any of the following 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, 585, 587, 589, 590 DC / DC Converter Performance
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P314A-828 Inverter Coolant Pump Speed Signal

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A94-557 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:  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:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  3

  3. CHECK QUANTITY OF HV COOLANT 

    Refer to PROCEDURE - Step 3

    Result

    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:  2

    B 

    ADD HV COOLANT 

    Result:  3

    C 

    INSPECT FOR HV COOLANT LEAK AND ADD HV COOLANT 

    Result:  1

    A 

    See step  4

  4. CHECK COOLANT HOSE 

    Refer to PROCEDURE - Step 4

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE COOLANT HOSE 

    Result:  1

    OK 

    See step  5

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

    Refer to PROCEDURE - Step 5

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    CHECK COOLING FAN SYSTEM. Refer to  Cooling Fan Circuit [02/2014 - 11/2016] 

    Result:  1

    OK 

    See step  6

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

    Refer to PROCEDURE - Step 16

    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

    Result:  2

    B 

    See step  38

    Result:  1

    A 

    See step  7

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

    Refer to PROCEDURE - Step 3

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  8

  8. CHECK GENERATOR RESOLVER 

    Refer to PROCEDURE - Step 4

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  36

    Result:  1

    OK 

    See step  9

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

    Refer to PROCEDURE - Step 5

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  10

  10. CHECK MOTOR RESOLVER 

    Refer to PROCEDURE - Step 6

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  34

    Result:  1

    OK 

    See step  11

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

    Refer to PROCEDURE - Step 7

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  12

  12. CHECK REAR MOTOR RESOLVER 

    Refer to PROCEDURE - Step 8

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  32

    Result:  1

    OK 

    See step  13

  13. 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  14

  14. 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  15

  15. 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  16

  16. 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  17

  17. 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  18

  18. 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  29

    Result:  1

    OK 

    See step  19

  19. CHECK FUSE (PCU) 

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

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  26

    Result:  1

    OK 

    See step  20

  20. 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  21

  21. 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  22

  22. 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  23

  23. 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  24

  24. 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  25

  25. 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:  1

    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 

  26. 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  28

    Result:  1

    OK 

    See step  27

  27. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

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

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    REPLACE FUSE (PCU) 

  28. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result:  1

    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 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  30

  30. 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  31

  31. 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] 

  32. 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  33

  33. 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] 

  34. 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  35

  35. 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] 

  36. 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  37

  37. 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] 

  38. REPLACE HV COOLANT 

    Refer to PROCEDURE - Step 7

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    COMPLETED 

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