DESCRIPTION The hybrid
vehicle control ECU monitors the battery voltage sensor and detects
insulation malfunctions in the high-voltage system.
DTC No. | Detection Item |
DTC Detection Condition | Trouble Area |
MIL | Warning Indicate |
P0AA649 | Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure |
Insulation resistance between the high-voltage circuit and the body has decreased.*1
(1 trip detection logic) |
- Inverter with converter assembly
- HV floor under wire
- HV battery junction block assembly
- Battery voltage sensor
- Hybrid battery terminal block
- HV battery
- Hybrid vehicle transaxle assembly
- Motor cable
- Air conditioning system
- Air conditioning wire
| Does not come on |
Master Warning Light: Comes on |
P1C7C49 | Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure |
Insulation resistance of the compressor with motor assembly or air conditioning inverter has decreased.*2
(1 trip detection logic) |
Air conditioning system |
Does not come on | Master Warning Light:
Comes on | P1C7D49 |
Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure |
Insulation resistance of the HV battery, battery voltage sensor or SMR has decreased.*2
(1 trip detection logic) |
- HV battery junction block assembly
- Battery voltage sensor
- Hybrid battery terminal block
- HV battery
| Does not come on |
Master Warning Light: Comes on |
P1C7E49 | Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure |
Insulation
resistance of the hybrid vehicle transaxle assembly or inverter for the
generator (MG1) and motor (MG2) has decreased.*2 (1 trip detection logic) |
- Hybrid vehicle transaxle assembly
- Motor cable
- Inverter with converter assembly
| Does not come on |
Master Warning Light: Comes on |
P1C7F49 | Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure |
Insulation
resistance of the inverter for the generator (MG1) and motor (MG2), A/C
inverter, SMR or No. 2 engine room wire has decreased.*2 (1 trip detection logic) |
- Inverter with converter assembly
- HV floor under wire
- HV battery junction block assembly
- Air conditioning system
- Air conditioning wire
| Does not come on |
Master Warning Light: Comes on |
HINT:
Related Data List (Reproduction of Phenomenon and Check)
DTC No. | Data List |
P0AA649 |
- Short Wave Highest Value Level
- Hybrid Battery Voltage
- VL-Voltage before Boosting
- VH-Voltage after Boosting
- Boost Ratio
- A/C Consumption Power
- SMRP Status
- SMRB Status
- SMRG Status
- Generator Inverter Shutdown Status
- Motor Inverter Shutdown Status
- Insulation Resistance Division Check Completion using MG Inv
- Insulation Resistance Division Check Completion using A/C Inv
- Insulation Resistance Division Check Completion using SMR
- Short Wave Highest Value Availability just after MG Inv On/Off
- Short Wave Highest Value Availability just after A/C Inv On/Off
- Short Wave Highest Value Availability just after SMR On/Off
| P1C7C49 |
P1C7D49 | P1C7E49 |
P1C7F49 | Use the following items as a reference when duplicating the vehicle conditions at the time when the malfunction occurred. Data List
- Vehicle Speed
- Engine Run Time
- BATT Voltage
- Distance from DTC Cleared
- Ready Signal
- Hybrid Battery SOC
CONFIRMATION DRIVING PATTERN CONFIRMATION AFTER REPLACING PARTS
HINT: After
repair has been completed, clear the DTC and then check that the
vehicle has returned to normal by performing the following All Readiness
check procedure. (Do not turn the power switch off (READY off) during
this inspection.) Click here
- Connect the Techstream to the DLC3.
- Turn the power switch on (IG) and turn the Techstream on.
- Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
- Turn the power switch off and wait for 2 minutes or more.
- Apply the parking brake and secure the wheels using chocks.
- When the vehicle is stationary, turn the power switch on (READY) with shift lever in P and wait for 1 minute or more.
- Turn the air conditioning system on (MAX COLD, blower speed HI).
- While depressing the brake pedal without depressing the accelerator pedal, move the shift lever to D and wait for 5 minutes.
- If step A is performed within the same trip after DTC
P0AA649 is stored, the parts with insufficient insulation resistance
will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will
be stored.
- If no DTCs are output, proceed to the next step.
- Drive the vehicle for approximately 5 minutes referring to the following
freeze frame data items: "Vehicle Speed", "Shift Position",
"Accelerator Position Sensor No.1 Voltage %", "Engine Speed", "Coolant
Temperature", "Master Cylinder Control Torque", "Motor Temperature" and
"Generator Temperature"
(If the freeze frame data item "Vehicle Speed" is 10 km/h (6 mph) or less, drive the vehicle at 10 km/h (6 mph) or more.)
-
If step A is performed within the same trip after DTC P0AA649 is
stored, the parts with insufficient insulation resistance will be
determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be
stored.
- If DTC P0AA649 is output, complete the Step A immediately as quickly as possible.
- Wait for 1 minute or more with the vehicle stopped, the power switch on
(READY), shift lever in P and the air conditioning system on (Lo/COOL
MAX, blower speed HI), then turn the power switch off and wait for 2
minutes or more. (Step A)
- Turn the power switch on (IG) and turn the Techstream on.
- Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
- Check the DTC judgment result.
HINT:
- If the judgment result shows NORMAL, the system is normal.
- If the judgment result shows ABNORMAL, the system has a malfunction.
- If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.
WIRING DIAGRAM
*1 | HV Battery |
*2 | Battery Voltage Sensor |
*3 | SMRB |
*4 | SMRG |
*5 | SMRP |
*6 | System Main Resistor |
*7 | Service Plug Grip |
*8 | Inverter with Converter Assembly |
*9 | Boost Converter |
*10 | Inverter |
*11 | Generator (MG1) |
*12 | Motor (MG2) |
*13 | Compressor with Motor Assembly |
*14 | A/C Inverter |
*15 | A/C Motor |
- | - |
*a | High-voltage Areas |
*b | DTC P0AA649 Vehicle Insulation Resistance Reduction Area |
*c | DTC P1C7C49 Air Conditioning System Area |
*d | DTC P1C7D49 HV Battery Area |
*e | DTC P1C7E49 Hybrid Vehicle Transaxle Assembly Area |
*f | DTC P1C7F49 High Voltage Direct Current Area |
SYSTEM DESCRIPTION
HINT: If
a decrease in insulation resistance cannot be confirmed using a
megohmmeter, check "Short Wave Highest Value Level" in the Data List. SHORT WAVE HIGHEST VALUE LEVEL
(a)
"Short Wave Highest Value Level" shows a decrease in insulation
resistance. When insulation resistance decreases, "Insulation Lower"
will be displayed. However, even though the insulation resistance of the
vehicle is normal, "Short Wave Highest Value Level" may decrease, so
that "Not Judge" will be displayed for any of the following conditions.
- Within approximately 1 minute since the power switch was turned on (IG).
- When the system voltages ("Hybrid Battery Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting") are changing.
- During boosting. If the Data List item "Boost Ratio" is not 0% or within
a few seconds of it becoming 0%. (The values of "Hybrid Battery
Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting"
are about the same when not boosting.)
- When "No" is displayed for any of the following Data List items:
- Short Wave Highest Value Availability just after MG Inv On/Off
- Short Wave Highest Value Availability just after A/C Inv On/Off
- Short Wave Highest Value Availability just after SMR On/Off
(b)
When "Short Wave Highest Value Level" shows "Insulation Lower LV3",
insulation resistance will be close to 0 Ω. In this case, damage to a
high-voltage cable or hybrid component (high-voltage), or a short to
body ground due to intrusion of foreign matter, such as metal particles,
can be suspected.
- If problem symptoms cannot be reproduced and a malfunction still exists
after replacing a part as instructed, checking the following freeze
frame data can help determine a trouble area.
Items to be Checked Using Freeze Frame Data:
Freeze Frame Data | Diagnostic Note |
Short Wave Highest Value Level |
Indicates that the insulation resistance has decreased. |
- VL-Voltage before Boosting
- VH-Voltage after Boosting
- Hybrid Battery Voltage
- Boost Ratio
| During
boosting (when "Boost Ratio" is not 0%), or when "VL-Voltage before
Boosting", "VH-Voltage after Boosting" or "Hybrid Battery Voltage" is
varying, "Short Wave Highest Value Level" may decrease even though the
insulation resistance is normal. |
- SMRP Status
- SMRB Status
- SMRG Status
| When
"SMRP Status", "SMRB Status" and "SMRG Status" are all OFF, the
insulation malfunction detection circuit detects a decrease in
insulation resistance in the HV battery area ((*d) in the wiring
diagram). Example:
- When the power switch is turned on (IG) (not on (READY)), all 3 system
main relays are off and it is suspected that the HV battery assembly is
disconnected from the high voltage circuits. If "Short Wave Highest
Value Level" decreases a few minutes after the power switch is turned on
(IG) (not on (READY)), the HV battery assembly may have an insulation
malfunction.
| Motor Inverter Shutdown Status |
When
"Motor Inverter Shutdown Status" is ON, the insulation malfunction
detection circuit cannot detect a decrease in insulation resistance in
the motor system AC (alternating current) section (motor (MG2) side of
(*e) in the wiring diagram). The motor system AC
(alternating current) section includes the motor (MG2) in the hybrid
vehicle transaxle assembly, motor cables and the AC (alternating
current) section of the motor drive circuit in the inverter with
converter assembly. | Generator Inverter Shutdown Status |
When
"Generator Inverter Shutdown Status" is ON, the insulation malfunction
detection circuit cannot detect a decrease in insulation resistance in
the generator system AC (alternating current) section (generator (MG1)
side of (*e) in the wiring diagram). The generator
system AC (alternating current) section includes the generator (MG1) in
the hybrid vehicle transaxle assembly, generator cables and the AC
(alternating current) section of the generator drive circuit in the
inverter with converter assembly. |
A/C Consumption Power | The
compressor with motor assembly AC (alternating current) section ((*c)
in the wiring diagram) includes the air conditioning motor, wiring
between the air conditioning motor and air conditioning inverter, and
the AC (alternating current) section of the air conditioning motor drive
circuit in the air conditioning inverter. With the
vehicle stopped, turn on/off the air conditioning system and observe
"Short Wave Highest Value Level" to use as a diagnosis reference. |
RELATED FREEZE FRAME DATA
HINT:
CAUTION / NOTICE / HINT
CAUTION:
- When troubleshooting DTC P0AA649, use either a tool wrapped with vinyl
insulation tape or an insulated tool. (It is extremely dangerous when a
high-voltage charge passes through a non-insulated tool causing a
short.)
- Before the following operations are conducted, take precautions to
prevent electric shock by turning the power switch off, wearing
insulated gloves, and removing the service plug grip from HV battery.
- Inspecting the high-voltage system
- Disconnecting the low voltage connector of the inverter with converter assembly
- Disconnecting the low voltage connector of the HV battery
- To prevent electric shock, make sure to remove the service plug grip to
cut off the high voltage circuit before servicing the vehicle.
- After removing the service plug grip from the HV battery, put it in your
pocket to prevent other technicians from accidentally reconnecting it
while you are working on the high-voltage system.
- After removing the service plug grip, wait for at least 10 minutes
before touching any of the high-voltage connectors or terminals. After
waiting for 10 minutes, check the voltage at the terminals in the
inspection point in the inverter with converter assembly. The voltage
should be 0 V before beginning work.
Click here
*a |
Without waiting for 10 minutes |
HINT:
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
- Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.
If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.
- When disposing of an HV battery, make sure to return it through an
authorized collection agent who is capable of handling it safely. If the
HV battery is returned via the manufacturer specified route, it will be
returned properly and in a safe manner by an authorized collection
agent.
*a |
Dealer |
*b |
Battery Collection Agent |
- Before returning the HV battery, make sure to perform a recovery inspection.
- Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HV battery.
NOTICE: After
turning the power switch off, waiting time may be required before
disconnecting the cable from the negative (-) auxiliary battery
terminal. Therefore, make sure to read the disconnecting the cable from
the negative (-) auxiliary battery terminal notices before proceeding
with work. Click here HINT:
When measuring insulation resistance using a megohmmeter, set the megohmmeter to 500 V. PROCEDURE
1. |
CHECK DTC OUTPUT (HYBRID CONTROL) | (a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG). (c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
(d) Check for DTCs. Powertrain > Hybrid Control > Trouble Codes
Result | Proceed to |
P0AA649, P1C7C49, P1C7D49, P1C7E49 or P1C7F49 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 |
Malfunction Content |
Relevant DTC |
Microcomputer malfunction |
P060647 | Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure |
P060687 | Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message |
P060A29 | Hybrid/EV Powertrain Control Module Monitoring Processor Signal Invalid |
P060A44 | Hybrid/EV Powertrain Control Module Monitoring Processor Data Memory Failure |
P060A45 | Hybrid/EV Powertrain Control Module Monitoring Processor Program Memory Failure |
P060A47 | Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure |
P060A49 | Hybrid/EV Powertrain Control Module Monitoring Processor Internal Electronic Failure |
P060A87 | Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message |
P060B1C | Hybrid/EV Powertrain Control Module A/D Processing Voltage Out of Range |
P060B49 | Hybrid/EV Powertrain Control Module A/D Processing Internal Electronic Failure |
P060B71 | Hybrid/EV Powertrain Control Module A/D Processing Actuator Stuck |
P1CE31C | Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Voltage Out of Range |
P1CE349 | Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Internal Electronic Failure |
P1CE371 | Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Actuator Stuck |
P0AFC96 | Hybrid/EV Battery Sensor Module Component Internal Failure |
P0AFC00 | Hybrid/EV Battery Sensor Module |
P0AFC49 | Hybrid/EV Battery Sensor Module Internal Electronic Failure |
P0AFC62 | Hybrid/EV Battery Sensor Module Signal Compare Failure |
Power Source Circuit Malfunction | P06881F |
ECM/PCM Power Relay Sense Circuit Intermittent |
P0AFC16 | Hybrid/EV Battery Sensor Module Circuit Voltage Below Threshold |
System malfunction | P1C9E9F |
Hybrid/EV System Reset Stuck Off |
HINT:
- P0AA649 may be output as a result of the malfunction indicated by the DTCs above.
- The chart above is listed in inspection order of priority.
- Check DTCs that are output at the same time by following the listed
order. (The main cause of the malfunction can be determined without
performing unnecessary inspections.)
(e) Turn the power switch off.
B |
| GO TO DTC CHART (HYBRID CONTROL SYSTEM) |
A |
| |
2. |
CHECK DTC OUTPUT (HYBRID CONTROL) | (a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG). (c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
(d) Check for DTCs. Powertrain > Hybrid Control > Trouble Codes
NOTICE:
- DTC P1C7C49, P1C7D49, P1C7E49 and P1C7F49 are not stored with P0AA649 at
the same time. If a drop in insulation resistance is detected and DTC
P0AA649 is output, wait for 1 minute with the power switch on (READY),
the shift lever in D and the air conditioning system on within the same
trip, then turn the power switch off and wait for 2 minutes to determine
the DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49).
- If only DTC P0AA649 is output, perform the diagnostic procedure for DTC P0AA649 to inspect all of the high voltage circuits.
- When any other DTC indicating parts which the insulation resistance
dropped are output, perform the diagnostic procedure for each DTC.
Result | Proceed to |
P0AA649 (decrease in the insulation resistance of the high-voltage circuit) only is output. |
A | P0AA649 and P1C7C49 (decrease in the insulation resistance of the air conditioning system area) are output. |
B | P0AA649 and P1C7D49 (decrease in the insulation resistance of the HV battery area) are output. |
C | P0AA649 and P1C7E49 (decrease in the insulation resistance of the hybrid vehicle transaxle assembly area) are output. |
D | P0AA649 and P1C7F49 (decrease in the insulation resistance of the high-voltage direct current area) are output. |
E | (e) Turn the power switch off.
B |
| GO TO STEP 11 |
C |
| GO TO STEP 8 |
D |
| GO TO STEP 19 |
E |
| GO TO STEP 25 |
A |
| |
3. |
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG2)) |
CAUTION: Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the motor cable from the inverter with converter assembly.
HINT: Make sure that no foreign matter, coolant or water enters the inverter with converter assembly. |
|
(c) Connect the cable to the negative (-) auxiliary battery terminal. HINT:
As the insulation resistance may vary when motor (MG2) rotates, perform this inspection while rotating the front wheels.
(d) Turn the power switch on (IG). NOTICE: Turning
the power switch on (IG) with the service plug grip removed causes DTCs
to be stored. Clear the DTCs after performing this inspection. (e) Move the shift lever to N and lift the vehicle.
(f) Turn the power switch off.
(g)
Using a megohmmeter set to 500 V, measure the resistance according to
the value(s) in the table below while rotating the front wheels 2
revolutions in the same direction simultaneously.
NOTICE:
- Carefully perform this inspection as the motor (MG2) may generate current when the front wheels are rotated by hand.
- 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 |
W2-2 (U) - Body ground and shield ground |
Power switch off |
100 MΩ or higher |
W2-3 (V) - Body ground and shield ground |
Power switch off |
100 MΩ or higher |
W2-1 (W) - Body ground and shield ground |
Power switch off |
100 MΩ or higher | |
|
*1 | Shield Ground |
*a | Motor Cable (for MG2) (Inverter with Converter Assembly Side) | | |
(h) Lower the vehicle and move the shift lever to P. (i) Disconnect the cable from the negative (-) auxiliary battery terminal.
NG |
| GO TO STEP 12 |
OK |
| |
4. |
CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG1)) |
CAUTION: Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Connect the cable to the negative (-) auxiliary battery terminal.
HINT: As the insulation resistance may vary when generator (MG1) rotates, perform this inspection while rotating the front wheels.
(c) Turn the power switch on (IG). NOTICE: Turning
the power switch on (IG) with the service plug grip removed causes DTCs
to be stored. Clear the DTCs after performing this inspection. (d) Move the shift lever to N and lift the vehicle.
(e) Turn the power switch off.
(f)
Using a megohmmeter set to 500 V, measure the resistance according to
the value(s) in the table below while rotating the front wheels 2
revolutions in the same direction simultaneously.
NOTICE:
- Carefully perform this inspection as the generator (MG1) may generate current when the front wheels are rotated by hand.
- 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 |
W2-5 (U) - Body ground and shield ground |
Power switch off |
100 MΩ or higher |
W2-6 (V) - Body ground and shield ground |
Power switch off |
100 MΩ or higher |
W2-4 (W) - Body ground and shield ground |
Power switch off |
100 MΩ or higher | |
|
*1 | Shield Ground |
*a | Motor Cable (for MG1) (Inverter with Converter Assembly Side) | | |
(g) Lower the vehicle and move the shift lever to P. (h) Disconnect the cable from the negative (-) auxiliary battery terminal.
NG |
| GO TO STEP 13 |
OK |
| |
5. |
CHECK HV AIR CONDITIONING WIRE | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the HV air conditioning wire connector from the inverter with converter assembly.
HINT: Make sure that no foreign matter has entered or contaminated the HV air conditioning wire. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE:
- 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.
- Be sure to inspect with connecting the tester probes to the tips of the terminal.
Standard Resistance:
Tester Connection | Condition |
Specified Condition |
T2-1 (ACPB) - Body ground and shield ground |
Power switch off |
3 MΩ or higher |
T2-2 (ACPE) - Body ground and shield ground |
Power switch off |
3 MΩ or higher | |
|
*1 | Shield Ground |
*a | HV air conditioning wire
(Inverter with Converter Assembly Side) |
*b | Tip of Terminal | | |
NG |
| GO TO STEP 30 |
OK |
| |
6. |
CHECK HV FLOOR UNDER WIRE | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the HV floor under wire connector from the inverter with converter assembly.
HINT: Make sure that no foreign matter has entered or contaminated the HV floor under wire. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE:
- 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.
- Be sure not to damage or deform the terminal being inspected.
Standard Resistance:
Tester Connection | Condition |
Specified Condition |
S1-1 (CBI) - Body ground and shield ground |
Power switch off |
10 MΩ or higher |
S1-2 (CEI) - Body ground and shield ground |
Power switch off |
10 MΩ or higher | HINT: Visually
inspect the HV floor under wire for damage. If there is any damage,
then this is the likely cause of low insulation resistance. |
|
*1 | Shield Ground |
*a | HV Floor Under Wire
(Inverter with Converter Assembly Side) | | |
NG |
| GO TO STEP 28 |
OK |
| |
7. |
CHECK INVERTER WITH CONVERTER ASSEMBLY |
CAUTION: Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Connect the HV floor under wire connector to the inverter with converter assembly. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
High voltage terminal - Body ground |
Power switch off |
1 MΩ or higher | HINT: Perform this inspection with the motor cable and air conditioning wire disconnected from the inverter with converter assembly. |
|
NG |
| GO TO STEP 27 |
OK |
| |
8. |
CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY |
CAUTION: Be sure to wear insulated gloves. HINT: Make sure that no foreign matter or water has entered the HV battery.
(a) Check that the service plug grip is not installed. NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Remove the No. 1 HV battery cover panel RH. Click here
(c) Disconnect the high voltage cable connectors of the HV battery from the HV battery junction block assembly.
NOTICE: Insulate
each disconnected high-voltage connector with insulating tape. Wrap the
connector from the wire harness side to the end of the connector. |
|
(d) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
y5-1 (+) - Body ground |
Power switch off |
10 MΩ or higher |
y3-1 (-) - Body ground |
Power switch off |
10 MΩ or higher | |
|
*a | Component without harness connected
(HV Battery Junction Block Assembly) | | |
NG |
| GO TO STEP 29 |
OK |
| |
9. |
CHECK HV BATTERY (HIGH VOLTAGE CABLE) |
CAUTION: Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
2 - Body ground | Power switch off |
10 MΩ or higher | |
|
*a | Service Plug Grip Removed (Service Plug Grip Connecting Terminals) | | |
NG |
| GO TO STEP 23 |
OK |
| |
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed. NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
1 - Body ground | Power switch off |
10 MΩ or higher | |
|
*a | Service Plug Grip Removed (Service Plug Grip Connecting Terminals) | | |
OK |
| GO TO STEP 18 |
NG |
| GO TO STEP 14 |
11. |
GO TO AIR CONDITIONING SYSTEM (P1C7C49) |
Click here
NEXT |
| PERFORM CONFIRMATION AFTER REPLACING PARTS |
12. |
CHECK MOTOR CABLE (FOR MG2) | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Remove the motor cable from the hybrid vehicle transaxle assembly.
Click here
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
W2-2 (U) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-3 (V) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-1 (W) - Shield ground |
Power switch off |
100 MΩ or higher | |
|
*1 | Shield Ground |
*a | Motor Cable (for MG2) (Inverter with Converter Assembly Side) | | |
OK |
| GO TO STEP 22 |
NG |
| GO TO STEP 24 |
13. |
CHECK MOTOR CABLE (FOR MG1) | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Remove the motor cable from the hybrid vehicle transaxle assembly.
Click here
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
W2-5 (U) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-6 (V) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-4 (W) - Shield ground |
Power switch off |
100 MΩ or higher | |
|
*1 | Shield Ground |
*a | Motor Cable (for MG1) (Inverter with Converter Assembly Side) | | |
OK |
| GO TO STEP 22 |
NG |
| GO TO STEP 24 |
14. |
CHECK HV BATTERY (HIGH VOLTAGE CABLE) |
CAUTION: Be sure to wear insulated gloves and protective goggles.
(a) Check that the service plug grip is not installed. NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Remove the No. 1 HV battery shield panel. Click here
(c) Remove the bolt from the hybrid battery terminal block. |
|
(d) Disconnect the high voltage connector. NOTICE: Insulate
each disconnected high-voltage connector with insulating tape. Wrap the
connector from the wire harness side to the end of the connector. |
|
(e) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
y4-1 - HV battery carrier |
Power switch off |
10 MΩ or higher | |
|
*a | High Voltage Cable (Hybrid Battery Terminal Block Side) |
*b | HV Battery Carrier | | |
NG |
| GO TO STEP 23 |
OK |
| |
15. |
CHECK HV BATTERY (HIGH VOLTAGE CABLE) |
CAUTION: Be sure to wear insulated gloves and protective goggles.
(a) Check that the service plug grip is not installed. NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the high voltage connector.
NOTICE: Insulate
each disconnected high-voltage connector with insulating tape. Wrap the
connector from the wire harness side to the end of the connector. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
y1-1 - HV battery carrier |
Power switch off |
10 MΩ or higher | |
|
*a | High Voltage Cable (Hybrid Battery Terminal Block Side) |
*b | HV Battery Carrier | | |
NG |
| GO TO STEP 17 |
OK |
| |
16. |
REPLACE HYBRID BATTERY TERMINAL BLOCK |
Click here
NEXT |
| PERFORM CONFIRMATION AFTER REPLACING PARTS |
17. |
CHECK HV BATTERY (HIGH VOLTAGE CABLE) |
CAUTION: Be sure to wear insulated gloves and protective goggles.
(a) Check that the service plug grip is not installed. NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the y2 battery voltage sensor connector.
NOTICE: Insulate
each disconnected high-voltage connector with insulating tape. Wrap the
connector from the wire harness side to the end of the connector. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
y1-1 - HV battery carrier |
Power switch off |
10 MΩ or higher | |
|
*a | High Voltage Cable (Hybrid Battery Terminal Block Side) |
*b | HV Battery Carrier | | |
NG |
| GO TO STEP 23 |
OK |
| |
18. |
REPLACE BATTERY VOLTAGE SENSOR | Click here
NEXT | |
PERFORM CONFIRMATION AFTER REPLACING PARTS |
19. |
CHECK INVERTER WITH CONVERTER ASSEMBLY |
CAUTION: Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the motor cable from the inverter with converter assembly.
HINT: Make sure that no foreign matter, coolant or water enters the inverter with converter assembly. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
High voltage terminal - Body ground |
Power switch off |
1 MΩ or higher | HINT: Perform this inspection with the motor cable disconnected from the inverter with converter assembly. |
|
NG |
| GO TO STEP 27 |
OK |
| |
20. |
CHECK MOTOR CABLE (FOR MG2) | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Remove the motor cable from the hybrid vehicle transaxle assembly.
Click here
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
W2-2 (U) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-3 (V) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-1 (W) - Shield ground |
Power switch off |
100 MΩ or higher | |
|
*1 | Shield Ground |
*a | Motor Cable (for MG2) (Inverter with Converter Assembly Side) | | |
NG |
| GO TO STEP 24 |
OK |
| |
21. |
CHECK MOTOR CABLE (FOR MG1) | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Remove the motor cable from the hybrid vehicle transaxle assembly.
Click here
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE: 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 |
W2-5 (U) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-6 (V) - Shield ground |
Power switch off |
100 MΩ or higher |
W2-4 (W) - Shield ground |
Power switch off |
100 MΩ or higher | |
|
*1 | Shield Ground |
*a | Motor Cable (for MG1) (Inverter with Converter Assembly Side) | | |
NG |
| GO TO STEP 24 |
OK |
| |
22. |
REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY |
Click here
NEXT |
| PERFORM CONFIRMATION AFTER REPLACING PARTS |
Click here
NEXT | |
PERFORM CONFIRMATION AFTER REPLACING PARTS |
Click here
NEXT | |
PERFORM CONFIRMATION AFTER REPLACING PARTS |
25. |
CHECK HIGH VOLTAGE DIRECT CURRENT AREA |
CAUTION: Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the HV floor under wire connector from the inverter with converter assembly.
HINT: Make sure that no foreign matter has entered or contaminated the HV floor under wire. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE:
- 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.
- Be sure not to damage or deform the terminal being inspected.
Standard Resistance:
Tester Connection | Condition |
Specified Condition |
S1-1 (CBI) - Body ground and shield ground |
Power switch off |
10 MΩ or higher |
S1-2 (CEI) - Body ground and shield ground |
Power switch off |
10 MΩ or higher | HINT: Visually
inspect the HV floor under wire for damage. If there is any damage,
then this is the likely cause of low insulation resistance. |
|
*1 | Shield Ground |
*a | HV Floor Under Wire
(Inverter with Converter Assembly Side) | | |
NG |
| GO TO STEP 28 |
OK |
| |
26. |
CHECK HV AIR CONDITIONING WIRE | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the HV air conditioning wire connector from the inverter with converter assembly.
HINT: Make sure that no foreign matter has entered or contaminated the HV air conditioning wire. |
|
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE:
- 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.
- Be sure to inspect with connecting the tester probes to the tips of the terminal.
Standard Resistance:
Tester Connection | Condition |
Specified Condition |
T2-1 (ACPB) - Body ground and shield ground |
Power switch off |
3 MΩ or higher |
T2-2 (ACPE) - Body ground and shield ground |
Power switch off |
3 MΩ or higher | |
|
*1 | Shield Ground |
*a | HV air conditioning wire
(Inverter with Converter Assembly Side) |
*b | Tip of Terminal | | |
NG |
| GO TO STEP 30 |
OK |
| |
27. |
REPLACE INVERTER WITH CONVERTER ASSEMBLY |
Click here
NEXT |
| PERFORM CONFIRMATION AFTER REPLACING PARTS |
28. |
CHECK HV FLOOR UNDER WIRE | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Remove the No. 1 HV battery cover panel RH. Click here
(c) Disconnect the HV floor under wire connectors from the HV battery junction block assembly. |
|
HINT: Make sure that no foreign matter has entered or contaminated the HV floor under wire.
(d) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE:
- 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.
- Be sure not to damage or deform the terminal being inspected.
Standard Resistance:
Tester Connection | Condition |
Specified Condition |
S1-1 (CBI) - Body ground and shield ground |
Power switch off |
10 MΩ or higher |
S1-2 (CEI) - Body ground and shield ground |
Power switch off |
10 MΩ or higher | HINT: Visually
inspect the HV floor under wire for damage. If there is any damage,
then this is the likely cause of low insulation resistance. |
|
*1 | Shield Ground |
*a | HV Floor Under Wire
(Inverter with Converter Assembly Side) | | |
NG |
| GO TO STEP 32 |
OK |
| |
29. |
REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY |
Click here
NEXT |
| PERFORM CONFIRMATION AFTER REPLACING PARTS |
30. |
CHECK HV AIR CONDITIONING WIRE | CAUTION:
Be sure to wear insulated gloves. (a) Check that the service plug grip is not installed.
NOTICE: After
removing the service plug grip, do not turn the power switch on
(READY), unless instructed by the repair manual because this may cause a
malfunction. (b) Disconnect the HV air conditioning wire from the compressor with motor assembly.
Click here | |
(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
NOTICE:
- 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.
- Be sure to inspect with connecting the tester probes to the tips of the terminal.
Standard Resistance:
Tester Connection | Condition |
Specified Condition |
T2-1 (ACPB) - Body ground and shield ground |
Power switch off |
10 MΩ or higher |
T2-2 (ACPE) - Body ground and shield ground |
Power switch off |
10 MΩ or higher | |
|
*1 | Shield Ground |
*a | HV air conditioning wire
(Inverter with Converter Assembly Side) |
*b | Tip of Terminal | | |
NG |
| GO TO STEP 33 |
OK |
| |
31. |
GO TO AIR CONDITIONING SYSTEM (P1C7C49) |
Click here
NEXT |
| PERFORM CONFIRMATION AFTER REPLACING PARTS |
32. |
REPLACE HV FLOOR UNDER WIRE | Click here
NEXT | |
PERFORM CONFIRMATION AFTER REPLACING PARTS |
33. |
REPLACE HV AIR CONDITIONING WIRE |
NEXT |
| PERFORM CONFIRMATION AFTER REPLACING PARTS | |