RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604232 HYBRID CONTROL SYSTEM C

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  P1C8349  High Voltage Power Resource Circuit Voltage Sensor after Boosting Malfunction  


DTC SUMMARY

MALFUNCTION DESCRIPTION


The hybrid vehicle control ECU monitors the high-voltage wiring between the HV battery and inverter with converter assembly and detects a power supply malfunction.

The cause of this malfunction may be one of the following:

Inverter voltage sensor (VL) internal circuit malfunction
·

Voltage sensor (VL) malfunction

·

Motor generator control ECU (MG ECU) malfunction

·

Communication (wire harness) malfunction


High voltage system malfunction
·

HV battery malfunction

·

HV battery junction block assembly malfunction

·

Inverter with converter assembly malfunction

·

Air conditioner system malfunction

·

High-voltage wire harness malfunction

·

High-voltage connector or connection malfunction


Low-voltage circuit (12 V) malfunction
·

Hybrid vehicle control ECU malfunction

·

HV battery junction block assembly malfunction

·

Low voltage wire harness malfunction

·

Low voltage connector malfunction



INSPECTION DESCRIPTION


A520712
0.385,2.99 1.167,3.615 0.781,0.625 10 false Service Plug Grip 1.302,3.292 2.979,3.896 1.677,0.604 10 false HV Battery Junction Block Assembly 0.094,1.521 0.823,1.729 0.729,0.208 10 false HV Battery 1.813,1.917 2.427,2.115 0.615,0.198 10 false SMRB 1.813,2.802 2.427,3 0.615,0.198 10 false SMRG 2.74,4.698 4.5,4.948 1.76,0.25 10 false Hybrid Vehicle Control ECU 4.25,4.146 6.396,4.365 2.146,0.219 10 false Inverter with Converter Assembly 4.604,2.771 5.792,3.031 1.188,0.26 10 false Boost Converter 5.917,2.76 6.531,3.042 0.615,0.281 10 false Inverter 4.479,0.854 6.594,1.042 2.115,0.188 10 false Compressor with Motor Assembly 5.406,5.49 6.438,5.875 1.031,0.385 10 false Auxiliary Battery 5.969,4.865 6.479,5.073 0.51,0.208 10 false DC/DC 5.188,3.531 6.302,3.844 1.115,0.313 10 false DC/DC Converter 4.688,1.99 5,2.188 0.313,0.198 10 false VL 5.646,1.99 5.958,2.188 0.313,0.198 10 false VH 1.219,5.646 2.51,5.865 1.292,0.219 10 false : High Voltage Line 1.229,6.167 2.427,6.438 1.198,0.271 10 false : Inspection Areas 3.917,0.104 4.229,0.302 0.313,0.198 10 false *a 1.26,1.063 1.573,1.26 0.313,0.198 10 false *b 6.823,4.115 7.135,4.313 0.313,0.198 10 false *c 3.917,1.115 4.229,1.313 0.313,0.198 10 false *d

System Diagram Range Inspection Content Reason
*a Check high-voltage wiring connection condition of the air conditioner compressor with motor assembly Check for short circuit
*b Check the high voltage cables between the HV battery junction block assembly Check for open circuit and defective connection (arc marks) due to looseness
*c Check connection condition and wire harness continuity between DC/DC converter and auxiliary Battery Check for open circuit and defective connection (arc marks) due to looseness
*d Check connection condition and wire harness continuity between DC/DC converter and hybrid vehicle control ECU Check for open circuit and defective connection (arc marks) due to looseness


DESCRIPTION

Refer to the description for DTC P0AD911.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>P0AD911

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate Note
P1C8349 High Voltage Power Resource Circuit Voltage Sensor after Boosting Malfunction Although an SMR on request was sent when the ignition switch is operated, the voltage did not increase after boosting.
High-voltage circuit malfunctions between the HV battery and inverter with converter assembly, or high-voltage cable has an open circuit.
(2 trip detection logic)
·

HV battery junction block assembly

·

HV floor under wire

·

Inverter with converter assembly

·

Compressor with motor assembly

·

HV battery

·

Wire harness or connector


Does not come on Master Warning:
Comes on 		SAE Code:
P3004

CONFIRMATION DRIVING PATTERN

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.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>UTILITY


1.

Connect the GTS to the DLC3.

2.

Turn the ignition switch to ON and turn the GTS on.

3.

Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

4.

Turn the ignition switch off and wait for 30 seconds or more.

5.

Turn the ignition switch to ON (READY) and wait for 30 seconds or more.

6.

Turn the ignition switch off and wait for 30 seconds or more.

7.

Turn the ignition switch to ON and turn the GTS on.

8.

Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

9.

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, perform driving pattern again.




CAUTION / NOTICE / HINT

CAUTION:

Refer to the precautions before inspecting high voltage circuit.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PRECAUTION


NOTICE:
·

After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY

·

When disconnecting and reconnecting the auxiliary battery

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART




HINT:
·

P1C8349 may be output as a result of the malfunction indicated by the DTCs in table below.

(a)

The chart above is listed in inspection order of priority.

(b)

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.)



Malfunction Content System Relevant DTC
Microcomputer malfunction Hybrid control system P0A1B49 Drive Motor "A" Control Module Internal Electronic Failure
P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
P060687 Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message
P060A47 Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure
P060A87 Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message
P1C9E9F Hybrid/EV System Reset Stuck Off
P060B49 Hybrid/EV Powertrain Control Module A/D Processing Internal Electronic Failure
Motor generator control system P0A1B1F Generator Control Module Circuit Intermittent
P0A1A47 Generator Control Module Watchdog / Safety μC Failure
P0A1A49 Generator Control Module Internal Electronic Failure
P1C2A1C Generator A/D Converter Circuit Circuit Voltage Out of Range
P1C2A49 Generator A/D Converter Circuit Internal Electronic Failure
P313383 Communication Error from Generator to Drive Motor "A" Value of Signal Protection Calculation Incorrect
P313386 Communication Error from Generator to Drive Motor "A" Signal Invalid
Hybrid battery system P060B49 Hybrid/EV Battery Energy Control Module A/D Processing Internal Electronic Failure
P060687 Hybrid/EV Battery Energy Control Module Processor to Monitoring Processor Missing Message
P060A47 Hybrid/EV Battery Energy Control Module Monitoring Processor Watchdog / Safety MCU Failure
P060A87 Hybrid/EV Battery Energy Control Module Processor from Monitoring Processor Missing Message
P0E2D00 Hybrid/EV Battery Energy Control Module Hybrid/EV Battery Monitor Performance
Power source circuit malfunction Motor generator control system P06D61C Generator Control Module Offset Power Circuit Voltage Out of Range
Communication system malfunction Hybrid control system U011187 Lost Communication with Hybrid/EV Battery Energy Control Module "A" Missing Message
U01BD87 Lost Communication with DC/DC Converter Control Module "C"
Motor generator control system P313387 Communication Error from Generator to Drive Motor "A" Missing Message
Sensor and actuator circuit malfunction Hybrid control system P0AD915 Hybrid/EV Battery Positive Contactor Circuit Short to Auxiliary Battery or Open
P0AD911 Hybrid/EV Battery Positive Contactor Circuit Short to Ground
P0ADD15 Hybrid/EV Battery Negative Contactor Circuit Short to Auxiliary Battery or Open
P0ADD11 Hybrid/EV Battery Negative Contactor Circuit Short to Ground
P0B231C Hybrid/EV Battery "A" Voltage Sensor Voltage Out of Range
P0ABF00 Hybrid/EV Battery Current Sensor "A" Circuit Range/Performance
P0D2D1C Drive Motor "A" Inverter Voltage Sensor Voltage Out of Range
Hybrid battery system P0ABF11 Hybrid/EV Battery Current Sensor "A" Circuit Short to Ground
P0B0E11 Hybrid/EV Battery Current Sensor "B" Circuit Short to Ground
P0B0E15 Hybrid/EV Battery Current Sensor "B" Circuit Short to Auxiliary Battery or Open
P0ABF15 Hybrid/EV Battery Current Sensor "A" Circuit Short to Auxiliary Battery or Open
P301A1C Hybrid Battery Stack 1 Cell Voltage Detection Voltage Out of Range
P1A001C Hybrid Battery Stack 2 Cell Voltage Detection Voltage Out of Range
P1AFD1C Flying Capacitor/Internal Control Module Hybrid/EV Battery Monitor Voltage Out of Range
P0ABF28 Hybrid/EV Battery Current Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure
P0ABF2A Hybrid/EV Battery Current Sensor "A" Signal Stuck In Range
P1CBB12 Hybrid/EV Battery Current Sensor Power Supply Circuit Short to Auxiliary Battery
P1CBB14 Hybrid/EV Battery Current Sensor Power Supply Circuit Short to Ground or Open
P0B1362 Hybrid/EV Battery Current Sensor "A"/"B" Signal Compare Failure
Motor generator control system P0D2D16 Drive Motor "A" Inverter Voltage Sensor(VH) Circuit Voltage Below Threshold
P0D2D17 Drive Motor "A" Inverter Voltage Sensor(VH) Circuit Voltage Above Threshold
System malfunction Hybrid control system P0C7600 Hybrid/EV Battery System Discharge Time Too Long
P0D2D1C Drive Motor "A" Inverter Voltage Sensor Voltage Out of Range
P0A1F94 Hybrid/EV Battery Energy Control Module Unexpected Operation
P1C8349 High Voltage Power Resource Circuit Voltage Sensor after Boosting Malfunction
P1CCC49 DC/DC Converter Internal Electronic Failure
Motor generator control system P0D2D16 Drive Motor "A" Inverter Voltage Sensor(VH) Circuit Voltage Below Threshold
P0D2D17 Drive Motor "A" Inverter Voltage Sensor(VH) Circuit Voltage Above Threshold
P1CB69E Drive Motor "A" Inverter Voltage Sensor(VH) Stuck On
P0CA300 DC/DC Converter Step Up Voltage Performance


PROCEDURE

1.CHECK FREEZE FRAME DATA (HYBRID CONTROL)
a.

Read the Freeze Frame Data of DTC P1C8349.

Powertrain > Hybrid Control > Trouble Codes
50001 397
Result:
Result Proceed to
All of the following conditions are met:
·

Difference between "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" is 39 V or less.

·

Difference between "Hybrid/EV Battery Voltage" and "VH-Voltage after Boosting" is more than 60 V.

·

Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is more than 76 V.


A
All of the following conditions are met:
·

Difference between "Hybrid/EV Battery Voltage" and "VH-Voltage after Boosting" is 39 V or less.

·

Difference between "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" is more than 60 V.

·

Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is more than 76 V.


Freeze Frame Data item "DC/DC Converter Unavailable Status" is ON.
Except above B



b.

Turn the ignition switch off.



A

REPLACE INVERTER WITH CONVERTER ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER>REMOVAL


B

2.CHECK COMPRESSOR WITH MOTOR ASSEMBLY
2.CHECK COMPRESSOR WITH MOTOR 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517691
1.198,0.531 1.521,0.813 0.323,0.281 1.25,0.563 1.49,0.76 0.24,0.198 10 true X2

Disconnect the HV air conditioning wire from the inverter with converter assembly.

HINT:

Make sure that no foreign matter has entered or contaminated the HV air conditioning wire.



c.
A515024
0.5,0.583 0.844,0.813 0.344,0.229 1.635,0.927 1.094,1.396 true 1.833,0.927 2.375,1.438 true 0.063,0.063 0.375,0.219 0.313,0.156 10 false *a 0.604,0.615 0.917,0.771 0.313,0.156 10 false X2 0.927,1.417 1.344,1.604 0.417,0.188 10 false ACPE 2.24,1.458 2.656,1.646 0.417,0.188 10 false ACPB
*a HV Air Conditioning Wire
(Inverter with Converter Assembly Side)


Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection
(Tester Probe Polarity) 		Condition Specified Condition
X2-2 (ACPE) (Negative (-) probe) - X2-1 (ACPB) (Positive (+) probe) Ignition switch off 100 kΩ or higher


NOTICE:
·

Do not use a megohmmeter.

·

Read the resistance after the value has stabilized.

·

Be sure to inspect with connecting the tester probes to the tips of the terminal.




d.

Reconnect the HV air conditioning wire.


Result:
Proceed to
OK
NG



OK

3.CHECK INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION)

NG

14.CHECK HV AIR CONDITIONING WIRE
3.CHECK INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A520715

Check that the bolts for the HV floor under wire are tightened to the specified torque, the HV floor under wire is connected securely, and there are no contact problems.

Specified Condition:

T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)



c.

Disconnect the HV floor under wire from the inverter with converter assembly.


d.

Check for arc marks on the terminals for the HV floor under wire and inverter with converter assembly.

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



e.

Reconnect the HV floor under wire.



A

4.CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION)

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

4.CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517686
1.135,0.333 1.5,0.563 0.365,0.229 2,0.615 2.323,0.833 0.323,0.219 2.031,0.635 2.313,0.813 0.281,0.177 10 true W6 1.156,0.344 1.479,0.531 0.323,0.188 10 true W7

Check that the HV floor under wire is connected securely, and there are no contact problems.


c.

Disconnect the HV floor under wire connectors from the HV battery junction block assembly.


d.

Check for arc marks on the terminals of the HV floor under wire and the HV battery junction block assembly.

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



e.

Reconnect the HV floor under wire connectors.



A

5.CHECK FLOOR UNDER WIRE

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

5.CHECK 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517686
1.135,0.333 1.5,0.563 0.365,0.229 2,0.615 2.323,0.833 0.323,0.219 2.031,0.635 2.313,0.813 0.281,0.177 10 true W6 1.156,0.344 1.479,0.531 0.323,0.188 10 true W7

Disconnect the HV floor under wire connectors from the HV battery junction block assembly.


c.
A520715

Disconnect the HV floor under wire from the inverter with converter assembly.


d.

Measure the resistance according to the value(s) in the table below.

A515373
1.583,0.156 1.969,0.365 0.385,0.208 3.375,0.406 3.76,0.615 0.385,0.208 5.146,0.438 5.51,0.646 0.365,0.208 1.281,1.406 1.698,0.99 true 2.333,1.365 1.865,0.99 true 3.917,1.469 3.667,1.219 true 5.688,1.448 5.438,1.198 true 0.969,1.406 1.271,1.615 0.302,0.208 10 true CBI 2.969,0.156 3.146,0.302 0.177,0.146 10 true *b 0.99,0.188 1.198,0.344 0.208,0.156 10 true *a 3.833,1.5 4.438,1.708 0.604,0.208 10 true CBI 2.281,1.417 2.865,1.635 0.583,0.219 10 true CEI 5.615,1.49 6.302,1.729 0.688,0.24 10 true CEI 1.667,0.177 1.979,0.375 0.313,0.198 10 false W1 5.229,0.458 5.542,0.656 0.313,0.198 10 false W6 3.458,0.427 3.917,0.625 0.458,0.198 10 false W7
*a HV Floor Under Wire
(Inverter with Converter Assembly Side) 		*b HV Floor Under Wire
(HV Battery Junction Block Assembly Side)


Standard Resistance:
Tester Connection Condition Specified Condition
W1-1 (CBI) - W7-1 (CBI) Ignition switch off Below 1 Ω
W1-2 (CEI) - W6-1 (CEI) Ignition switch off Below 1 Ω


NOTICE:

Be sure not to damage or deform the terminal being inspected.



e.

Reconnect the HV floor under wire to the inverter with converter assembly.


f.

Reconnect the HV floor under wire connectors to the HV battery junction block assembly.


Result:
Proceed to
OK
NG



OK

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

NG

REPLACE FLOOR UNDER WIRE

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>FRAME WIRE>REMOVAL


6.CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A520717

Check the connection condition of the low voltage connectors of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and the connector for water and foreign matter.

Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>ELECTRONIC CIRCUIT INSPECTION PROCEDURE

NOTICE:

Before disconnecting the connector, confirm that it is properly connected by checking that the claws of the lock levers are engaged and that the connector cannot be pulled off.


OK:

- The connector is connected securely.

- The terminals are not deformed and are connected securely.

- No water or foreign matter in the connector.


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


HINT:

When connecting the connector, connect it with the lock levers raised. Rotate each lock lever downward and make sure that the connector is securely connected. When a lock lever is fully lowered, a click will be heard as its claw engages. After the click is heard, pull up on the connector to confirm that it is securely connected.




A

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

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

7.CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
a.
A517671

Check the connection condition of the hybrid vehicle control ECU and the contact pressure of each terminal. Check the terminals for deformation, and the connector for water and foreign matter.

Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>ELECTRONIC CIRCUIT INSPECTION PROCEDURE

NOTICE:

Before disconnecting the connector, confirm that it is properly connected by checking that the claws of the lock levers are engaged and that the connector cannot be pulled off.


OK:

- The connector is connected securely.

- The terminals are not deformed and are connected securely.

- No water or foreign matter in the connector.


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


HINT:

When connecting the connector, connect it with the lock levers raised. Rotate each lock lever downward and make sure that the connector is securely connected. When a lock lever is fully lowered, a click will be heard as its claw engages. After the click is heard, pull up on the connector to confirm that it is securely connected.




A

8.CHECK FUSE (DC/DC)

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

8.CHECK FUSE (DC/DC)
a.

Disconnect the cable from the negative (-) auxiliary battery terminal.


b.

Remove the DC/DC fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
DC/DC fuse Always Below 1 Ω



d.

Install the DC/DC fuse.


e.

Connect the cable to the negative (-) auxiliary battery terminal.


Result:
Proceed to
OK
NG



OK

9.CHECK AMD TERMINAL VOLTAGE

NG

REPLACE FUSE (DC/DC)

9.CHECK AMD TERMINAL VOLTAGE
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Connect the cable to the negative (-) auxiliary battery terminal.


c.
A517676
3.063,1.427 2.833,1.042 true 2.615,1.823 2.844,2.021 0.229,0.198 10 true *2 2.323,1.469 2.542,1.667 0.219,0.198 10 true *1 2.99,1.448 3.208,1.656 0.219,0.208 10 true *a
*1 AMD Terminal (Inverter with Converter Assembly Side)
*2 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side)
*a D1-1 (AMD)


Measure the voltage according to the value(s) in the table below.

Standard Voltage:
Tester Connection Condition Specified Condition
D1-1 (AMD) - Body ground Ignition switch off Same as auxiliary battery voltage



d.

Disconnect the cable from the negative (-) auxiliary battery terminal.


Result:
Proceed to
OK
NG



OK

10.CHECK AMD TERMINAL CONNECTION CONDITION

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

10.CHECK AMD TERMINAL CONNECTION CONDITION
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517676C01
2.615,1.823 2.844,2.021 0.229,0.198 10 true *2 2.323,1.469 2.542,1.667 0.219,0.198 10 true *1
*1 AMD Terminal (Inverter with Converter Assembly Side)
*2 AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side)


Check that the nuts for the AMD terminal are tightened to the specified torque, the AMD terminal is connected securely, and there are no contact problems.

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




A

11.CHECK GROUND WIRE CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY)

B

CONNECT SECURELY

C

REPLACE MALFUNCTIONING PARTS

11.CHECK GROUND WIRE CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY)

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER>INSTALLATION

OK:

The ground wire is securely installed.


Result:
Proceed to
OK
NG



OK

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

NG

CONNECT SECURELY

12.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the inverter with converter assembly connector.


c.

Disconnect the hybrid vehicle control ECU connector.


d.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A193-5 (CNH) - I278-9 (CA4H) Ignition switch off Below 1 Ω
A193-4 (CNL) - I278-22 (CA4L) Ignition switch off Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
A193-5 (CNH) or I278-9 (CA4H) - Body ground and other terminals Ignition switch off 10 kΩ or higher
A193-4 (CNL) or I278-22 (CA4L) - Body ground and other terminals Ignition switch off 10 kΩ or higher



e.

Reconnect the hybrid vehicle control ECU connector.


f.

Reconnect the inverter with converter assembly connector.


Result:
Proceed to
OK
NG



OK

13.INSPECT HYBRID VEHICLE CONTROL ECU

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

13.INSPECT HYBRID VEHICLE CONTROL ECU
a.

Disconnect the hybrid vehicle control ECU connector.


b.

Measure the resistance according to the value(s) in the table below.

A460286
4.646,0.292 5.052,0.531 0.406,0.24 4.25,2.292 4.531,1.323 true 5.615,2.292 4.677,1.406 true 0.313,0.24 0.625,0.396 0.313,0.156 10 false *a 5.5,2.323 6.135,2.573 0.635,0.25 10 false CA4L 4.083,2.333 4.719,2.677 0.635,0.344 10 false CA4H 4.719,0.323 5.073,0.51 0.354,0.188 10 false I278
*a Component without harness connected
(Hybrid Vehicle Control ECU) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
I278-9 (CA4H) - I278-22 (CA4L) Ignition switch off 80 to 170 Ω



c.

Reconnect the hybrid vehicle control ECU connector.


Result:
Proceed to
OK
NG



OK

REPLACE INVERTER WITH CONVERTER ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER>REMOVAL


NG

REPLACE HYBRID VEHICLE CONTROL ECU

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID VEHICLE CONTROL ECU>REMOVAL


14.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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517691
1.198,0.531 1.521,0.813 0.323,0.281 1.25,0.563 1.49,0.76 0.24,0.198 10 true X2

Disconnect the HV air conditioning wire from the inverter with converter assembly.

HINT:

Make sure that no foreign matter has entered or contaminated the HV air conditioning wire.



c.
A517717
1.719,0.365 2.052,0.604 0.333,0.24 1.771,0.385 2.021,0.583 0.25,0.198 10 true X1

Disconnect the HV air conditioning wire connector from the compressor with motor assembly.

HINT:

Make sure that no foreign matter has entered or contaminated the HV air conditioning wire.



d.
A515024
0.5,0.583 0.844,0.813 0.344,0.229 1.635,0.927 1.094,1.396 true 1.833,0.927 2.375,1.438 true 0.063,0.063 0.375,0.219 0.313,0.156 10 false *a 0.604,0.615 0.917,0.771 0.313,0.156 10 false X2 0.927,1.417 1.344,1.604 0.417,0.188 10 false ACPE 2.24,1.458 2.656,1.646 0.417,0.188 10 false ACPB
*a HV Air Conditioning Wire
(Inverter with Converter Assembly Side)


Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
X2-2 (ACPE) - X2-1 (ACPB) Ignition switch off 10 kΩ or higher


NOTICE:

Be sure to inspect with connecting the tester probes to the tips of the terminal.



e.

Reconnect the HV air conditioning wire to the inverter with converter assembly.


f.

Reconnect the HV air conditioning wire connector to the compressor with motor assembly.


Result:
Proceed to
OK
NG



OK

REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for HEV Model)>REMOVAL


NG

REPLACE HV AIR CONDITIONING WIRE