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P0A94-557 - DC / DC Converter Performance





HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0A94-557: DC / DC Converter Performance
P0A94-557 - DC / DC Converter Performance

DESCRIPTION

The MG ECU uses a voltage sensor that is built into the boost converter to detect pre-boost high voltage (VL) to allow boost control. The boost converter voltage sensor outputs a voltage that varies between 0 and 5 V in accordance with changes in pre-boost voltage (VL). The higher the pre-boost voltage, the higher the sensor output voltage. Conversely, the lower the pre-boost voltage, the lower the output voltage. The MG ECU monitors the boost converter voltage sensor signal line and detects a malfunction.

If a malfunction occurs in the boost converter, the MG ECU detects it and transmits this information to the hybrid vehicle control ECU.





MONITOR DESCRIPTION

If the boost converter detects a circuit malfunction, it will transmit a boost converter fail signal to the MG ECU. The MG ECU will send information about the malfunction to the hybrid vehicle control ECU. Upon receiving this information, the hybrid vehicle control ECU will illuminate the MIL and set a DTC.

MONITOR STRATEGY





TYPICAL ENABLING CONDITIONS





TYPICAL MALFUNCTION THRESHOLDS





COMPONENT OPERATING RANGE





WIRING DIAGRAM









INSPECTION PROCEDURE

CAUTION:
- Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
- After disconnecting 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.
NOTICE:
After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CHECK DTC OUTPUT (HV)

(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 if DTCs are output.

Result:









HINT
- *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
- P0A94-557 may be set due to a malfunction which also causes DTCs in the preceding table to be set. 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.
(e) Turn the power switch off.

B -- GO TO DTC CHART Hybrid Control System
A -- Continue to next step.

2. CHECK AMOUNT OF GASOLINE P0A7A

B -- REFUEL VEHICLE
A -- Continue to next step.

3. CHECK ENGINE START P0A7A

B -- CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
A -- Continue to next step.

4. CHECK CRANKSHAFT PULLEY REVOLUTION (WITH PARK (P) SELECTED) P0A7A

B -- CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
A -- Continue to next step.

5. CHECK CRANKSHAFT PULLEY REVOLUTION (WITH NEUTRAL (N) SELECTED) P0A7A

B -- REPAIR OR REPLACE ENGINE ASSEMBLY

A -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

6. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) P0343

NG -- CONNECT SECURELY
OK -- Continue to next step.

7. CHECK QUANTITY OF HV COOLANT P0A01

C -- CHECK FOR COOLANT LEAKS AND ADD COOLANT

B -- ADD COOLANT
A -- Continue to next step.

8. CHECK COOLANT HOSE P0A01

NG -- CORRECT THE PROBLEM
OK -- Continue to next step.

9. PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE WATER PUMP) P0A01

NG -- PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE WATER PUMP)
OK -- Continue to next step.

10. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE ELECTRIC COOLING FAN) P0A01

NG -- CHECK COOLING FAN SYSTEM Cooling Fan Circuit
OK -- Continue to next step.

11. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING) P0A01

B -- REPLACE HV COOLANT
A -- Continue to next step.

12. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

13. CHECK GENERATOR RESOLVER P0A1A

NG -- CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
OK -- Continue to next step.

14. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

15. CHECK MOTOR RESOLVER P0A1A

NG -- CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
OK -- Continue to next step.

16. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) P0A1B

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

17. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) P0A1B

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

18. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) P0A1B

NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components
OK -- Continue to next step.

19. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) P0A1B

NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components
OK -- Continue to next step.

20. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY

OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

22. PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE WATER PUMP) P0A01

B -- ADD COOLANT
A -- Continue to next step.

23. CHECK FUSE (IGCT NO. 3) P0A01

NG -- CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP WITH MOTOR ASSEMBLY CONNECTOR)
OK -- Continue to next step.

24. CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP WITH MOTOR ASSEMBLY CONNECTOR) P0A01

NG -- CONNECT SECURELY
OK -- Continue to next step.

25. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) P0343

NG -- CONNECT SECURELY
OK -- Continue to next step.

26. CHECK HARNESS AND CONNECTOR (WATER PUMP WITH MOTOR ASSEMBLY CIRCUIT) P0A01

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

27. CHECK WATER PUMP WITH MOTOR ASSEMBLY P0A01

NG -- REPLACE WATER PUMP WITH MOTOR ASSEMBLY Components

OK -- REPLACE HYBRID VEHICLE CONTROL ECU Components

28. REPLACE HV COOLANT P0A01

NEXT -- Continue to next step.

29. CHECK WATER PUMP WITH MOTOR ASSEMBLY P0A01

NG -- REPLACE WATER PUMP WITH MOTOR ASSEMBLY Components

OK -- COMPLETED

30. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

31. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

32. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

33. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

34. CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP WITH MOTOR ASSEMBLY CONNECTOR) P0A01

NG -- CONNECT SECURELY
OK -- Continue to next step.

35. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) P0343

NG -- CONNECT SECURELY
OK -- Continue to next step.

36. CHECK HARNESS AND CONNECTOR (WATER PUMP WITH MOTOR ASSEMBLY CIRCUIT) P0A01

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

37. CHECK WATER PUMP WITH MOTOR ASSEMBLY P0A01

NG -- REPLACE WATER PUMP WITH MOTOR ASSEMBLY
OK -- Continue to next step.

38. REPLACE HYBRID VEHICLE CONTROL ECU P0A01

NEXT -- REPLACE FUSE (IGCT NO. 3)

39. CONNECT SECURELY P0A01

NEXT -- REPLACE FUSE (IGCT NO. 3)

40. CONNECT SECURELY P0A01

NEXT -- REPLACE FUSE (IGCT NO. 3)

41. REPAIR OR REPLACE HARNESS OR CONNECTOR P0A01

NEXT -- REPLACE FUSE (IGCT NO. 3)

42. REPLACE WATER PUMP WITH MOTOR ASSEMBLY P0A01

NEXT -- REPLACE FUSE (IGCT NO. 3)
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