P0A08-264

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0A08-264: DC / DC Converter Status Circuit
P0A08-264 - DC / DC Converter Status Circuit

DESCRIPTION

The hybrid vehicle converter (DC/DC converter) converts the DC 244.8 V of the HV battery into DC 12 V in order to supply power to areas such as the vehicle's lighting, audio, and ECU systems. In addition, it charges the auxiliary battery. A transistor bridge circuit initially converts DC 244.8 V into alternating current, and a transformer lowers its voltage. Then, it is rectified and smoothed (into DC) and converted into DC 12 V. The hybrid vehicle converter controls the output voltage in order to keep a constant voltage at the terminals of the auxiliary battery.

The hybrid vehicle control ECU uses the NODD signal line to transmit a stop command to the hybrid vehicle converter and receive signals indicating the normal or abnormal condition of the 12 V charging system. If the vehicle is being driven with an inoperative hybrid vehicle converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the hybrid vehicle control ECU monitors the operation of the hybrid vehicle converter and alerts the driver if it detects a malfunction.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AE6-225 P0AE6.

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.
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
DTC P0A08-264 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.

(e) Turn the power switch off.

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

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

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

3. CHECK CONNECTOR CONNECTION CONDITION (ENGINE ROOM JUNCTION BLOCK ASSEMBLY CONNECTOR)

(a) Check the connection of the frame wire 1E connector.

OK:

The connector is connected securely and there are no contact problems.

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

4. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

(a) Check that the bolt for the frame wire terminal is tightened to the specified torque, the frame wire terminal is connected securely, and there are no contact problems.

Torque:

8.4 N*m {85 kgf*cm , 74 in.*lbf }

(b) Check for arc marks at the bolts for the frame wire.

Result:

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

C -- CONNECT SECURELY
A -- Continue to next step.

5. CHECK FUSES

(a) Measure the resistance of the headlight system fuses, A/C blower system, defogger system, stop light system and power window system.

OK:

Below 1 Ohms

HINT
If any of the fuses is broken, replace the fuse and repair the shorted circuit.

NG -- REPAIR OR REPLACE SHORTED CIRCUIT AND REPLACE BROKEN FUSE
OK -- Continue to next step.

6. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR) P0A09-265

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

7. CHECK HYBRID VEHICLE CONVERTER (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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Check that the nuts for the AMD terminals are tightened to the specified torque, the AMD terminals are connected securely, and there are no contact problems.

Torque:

Nut A
9.0 N*m {92 kgf*cm , 80 in.*lbf }

Nut B
7.5 N*m {76 kgf*cm , 66 in.*lbf }

(c) Check for arc marks at the nuts for the AMD terminals.

Result:

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

C -- CONNECT SECURELY
A -- Continue to next step.

8. CHECK HYBRID VEHICLE CONVERTER (INSTALLATION 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Check that the hybrid vehicle converter installation nuts and HV battery assembly installation bolts are tightened to the specified torque. Check that the hybrid vehicle converter installation nuts and HV battery assembly installation bolts are connected securely and that there are no contact problems.

Torque:

A
7.5 N*m {76 kgf*cm , 66 in.*lbf } (Hybrid vehicle converter installation nut)

B
19 N*m {194 kgf*cm , 14 ft.*lbf } (HV battery assembly installation bolt)

Text in Illustration

HINT
Because the hybrid vehicle converter is body grounded, DTC P0A08-264 may be set if there are any contact or connection problems.

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

C -- CONNECT SECURELY
A -- Continue to next step.

9. CHECK HYBRID VEHICLE CONTROL ECU

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 connector z17 from the hybrid vehicle converter.

Standard Resistance:

Text in Illustration

(d) Connect the hybrid vehicle converter connector.

NG -- CHECK HARNESS AND CONNECTOR
OK -- Continue to next step.

10. CHECK HYBRID BATTERY JUNCTION BLOCK 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) Check the connections of the hybrid battery junction block assembly connectors.

OK:

The connectors are connected securely and there are no contact problems.

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

11. CHECK ELECTRIC VEHICLE FUSE (DC/DC)

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

Standard Resistance:

NG -- REPLACE ELECTRIC VEHICLE FUSE
OK -- Continue to next step.

12. CHECK ELECTRIC VEHICLE FUSE (INSTALLATION 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Check that the bolts for the electric vehicle fuse are tightened to the specified torque, the electric vehicle fuse are connected securely, and there are no contact problems.

Torque:

4.5 N*m {46 kgf*cm , 40 in.*lbf }

(c) Check for arc marks at the bolts for the electric vehicle fuse terminals.

Result:

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

C -- CONNECT SECURELY
A -- Continue to next step.

13. CHECK HARNESS AND 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect connector A58 from the hybrid vehicle control ECU.

(c) Disconnect connector z17 from the hybrid vehicle converter.

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

Standard Resistance:

Text in Illustration

(e) Connect the hybrid vehicle converter connector.

(f) Connect the hybrid vehicle control ECU connector.

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

14. CHECK HYBRID VEHICLE CONVERTER

(a) Connect the AC/DC 400 A probe of an ammeter to the output cable of the hybrid vehicle converter.

(b) Install the service plug grip.

(c) Measure the current flowing from the auxiliary battery with the power switch on (READY), the headlight switch and blower motor switch in the HI position, and the rear window defogger turned on.

Standard Current:

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

Standard Voltage:

(e) Turn the power switch off.

NG -- CHECK TERMINAL VOLTAGE (AMD TERMINAL VOLTAGE)
OK -- Continue to next step.

15. CHECK FOR INTERMITTENT PROBLEMS

(a) Check for intermittent problems Check for Intermittent Problems.

NG -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
OK -- Continue to next step.

16. CHECK REAR SEAT SIDE GARNISH LH

HINT
For details about the hybrid vehicle converter cooling duct, refer to the description for DTC P0A08-101 P0A08-101.

(a) Check that the air intake grill of the rear seat side garnish LH is not clogged.

OK:

The air intake grill is not clogged.

NG -- REMOVE FOREIGN OBJECT
OK -- Continue to next step.

17. CHECK AIR DUCT (ALL)

HINT
For details about the hybrid vehicle converter cooling duct, refer to the description for DTC P0A08-101 P0A08-101.

(a) Check if the ducts are installed correctly.

OK:

The ducts are installed correctly.

(b) Check the ducts for clogging.

OK:

The ducts are not clogged.

NG -- REPAIR OR REPLACE AIR DUCT (ALL)

OK -- REPLACE HYBRID VEHICLE CONVERTER Components

18. CHECK HARNESS AND 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect connector A58 from the hybrid vehicle control ECU.

(c) Disconnect connector z17 from the hybrid vehicle converter.

(d) Turn the power switch on (IG).

HINT
Turning the power switch on (IG) with the service plug grip removed causes interlock switch system DTC P0A0D-350 to be output.

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

Standard Voltage:

Text in Illustration

(f) Turn the power switch off.

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

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE CONTROL ECU Components

19. CHECK TERMINAL VOLTAGE (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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

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

Standard Voltage:

NG -- CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

OK -- REPLACE HYBRID VEHICLE CONVERTER Components

20. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

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

Standard Voltage:

NG -- CHECK FUSIBLE LINK BLOCK ASSEMBLY (MAIN)
OK -- Continue to next step.

21. CHECK FUSIBLE LINK (DC/DC)

(a) Disconnect connector 1E from the engine room junction block assembly.

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

Standard Resistance:

(c) Connect the engine room junction block assembly connector.

NG -- REPLACE FUSIBLE LINK (DC/DC)

OK -- REPAIR OR REPLACE FRAME WIRE (HYBRID VEHICLE CONVERTER - ENGINE ROOM JUNCTION BLOCK) Components

22. CHECK FUSIBLE LINK BLOCK ASSEMBLY (MAIN)

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

Standard Resistance:

NG -- REPLACE FUSIBLE LINK BLOCK ASSEMBLY (MAIN)
OK -- Continue to next step.

23. CHECK AUXILIARY BATTERY (TERMINAL CONNECTION CONDITION)

(a) Turn the power switch off.

(b) Check the connection of the auxiliary battery terminal cables.

OK:

The cables are connected securely and there are no contact problems.

(c) Check for arc marks on the auxiliary battery terminal cables.

Result:

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

C -- CONNECT SECURELY
A -- Continue to next step.

24. CHECK HARNESS AND CONNECTOR (AUXILIARY NEGATIVE BATTERY TERMINAL - BODY GROUND)

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

Standard Resistance:

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY NEGATIVE BATTERY TERMINAL - BODY GROUND)

OK -- REPAIR OR REPLACE FRAME WIRE (AUXILIARY POSITIVE BATTERY TERMINAL - ENGINE ROOM J/B) Components