Diesel Data: Automotive Repair
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P0A94-557








P311 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A94-557: DC / DC Converter Performance

DTC P0A94-557 - DC / DC Converter Performance

DESCRIPTION

The boost converter boosts the 244.8 V DC from the HV battery to a maximum of approximately 650 V DC. The inverter converts the voltage that has been boosted by the boost converter into alternating current, which is used for driving MG2 and MG1. When MG1 and MG2 operate as a generator, the alternating-current voltage from MG1 and MG2 is converted into direct-current voltage by the inverter. Then the boost converter drops this voltage to a direct-current voltage rating of 244.8 V in order to charge the HV battery.





The MG ECU uses a voltage sensor (VL) that is built into the boost converter to detect the high voltage before it is boosted. It also uses a voltage sensor (VH) that is built into the inverter to detect the high voltage after it is boosted. Based on the voltage before and after it is boosted, the hybrid vehicle control ECU controls the operation of the boost converter to boost the voltage to the target voltage.

If the boost converter detects a circuit malfunction, overheat, or internal short, it transmits this information to the FCV terminal of the MG ECU via the boost converter fail signal line.






MONITOR DESCRIPTION

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

MONITOR STRATEGY





TYPICAL ENABLING CONDITIONS





TYPICAL MALFUNCTION THRESHOLDS





COMPONENT OPERATING RANGE





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 inspection, 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) Select the following menu items: 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 flowchart.
- Turning the power switch on (IG) with the service plug grip and inverter cover removed causes interlock switch system DTC P0A0D-350 to be output.
- P0A94-557 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

YES -- GO TO DTC CHART
NO -- Continue to next step.
2. CHECK AMOUNT OF GASOLINE P0A7A
NG -- REFUEL VEHICLE
OK -- Continue to next step.
3. CHECK ENGINE START P0A7A
OK -- CHECK QUANTITY OF HV COOLANT
NG -- Continue to next step.
4. INSPECT CRANKSHAFT PULLEY REVOLUTION (P POSITION) P0A7A
OK -- CHECK QUANTITY OF HV COOLANT
NG -- Continue to next step.
5. INSPECT CRANKSHAFT PULLEY REVOLUTION (N POSITION) P0A7A
NG -- REPAIR OR REPLACE ENGINE ASSEMBLY
OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
6. CHECK QUANTITY OF HV COOLANT P0A93
C -- CHECK FOR COOLANT LEAKS AND ADD COOLANT
B -- ADD COOLANT
A -- Continue to next step.
7. CHECK COOLANT HOSE P0A93
NG -- CORRECT THE PROBLEM
OK -- Continue to next step.
8. CHECK FUSE (INV W/P FUSE) P0A93
NG -- REPLACE FUSE
OK -- Continue to next step.
9. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) P0343
NG -- CONNECT SECURELY
OK -- Continue to next step.
10. CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP WITH MOTOR & BRACKET ASSEMBLY CONNECTOR) P0A93
NG -- CONNECT SECURELY
OK -- Continue to next step.
11. PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE WATER PUMP) P0A93
NG -- PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE WATER PUMP)
OK -- Continue to next step.
12. CHECK CONNECTOR CONNECTION CONDITION (COOLING FAN MOTOR CONNECTOR) P0A93
NG -- CONNECT SECURELY
OK -- Continue to next step.
13. PERFORM ACTIVE TEST USING TECHSTREAM (DRIVING THE BATTERY COOLING FAN) P0A93
NG -- CHECK COOLING FAN SYSTEM
OK -- Continue to next step.
14. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) P0343
NG -- CONNECT SECURELY
OK -- Continue to next step.
15. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
16. CHECK GENERATOR RESOLVER P0A1A
NG -- CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
OK -- Continue to next step.
17. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1B
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
18. CHECK MOTOR RESOLVER P0A1B
NG -- CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
OK -- Continue to next step.
19. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) P0A1B
NG -- TIGHTEN TO SPECIFIED TORQUE
OK -- Continue to next step.
20. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) P0A1B
NG -- TIGHTEN TO SPECIFIED TORQUE
OK -- Continue to next step.
21. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) P0A1B
NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
OK -- Continue to next step.
22. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) P0A1B
NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
23. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A
NG -- CONNECT SECURELY
OK -- Continue to next step.
24. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
25. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1B
NG -- CONNECT SECURELY
OK -- Continue to next step.
26. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1B
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
27. PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE WATER PUMP) P0A93
OK -- ADD COOLANT
NG -- Continue to next step.
28. CHECK WATER PUMP WITH MOTOR & BRACKET ASSEMBLY P0A93
NG -- CHECK HARNESS AND CONNECTOR (WATER PUMP WITH MOTOR POWER SOURCE CIRCUIT)
OK -- Continue to next step.
29. CHECK HARNESS AND CONNECTOR (WATER PUMP WITH MOTOR & BRACKET ASSEMBLY - HV CONTROL ECU) P0A93
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
30. CHECK ENGINE ROOM R/B P0A93
NG -- REPAIR OR REPLACE ENGINE ROOM R/B
OK -- REPLACE HYBRID VEHICLE CONTROL ECU
31. CHECK HARNESS AND CONNECTOR (WATER PUMP WITH MOTOR POWER SOURCE CIRCUIT) P0A93
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE WATER PUMP WITH MOTOR & BRACKET ASSEMBLY
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