Diesel Data: Automotive Repair
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Part 2








P112 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0AA6-526: Hybrid Battery Voltage System Isolation Fault

DTC P0AA6-526 - Hybrid Battery Voltage System Isolation Fault

DTC P0AA6-611 - Hybrid Battery Voltage System Isolation Fault

DTC P0AA6-612 - Hybrid Battery Voltage System Isolation Fault

DTC P0AA6-613 - Hybrid Battery Voltage System Isolation Fault

DTC P0AA6-614 - Hybrid Battery Voltage System Isolation Fault

(Continued)

15. INSPECT JUNCTION BLOCK
CAUTION: Wear insulated gloves and goggles before performing the following operation.
(a) Following the previous step, remove the junction block.




(b) Visually check the junction block for any damage.
OK:
No cracks or damage
NG -- REPLACE JUNCTION BLOCK
OK -- Continue to next step.

16. INSPECT HV BATTERY ASSEMBLY
CAUTION: Wear insulated gloves and goggles before performing the following operation.




(a) Following the previous step, measure the insulation resistance between each terminal (positive and negative side) of each battery module of the HV battery assembly and the battery case using a megohmmeter set to 500 V.
NOTE: 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:
None of the battery modules have continuity of below 10 MOhms
NG -- REPLACE HV SUPPLY BATTERY ASSEMBLY
OK -- REPLACE BATTERY ECU ASSEMBLY
17. CHECK FRAME WIRE FOR INSULATION
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip has been detached.




(b) Disconnect the frame wire from the inverter.
(c) Using a megohmmeter set to 500 V, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground.
NOTE: 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:
10 MOhmsor higher
NG -- REPLACE FRAME WIRE
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
18. CHECK ELECTRIC INVERTER COMPRESSOR
CAUTION: Wear insulated gloves before performing the following operation.
(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.




(c) Disconnect the C4 electric inverter compressor connector.
(d) Using a megohmmeter set to 500 V, measure the insulation resistance between the high-voltage terminals of the electric inverter compressor connector and the body ground.
NOTE: 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:





NOTE: The A/C inverter is integrated with the inverter assembly. It is necessary to replace the PCU box assembly (inverter with converter assembly) if the A/C inverter (inverter assembly) needs to be replaced because the A/C inverter (inverter assembly) cannot be replaced alone.

NG -- REPLACE ELECTRIC INVERTER COMPRESSOR
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
19. CHECK HV BATTERY AREA
CAUTION: Wear insulated gloves before performing the following operation.
(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.




(c) Disconnect the B12 and B13 battery ECU connectors.




(d) Disconnect the main battery cables from the system main relays.
(e) Using a megohmmeter set to 500 V, measure the insulation resistance between the positive terminal on the HV battery side of the system main relay and the body ground.
NOTE: 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:
10 MOhms or higher
(f) Using a megohmmeter set to 500 V, measure the insulation resistance between the negative terminal on the HV battery side of the system main relay and the body ground.
NOTE: 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:
10 MOhms or higher
NG -- CHECK SYSTEM MAIN RELAYS FOR INSULATION
OK -- REPLACE BATTERY ECU ASSEMBLY
20. CHECK SYSTEM MAIN RELAYS FOR INSULATION
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip has been detached.




(b) Check that all the high-voltage terminals of the system main relays have been disconnected.
(c) Using a megohmmeter set to 500 V, measure the insulation resistance between the high-voltage terminals of the system main relays and the body ground.
NOTE: 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:
10 MOhms or higher
NG -- REPLACE SYSTEM MAIN RELAY WITH REDUCED INSULATION RESISTANCE
OK -- Continue to next step.

21. INSPECT MAIN BATTERY CABLE
CAUTION: Wear insulated gloves and goggles before performing the following operation.




(a) Remove the HV battery assembly Removal.
(b) Remove the battery cover Disassembly.
(c) Check if the main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body.
OK:
Electrical leads are not in contact with the battery case or body
(d) Remove the terminal (A in the illustration) on the battery module side of the main battery cable only.
(e) Using a megohmmeter set to 500 V, measure the insulation resistance between each terminal of the main battery cable and the shielded ground.
NOTE: 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:
10 MOhms or higher
NG -- REPLACE MAIN BATTERY CABLE
OK -- Continue to next step.

22. INSPECT NO. 2 MAIN BATTERY CABLE
CAUTION: Wear insulated gloves and goggles before performing the following operation.
(a) Following the previous step, check if the No. 2 main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body.
OK:
Electrical leads are not in contact with the battery case or body




(b) Remove the terminal (A in illustration) on the battery module side of the No. 2 main battery cable only.
(c) Using a megohmmeter set to 500 V, measure the insulation resistance between each terminal of the No. 2 main battery cable and the shielded ground.
NOTE: 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:
10 MOhms or higher
NG -- REPLACE NO. 2 MAIN BATTERY CABLE
OK -- Continue to next step.

23. INSPECT BATTERY PLUG
CAUTION: Wear insulated gloves and goggles before performing the following operation.




(a) Following the previous step, disconnect only the connecting terminal of the battery plug.
NOTE: Do not reinstall the service plug grip.
(b) Using a megohmmeter set to 500 V, measure the insulation resistance between each terminal of the battery plug wire harness and the body ground.
NOTE: 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:
10 MOhms or higher
NG -- REPLACE BATTERY PLUG
OK -- Continue to next step.

24. INSPECT NO. 2 FRAME WIRE
CAUTION: Wear insulated gloves and goggles before performing the following operation.




(a) Following the previous step, check if the No. 2 frame wire cover is not damaged or internal electrical leads are not in contact with the battery case or body.
OK:
Electrical leads are not in contact with the battery case or body.
(b) Remove all the terminals on the battery module side of the No. 2 frame wire.
(c) Using a megohmmeter set to 500 V, measure the insulation resistance between each terminal of the No. 2 frame wire connector and the battery case.
NOTE: 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:
10 MOhms or higher
NG -- REPLACE NO. 2 FRAME WIRE
OK -- Continue to next step.

25. INSPECT JUNCTION BLOCK
CAUTION: Wear insulated gloves and goggles before performing the following operation.




(a) Following the previous step, remove the junction block.
(b) Visually check the junction block for any damage.
OK:
No cracks or damage
NG -- REPLACE JUNCTION BLOCK
OK -- Continue to next step.

26. INSPECT HV BATTERY ASSEMBLY
CAUTION: Wear insulated gloves and goggles before performing the following operation.




(a) Following the previous step, measure the insulation resistance between each terminal (positive and negative side) of each battery module of the HV battery assembly and the battery case using a megohmmeter set to 500 V.
NOTE: 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:
None of the battery modules have continuity of below 10 MOhms
NG -- REPLACE HV SUPPLY BATTERY ASSEMBLY
OK -- REPLACE BATTERY ECU ASSEMBLY
27. CHECK HV TRANSAXLE ASSEMBLY FOR INSULATION
CAUTION: Wear insulated gloves before performing the following operation.
(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
(c) Remove the inverter cover Removal.




(d) Disconnect the three-phase alternating current cables for the motor and generator from the inverter.
(e) Using a megohmmeter set to 500 V, measure the insulation resistance between the 6 terminals of the three-phase alternating current cables on the transaxle side and the body ground.
NOTE: 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:






NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
28. CHECK HIGH VOLTAGE DIRECT CURRENT AREA FOR INSULATION
CAUTION: Wear insulated gloves before performing the following operation.
(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.




(c) Disconnect the frame wire from the inverter.
(d) Using a megohmmeter set to 500 V, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground.
NOTE: 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:
10 MOhms or higher
NG -- CHECK SYSTEM MAIN RELAYS FOR INSULATION
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
29. CHECK SYSTEM MAIN RELAYS FOR INSULATION
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip has been detached.
(b) Disconnect the frame wire and system main resistor from the system main relays.




(c) Using a megohmmeter set to 500 V, measure the insulation resistance between the high-voltage terminals of the system main relays and the body ground.
NOTE: 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:
10 MOhms or higher
NG -- REPLACE SYSTEM MAIN RELAY WITH REDUCED INSULATION RESISTANCE
OK -- Continue to next step.

30. CHECK SYSTEM MAIN RESISTOR FOR INSULATION
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip has been detached.




(b) Check that both terminals of the system main resistor have been disconnected.
(c) Using a megohmmeter set to 500 V, measure the insulation resistance between the high-voltage terminal of the system main resistor and the body ground.
NOTE: 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:
10 MOhms or higher
NG -- REPLACE SYSTEM MAIN RESISTOR
OK -- REPLACE FRAME WIRE
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