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HYBRID / BATTERY CONTROL: HYB...

Last Modified: 9-6-2012 6.4 C From: 201201 Model Year: 2012 Model: Prius PHV Doc ID: RM000000OMD03WXTitle: HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0AA6-526,P0AA6-611,P0AA6-612,P0AA6-613,P0AA6-614: Hybrid Battery Voltage System Isolation Fault (2012 Prius PHV)

DTC P0AA6-526 Hybrid Battery Voltage System Isolation Fault





DESCRIPTION

The power management control ECU monitors the battery smart unit and detects insulation malfunctions in thehigh-voltage system.

DTCNo.

INFCode DTC Detection Condition Trouble Area

P0AA6 526(*1) Insulation resistance between the high-voltage circuit andthe body has decreased.

Hybrid vehicle transaxleassemblyGenerator cableMotor cableInverter with converterassemblyFrame wireNo. 2 engine wireHybrid battery junction blockassemblyAir conditioning systemNo. 1 hybrid vehicle supplystack sub-assemblyNo. 2 hybrid vehicle supplystack sub-assemblyNo. 3 hybrid vehicle supplystack sub-assemblyNo. 4 hybrid vehicle supplystack sub-assemblyElectric vehicle fuseNo. 6 hybrid vehicle batteryterminalNo. 1 hybrid vehicle batterypack cableNo. 2 hybrid vehicle batterypack cableNo. 3 hybrid vehicle batterypack cableElectric vehicle battery plugassemblyBattery smart unit



DTCNo.

INFCode DTC Detection Condition Trouble Area

P0AA6 611 Insulation resistance of the high voltage circuit in the airconditioning system has decreased. Air conditioning system

P0AA6 612 Insulation resistance of the HV battery area has decreased.

Hybrid battery junction blockassemblyBattery smart unitNo. 1 hybrid vehicle supplystack sub-assemblyNo. 2 hybrid vehicle supplystack sub-assemblyNo. 3 hybrid vehicle supplystack sub-assemblyNo. 4 hybrid vehicle supplystack sub-assemblyElectric vehicle fuseNo. 6 hybrid vehicle batteryterminalNo. 1 hybrid vehicle batterypack cableNo. 2 hybrid vehicle batterypack cableNo. 3 hybrid vehicle batterypack cableElectric vehicle battery plugassembly

P0AA6 613 Insulation resistance of the transaxle area has decreased.

Hybrid vehicle transaxleassemblyGenerator cableMotor cableInverter with converterassembly

P0AA6 614 Insulation resistance of the high-voltage DC area hasdecreased.

Inverter with converterassemblyFrame wireAir conditioning systemNo. 2 engine wireHybrid battery junction blockassemblyElectric vehicle chargerassemblyElectric vehicle charger wire

HINT:

*1: INF code 526 is stored together with P0AA6.If DTC P0AA6 is stored, the vehicle cannot start.When measuring insulation resistance using a megohmmeter, measure the resistance while jiggling the highvoltage wire harness.

WIRING DIAGRAM



Text in Illustration

*1 HV Battery *2 Battery Smart Unit

*3 SMRB *4 SMRG

*5 SMRP *6 System Main Resistor

*7 Service Plug Grip *8 Inverter with Converter Assembly

*9 Boost Converter *10 Inverter

*11 MG1 *12 MG2

*13 Compressor with Motor Assembly *14 A/C Inverter



*15 A/C Motor *16 CHRB

*17 CHRG *18 Electric vehicle charger assembly

*a High-voltage Areas *b INF Code 526 Vehicle Insulation Resistance Reduction Area

*c INF Code 611 Air Conditioning SystemArea *d INF Code 612 HV Battery Area

*e INF Code 613 Transaxle Area *f INF Code 614 High Voltage Direct Current Area



SYSTEM DESCRIPTION

HINT:

If a decrease in insulation resistance cannot be confirmed using a megohmmeter, check the Short Wave HighestVal in the Data List.

1. Characteristics of Short Wave Highest Value

(a) The Data List item Short Wave Highest Val and insulation resistance have the relationship shown in the tablebelow. Short Wave Highest Val decreases with a decrease in insulation resistance. However, in some cases, eventhough the insulation resistance of the vehicle is normal, Short Wave Highest Val may decrease. Therefore, checkShort Wave Highest Val under the following conditions:

Approximately 1 minute has passed since the power switch was turned on (IG).*1There is no difference between the system voltages (Power Resource VB, VL-Voltage before Boosting, andVH-Voltage after Boosting).*2

Short Wave Highest Value Trouble Area

Both conditions (*1 and *2) are met andShort Wave Highest Val is approximately 0V

Since the insulation resistance is close to 0 Ω, there is a strongpossibility of interference with a metal object.

Both conditions (*1 and *2) are met andShort Wave Highest Val is between 0 and5 V

Since the insulation resistance is several hundred kilo ohms,there is a strong possibility of the presence of fluid such ascoolant.

2. How to Determine Part with Insulation Malfunction

(a) Jiggle the high-voltage wire harness to check if the resistance to body ground changes with the position ofthe wire harness or force applied.

(b) Repeat rotating and stopping of the MG1, MG2 and compressor with motor assembly. Check that the ShortWave Highest Val does not decrease (for example if the motor stops with foreign matter forming a leak path)



when the motor stops, or that the Short Wave Highest Val does not return to normal (for example if foreignmatter moves away from the leak path) when the motor rotates.

(c) Increase the temperature of MG1and MG2. Check if the Short Wave Highest Val decreases with thetemperature increase.

(d) Check that the transaxle fluid is not cloudy and the coolant level in the reserve tank has not dropped as thetransaxle fluid will become cloudy when mixed with coolant, resulting in low insulation resistance.

INSPECTION PROCEDURE

CAUTION:

When performing P0AA6 troubleshooting, use either a tool wrapped with vinyl insulation tape or a insulatedtool. (It is extremely dangerous when a high-voltage charge passes through a non-insulated tool causing ashort.)Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter withconverter assembly or electric vehicle charger assembly, turn the power switch off. Also, take safetyprecautions such as wearing insulated gloves and removing the service plug grip to prevent electricalshocks. After removing the service plug grip, put it in your pocket to prevent other technicians fromaccidentally reconnecting it while you are working on the high-voltage system.After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltageconnectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspectionpoint 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 withconverter assembly and electric vehicle charger assembly.

When disposing of HV batteries and hybrid vehicle supply stack sub-assemblies, make sure to return themthrough an authorized collection agent who is capable of handling them safely. If they are returned via themanufacturer specified route, they will be returned properly and in a safe manner by an authorizedcollection agent.Before returning the HV battery, make sure to perform a recovery inspection .Before returning the hybrid vehicle supply stack sub-assembly, make sure to perform a recovery inspection

.Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HVbattery and hybrid vehicle supply stack sub-assemblies.

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from thenegative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from thenegative (-) auxiliary battery terminal notices before proceeding with work .

HINT:

When measuring insulation resistance using a megohmmeter, set the megohmmeter to 500 V.

PROCEDURE

1. CHECK DTC OUTPUT (HYBRID CONTROL)

(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:

Result Proceed to



A

Result Proceed to

P0AA6 only is output. A

P0AA6 and P0A1D (power management control ECU malfunction) are output. B

P0AA6 and P0AA7 (malfunction in the battery smart unit) are output. C

P0AA6 and P0AFC (Hybrid Battery Pack Sensor Module) are output. D

(e) Turn the power switch off.

B GO TO DTC CHART (P0A1D)

C GO TO DTC CHART (P0AA7)

D GO TO DTC CHART (P0AFC)

2. CHECK INFORMATION CODE

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

(b) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(c) Access the freeze frame data of DTC P0AA6 and read the INF code.

NOTICE:

INF codes 611, 612, 613 and 614 are not stored at the same time with INF code 526. If INF code 526 only isoutput, turn the power switch off and wait 30 seconds to determine the malfunctioning area. Then, turn thepower switch on (IG) and read the INF code again.

Result:

Result Proceed to

526 (decrease in the insulation resistance of the high-voltage circuit) only is output A

526 and 611 (decrease in the insulation resistance of theair conditioning system area) are output

Refer to the troubleshooting procedures for P0AA6-611 (Air conditioning system)

526 and 612 (decrease in the insulation resistance of thebattery area) are output B

526 and 613 (decrease in the insulation resistance of thetransaxle area) are output C



A

Result Proceed to

526 and 614 (decrease in the insulation resistance of thehigh-voltage DC area) are output D

(d) Turn the power switch off.

B CHECK HV BATTERY AREA

C CHECK INVERTER WITH CONVERTER ASSEMBLY

D CHECK HIGH VOLTAGE DIRECT CURRENT AREA

3. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE)

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 repairmanual because this may cause a malfunction.

(b) Remove the inverter cover from the inverter with converter assembly.

HINT:

Make sure that no foreign objects have entered or contaminated the inverter withconverter assembly.

(c) Disconnect connector e1 and f1 of the motor cable and generator cable from theinverter with converter assembly.


*1 Motor Cable

*2 Generator Cable

(d) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) inthe table below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higherthan 500 V can result in damage to the component being inspected.

Standard Resistance:



OK

Tester Connection Switch Condition Specified ConditionTester Connection Switch Condition Specified Condition

e1-2 (U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

e1-3 (V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

e1-1 (W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher


*1Motor Cable

(Inverter with Converter Assembly Side)

*2 Shield Ground

NG CHECK MOTOR CABLE

4. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE)

CAUTION:



NOTICE:


(b) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) inthe table below.

NOTICE:



Tester Connection Switch Condition Specified Condition

f1-3 (V) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

f1-2 (U) - Body ground and shielded wire ground Power switch off 100 MΩ or higher

f1-1 (W) - Body ground and shielded wire ground Power switch off 100 MΩ or higher



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OK

*1Generator Cable


*2 Shield Ground

NG CHECK GENERATOR CABLE

5. CHECK NO. 2 ENGINE WIRE

CAUTION:



NOTICE:


(b) Disconnect connector E3 of the No. 2 engine wire (air conditioning harness) from theinverter with converter assembly.

HINT:

Make sure that no foreign objects have entered or contaminated the terminal of the No. 2engine wire (air conditioning harness) E3.

(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) inthe table below.

NOTICE:



Tester Connection SwitchCondition

SpecifiedCondition

E3-1 (ACPB) - Body ground and shielded wireground Power switch off 3 MΩ or higher

E3-2 (ACPE) - Body ground and shielded wireground Power switch off 3 MΩ or higher


*1No. 2 Engine Wire (Air Conditioning Harness)




OK

OK

*2 Shield Ground

NG CHECK NO. 2 ENGINE WIRE

6. CHECK INVERTER WITH CONVERTER ASSEMBLY

CAUTION:



NOTICE:


(b) Disconnect connector T12 of the frame wire from the inverter with converterassembly.

HINT:

Make sure that no foreign objects have entered or contaminated the terminal of theframe wire T12.


NOTICE:




High voltage terminal - Body ground Power switch off 1 MΩ or higher

HINT:

Perform this inspection with the motor cable, generator cable and No. 2 engine wire (airconditioning harness) disconnected from the inverter with converter assembly.

NG REPLACE INVERTER WITH CONVERTER ASSEMBLY

7. CHECK FRAME WIRE

CAUTION:



NOTICE:



OK



NOTICE:




SpecifiedCondition

T12-1 (CEI) - Body ground and shielded wireground Power switch off 10 MΩ or higher

T12-2 (CBI) - Body ground and shielded wireground Power switch off 10 MΩ or higher


*1Frame Wire


*2 Shield Ground

HINT:

Visually inspect the frame wire for damage. If there is any damage, then this is the likelycause of low insulation resistance.

NG CHECK FRAME WIRE

8. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:



NOTICE:


(b) Remove the No. 2 hybrid vehicle battery shield panel .

(c) Disconnect connector a3 of the electric vehicle charger wire from the hybrid batteryjunction block assembly.



OK


NOTICE:




a3-6 (DCHB) - Body ground Power switch off 10 MΩ or higher

a3-3 (DCHG) - Body ground Power switch off 10 MΩ or higher

T15-1 (CBI) - Body ground Power switch off 10 MΩ or higher

T14-1 (CEI) - Body ground Power switch off 10 MΩ or higher


*1 Hybrid Battery Junction Block Assembly

NG REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

9. CHECK ELECTRIC VEHICLE CHARGER WIRE

CAUTION:



NOTICE:



NOTICE:





OK


SpecifiedCondition

a3-6 (DCHB) - Body ground and shielded wireground Power switch off 10 MΩ or higher

a3-3 (DCHG) - Body ground and shielded wireground Power switch off 10 MΩ or higher


*1Electric Vehicle Charger Wire

(Hybrid Battery Junction Block Assembly Side)

*2 Shield Ground

NG CHECK ELECTRIC VEHICLE CHARGER WIRE

10. CHECK HV BATTERY AREA

CAUTION:



NOTICE:



(c) Disconnect connector i1, j1, u1 and v1 from the battery smart unit.


NOTICE:






1 - Body ground Power switch off 10 MΩ or higher

2 - Body ground Power switch off 10 MΩ or higher


*1Electric Vehicle Battery Plug Assembly

(Service Plug Grip Side)

NG CHECK HV BATTERY

OK REPLACE BATTERY SMART UNIT

11. CHECK INVERTER WITH CONVERTER ASSEMBLY

CAUTION:



NOTICE:



HINT:


(c) Disconnect connector e1 and f1 of the motor cable and generator cable from theinverter with converter assembly.


*1 Motor Cable

*2 Generator Cable


NOTICE:






High voltage terminal - Body ground Power switch off 1 MΩ or higher

Result:

Result Proceed to

NG A

OK B

B CHECK MOTOR CABLE

A REPLACE INVERTER WITH CONVERTER ASSEMBLY

12. CHECK HIGH VOLTAGE DIRECT CURRENT AREA

CAUTION:



NOTICE:



HINT:


(c) Disconnect connector T12 of the frame wire from the inverter with converterassembly.

HINT:

Make sure that no foreign objects have entered or contaminated the terminal of theframe wire T12.


NOTICE:





OK


SpecifiedConditionTester Connection Switch

ConditionSpecifiedCondition




*1Frame Wire


*2 Shield Ground

HINT:


NG CHECK FRAME WIRE

13. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:



NOTICE:



(c) Disconnect connector a3 of the electric vehicle charger wire from the hybrid batteryjunction block assembly.


NOTICE:





OK


a3-6 (DCHB) - Body ground Power switch off 10 MΩ or higher

a3-3 (DCHG) - Body ground Power switch off 10 MΩ or higher

T15-1 (CBI) - Body ground Power switch off 10 MΩ or higher

T14-1 (CEI) - Body ground Power switch off 10 MΩ or higher


*1 Hybrid Battery Junction Block Assembly

NG REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY


CAUTION:



NOTICE:



NOTICE:




SpecifiedCondition






OK

*1 Electric Vehicle Charger Wire


*2 Shield Ground

NG CHECK ELECTRIC VEHICLE CHARGER WIRE


CAUTION:



NOTICE:


(b) Disconnect connector E3 of the No. 2 engine wire (air conditioning harness) from theinverter with converter assembly.


NOTICE:




SpecifiedCondition






*2 Shield Ground



NG CHECK NO. 2 ENGINE WIRE

OK REPLACE INVERTER WITH CONVERTER ASSEMBLY


CAUTION:



NOTICE:


(b) Disconnect connector E1 of the No. 2 engine wire (air conditioning harness) from thecompressor with motor assembly .


NOTICE:




SpecifiedCondition






*2 Shield Ground

NG REPLACE NO. 2 ENGINE WIRE

OK GO TO AIR CONDITIONING SYSTEM (P0AA6-611)




CAUTION:



NOTICE:


(b) Disconnect connector a2 of the electric vehicle charger wire from the electric vehiclecharger assembly .


NOTICE:




SpecifiedCondition




*1Electric Vehicle Charger Wire


*2 Shield Ground

NG REPLACE ELECTRIC VEHICLE CHARGER WIRE

OK REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY

18. CHECK FRAME WIRE

CAUTION:





NOTICE:



(c) Disconnect the frame wire from the hybrid battery junction block assembly.


NOTICE:




SpecifiedCondition




*1Frame Wire


*2 Shield Ground

HINT:


NG REPLACE FRAME WIRE

OK REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

19. CHECK HV BATTERY

CAUTION:



OK



NOTICE:


(b) Disconnect connector of the No. 2 hybrid vehicle battery pack cable from the hybridbattery junction block assembly.


NOTICE:




w2-1 (+) - Body ground Power switch off 10 MΩ or higher


*1No. 2 Hybrid Vehicle Battery Pack Cable


NG CHECK HV BATTERY


CAUTION:



NOTICE:


(b) Disconnect connector q8 of the No. 1 hybrid vehicle battery pack cable from thehybrid battery junction block assembly.




NOTICE:




q8-1 (-) - Body ground Power switch off 10 MΩ or higher




NG CHECK HV BATTERY

OK REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY


CAUTION:

Be sure to wear insulated gloves and protective goggles.


NOTICE:


(b) Remove the upper hybrid battery cover sub-assembly .

(c) Disconnect the electric vehicle battery plug assembly from the electric vehiclefuse.


NOTICE:










NG CHECK HV BATTERY

OK REPLACE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY


CAUTION:



NOTICE:


(b) Remove the electric vehicle fuse.


NOTICE:






*1 No. 2 Hybrid Vehicle Battery Pack Cable




NG CHECK HV BATTERY

OK REPLACE ELECTRIC VEHICLE FUSE


CAUTION:



NOTICE:


(b) Remove the No. 6 hybrid vehicle battery terminal.


NOTICE:








NG CHECK HV BATTERY

OK REPLACE NO. 6 HYBRID VEHICLE BATTERY TERMINAL


CAUTION:





NOTICE:


(b) Disconnect the No. 3 hybrid vehicle battery pack cable from the No. 3 hybrid vehiclesupply stack sub-assembly.

(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in thetable below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higherthan 500 V can result in damage to the component being inspected.Wrap insulating tape around the terminal of the No. 3 hybrid vehicle battery pack cable onthe No. 3 hybrid vehicle supply stack sub-assembly side to prevent it from contacting thebody ground.







NG CHECK HV BATTERY

OK REPLACE NO. 3 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY


CAUTION:



NOTICE:






NOTICE:








NG CHECK NO. 2 HYBRID VEHICLE BATTERY PACK CABLE

OK REPLACE NO. 3 HYBRID VEHICLE BATTERY PACK CABLE (NO. 3 HYBRID VEHICLE SUPPLY STACK - NO. 4HYBRID VEHICLE SUPPLY STACK)

26. CHECK NO. 2 HYBRID VEHICLE BATTERY PACK CABLE

CAUTION:



NOTICE:




NOTICE:




Wrap insulating tape around the terminal of the No. 2 hybrid vehicle battery pack cable onthe No. 4 hybrid vehicle supply stack sub-assembly side to prevent it from contacting thebody ground.







NG REPLACE NO. 2 HYBRID VEHICLE BATTERY PACK CABLE



CAUTION:



NOTICE:


(b) Remove the upper hybrid battery cover sub-assembly .

(c) Disconnect the electric vehicle battery plug assembly from the No. 2 hybrid vehiclesupply stack sub-assembly.


NOTICE:










NG CHECK HV BATTERY

OK REPLACE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY


CAUTION:



NOTICE:




NOTICE:








NG CHECK HV BATTERY

OKREPLACE NO. 2 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY




CAUTION:



NOTICE:




NOTICE:








NG CHECK NO. 1 HYBRID VEHICLE BATTERY PACK CABLE

OK REPLACE NO. 3 HYBRID VEHICLE BATTERY PACK CABLE (NO. 1 HYBRID VEHICLE SUPPLY STACK - NO. 2HYBRID VEHICLE SUPPLY STACK)

30. CHECK NO. 1 HYBRID VEHICLE BATTERY PACK CABLE

CAUTION:



NOTICE:






NOTICE:








NG REPLACE NO. 1 HYBRID VEHICLE BATTERY PACK CABLE


31. CHECK MOTOR CABLE

CAUTION:



NOTICE:


(b) Disconnect the motor cable from the hybrid vehicle transaxle assembly .


NOTICE:










*1Motor Cable


*2 Shield Ground

NG REPLACE MOTOR CABLE

OK REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

32. CHECK GENERATOR CABLE

CAUTION:



NOTICE:


(b) Disconnect the generator cable from the hybrid vehicle transaxle assembly .


NOTICE:










*1Generator Cable


*2 Shield Ground

NG REPLACE GENERATOR CABLE


33. CHECK MOTOR CABLE

CAUTION:



NOTICE:


(b) Disconnect the motor cable from the hybrid vehicle transaxle assembly .


NOTICE:








*1Motor Cable


*2 Shield Ground

NGREPLACE MOTOR CABLE



OK

34. CHECK GENERATOR CABLE

CAUTION:



NOTICE:


(b) Disconnect the generator cable from the hybrid vehicle transaxle assembly .


NOTICE:








*1Generator Cable


*2 Shield Ground

NG REPLACE GENERATOR CABLE


Copyright 2011 - 2013 Service Repair Solutions, Inc.

Portions of materials contained herein have been reprinted under license from Toyota Motor Sales,U.S.A., Inc., License Agreement TMS1003.

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