Toyota Prius 2010 User manual

Last Modified: 5-3-2010 6.4 C From: 200904
Model Year: 2010 Model: Prius Doc ID: RM000000OMD01IX
Title: HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0AA6-526,P0AA6-611,P0AA6-612,P0AA6-
613,P0AA6-614: Hybrid Battery Voltage System Isolation Fault (2010 Prius)
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
DESCRIPTION
The power management control ECU monitors the battery smart unit and detects insulation malfunctions in the high-
voltage system.
DTC
NO.
INF
CODE
DTC DETECTION CONDITION TROUBLE AREA
P0AA6 526(*1) Insulation resistance between the high-voltage circuit and
the body has decreased.
Hybrid vehicle transaxle
assembly
Motor cable
Generator cable
Inverter with converter
assembly
Frame wire
No. 2 engine wire
Hybrid battery junction
block
Compressor with motor
assembly
HV battery
Battery smart unit

DTC
NO.
INF
CODE
DTC DETECTION CONDITION TROUBLE AREA
P0AA6 611 Insulation resistance of the with motor compressor
assembly has decreased. Compressor with motor assembly
P0AA6 612 Insulation resistance of the HV battery area has
decreased.
Hybrid battery junction
block
Battery smart unit
HV battery
P0AA6 613 Insulation resistance of the transaxle area has decreased.
Hybrid vehicle transaxle
assembly
Motor cable
Generator cable
Inverter with converter
assembly
P0AA6 614 Insulation resistance of the high-voltage DC area has
decreased.
Inverter with converter
assembly
Frame wire
Compressor with motor
assembly
No. 2 engine wire
Hybrid battery junction
block
Hybrid vehicle transaxle
assembly
Motor cable
Generator cable
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 high
voltage wire harness.
WIRING DIAGRAM

SYSTEM DESCRIPTION
HINT:
If a decrease in insulation resistance cannot be confirmed using a megohmmeter, check the Short Wave Highest
Val 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 table
below. Short Wave Highest Val decreases with a decrease in insulation resistance. However, in some cases,
even though the insulation resistance of the vehicle is normal, Short Wave Highest Val may decrease.
Therefore, check Short Wave Highest Val while considering the following.
Do not check until approximately 1 minute has passed after the power switch is turned on (IG) (*1).
Do not check when there is a difference between the system voltages (HV battery voltage, VL-
Voltage before boosting, and VH-Voltage after boosting) (*2).

SHORT WAVE HIGHEST VALUE TROUBLE AREA
Neither condition (*1) nor (*2) is met
and Short Wave Highest Val is
approximately 0 V
Since the insulation resistance is close to 0 Ω, there is
a strong possibility of interference with a metal object.
Neither condition (*1) nor (*2) is met
and Short Wave Highest Val is between 0
and 5 V
Since the insulation resistance is several hundred
kiloohms, there is a strong possibility of the presence
of fluid such as coolant.
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 of the
wire harness or force applied.
(b) Repeat rotating and stopping of the MG1, MG2 and compressor with motor. Check that the Short Wave
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 foreign matter
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 the
temperature increase.
INSPECTION PROCEDURE
CAUTION:
When troubleshooting P0AA6, be sure to wrap the tools with electrical tape. (It is very dangerous if high
voltage is shorted to ground through the tools.)
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.
When measuring insulation resistance using a megohmmeter, set the megohmmeter to 500 V.
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:

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 P0A1F (battery ECU malfunction) are output. D
(e) Turn the power switch off.
DGO TO DTC CHART (P0AFC)
CGO TO DTC CHART (P0AA7)
BGO TO DTC CHART (P0A1D)
2. CHECK INFORMATION CODE
(a) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
(b) 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 is
output, turn the power switch off and wait 30 seconds to determine the malfunctioning area. Then, turn the
power 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
the air conditioning area) are output
Refer to the troubleshooting procedures for P0AA6-611
(Heater and air conditioning system)
526 and 612 (decrease in the insulation resistance of
the battery area) are output B
526 and 613 (decrease in the insulation resistance of
the transaxle area) are output C
526 and 614 (decrease in the insulation resistance of
the high-voltage DC area) are output D
DCHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY
(MOTOR CABLE)
CCHECK INVERTER WITH CONVERTER ASSEMBLY

A
BCHECK HV BATTERY AREA
3. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE)
CAUTION:
Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) 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.
(c) Remove the inverter terminal cover from the inverter with
converter assembly.
HINT:
Make sure that no foreign objects have entered or contaminated the
inverter with converter assembly.
(d) Disconnect the motor cable e1 and generator cable f1 from the
inverter with converter assembly.
(e) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION

OK
e1-3 (V) - Body ground and
shielded wire ground
Power switch off 100 MΩ or higher
e1-2 (U) - 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
Text in Illustration
*1 Motor Cable
*2 Shielded Wire Ground
NG CHECK MOTOR CABLE
4. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR 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
repair manual because this may cause a malfunction.
(b) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
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
Text in Illustration

OK
*1 Generator Cable
*2 Shielded Wire Ground
NG CHECK GENERATOR CABLE
5. CHECK NO. 2 ENGINE WIRE
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 the No. 2 engine wire (air conditioning harness) E2
from the inverter with converter assembly.
HINT:
Make sure that no foreign objects have entered or contaminated the
connector of the No. 2 engine wire (air conditioning harness) E2.
(c) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
E2-1 (ACPB) - Body ground and
shielded wire ground
Power switch off 3 MΩ or higher
E2-2 (ACPE) - Body ground and
shielded wire ground
Power switch off 3 MΩ or higher
Text in Illustration
*1 No. 2 Engine Wire

OK
(Air Conditioning Harness)
*2 Shielded Wire Ground
NG CHECK NO. 2 ENGINE WIRE
6. CHECK INVERTER WITH CONVERTER 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) Disconnect the frame wire T1 from the inverter with converter
assembly.
HINT:
Make sure that no foreign objects have entered or contaminated the
connector of the frame wire T1.
(c) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
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 (air conditioning harness) disconnected from the inverter
with converter assembly.

OK
OK
NG REPLACE INVERTER WITH CONVERTER ASSEMBLY
7. CHECK FRAME WIRE
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) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH CONDITION SPECIFIED CONDITION
T1-1 (CEI) - Body ground Power switch off 10 MΩ or higher
T1-2 (CBI) - Body ground Power switch off 10 MΩ or higher
Text in Illustration
*1 Frame Wire
NG CHECK FRAME WIRE
8. CHECK HV BATTERY AREA
CAUTION:
Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) 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.
(c) Disconnect connector j1 from the battery smart unit
HINT:
For the removal and installation procedures related to the battery smart
unit connectors, .
(d) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH CONDITION SPECIFIED CONDITION
1 - Body ground Power switch off 10 MΩ or higher
2 - Body ground Power switch off 10 MΩ or higher
NG CHECK HYBRID BATTERY JUNCTION BLOCK
OK REPLACE BATTERY SMART UNIT
9. CHECK INVERTER WITH CONVERTER ASSEMBLY
CAUTION:
Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) 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.

(c) Remove the inverter terminal cover from the inverter with
converter assembly.
HINT:
Make sure that no foreign objects have entered or contaminated the
inverter with converter assembly.
(d) Disconnect the motor cable e1 and generator cable f1 from the
inverter with converter assembly.
(e) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
High voltage terminal - Body
ground
Power switch off 1 MΩ or higher
Result:
RESULT PROCEED TO
NG A
OK B
BCHECK MOTOR CABLE
AREPLACE INVERTER WITH CONVERTER ASSEMBLY
10. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE)
CAUTION:
Be sure to wear insulated gloves.

(a) Turn the power switch off.
(b) 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.
(c) Remove the inverter terminal cover from the inverter with
converter assembly.
HINT:
Make sure that no foreign objects have entered or contaminated the
inverter with converter assembly.
(d) Disconnect the motor cable e1 and generator cable f1 from the
inverter with converter assembly.
(e) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
e1-3 (V) - Body ground and
shielded wire ground
Power switch off 100 MΩ or higher
e1-2 (U) - 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
Text in Illustration
*1 Motor Cable
*2 Shielded Wire Ground

OK
OK
NG CHECK MOTOR CABLE
11. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR 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
repair manual because this may cause a malfunction.
(b) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
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
Text in Illustration
*1 Generator Cable
*2 Shielded Wire Ground
NG CHECK GENERATOR CABLE
12. CHECK HIGH VOLTAGE DIRECT CURRENT AREA

OK
CAUTION:
Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) 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.
(c) Disconnect the frame wire T1 from the inverter with converter
assembly.
HINT:
Make sure that no foreign objects have entered or contaminated the
connector of the frame wire T1.
(d) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH CONDITION SPECIFIED CONDITION
T1-1 (CEI) - Body ground Power switch off 10 MΩ or higher
T1-2 (CBI) - Body ground Power switch off 10 MΩ or higher
Text in Illustration
*1 Frame Wire
NG CHECK FRAME WIRE
13. CHECK NO. 2 ENGINE WIRE
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 the No. 2 engine wire (air conditioning harness) E2
from the inverter with converter assembly.
(c) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
E2-1 (ACPB) - Body ground and
shielded wire ground
Power switch off 3 MΩ or higher
E2-2 (ACPE) - Body ground and
shielded wire ground
Power switch off 3 MΩ or higher
Text in Illustration
*1 No. 2 Engine Wire
(Air Conditioning Harness)
*2 Shielded Wire Ground
NG CHECK NO. 2 ENGINE WIRE
OK REPLACE INVERTER WITH CONVERTER ASSEMBLY
14. CHECK NO. 2 ENGINE WIRE
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 the No. 2 engine wire (air conditioning harness) E1
from the compressor with motor assembly.
Text in Illustration
*1 Green Lock
(c) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
E2-1 (ACPB) - Body ground and
shielded wire ground
Power switch off 10 MΩ or higher
E2-2 (ACPE) - Body ground and
shielded wire ground
Power switch off 10 MΩ or higher
Text in Illustration
*1 No. 2 Engine Wire
(Air Conditioning Harness)
*2 Shielded Wire Ground
NG REPLACE NO. 2 ENGINE WIRE
OK AIR CONDITIONING SYSTEM (P0AA6-611)
15. CHECK FRAME WIRE
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 the frame wire T4 and T3 from the hybrid battery
junction block.
HINT:
For the removal and installation procedures related to the frame wire,
.
(c) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
T4-1 (CBI) - Body ground and
shielded wire ground
Power switch off 10 MΩ or higher
T3-1 (CEI) - Body ground and
shielded wire ground
Power switch off 10 MΩ or higher
NG REPLACE FRAME WIRE
OK REPLACE HYBRID BATTERY JUNCTION BLOCK
16. CHECK HYBRID BATTERY JUNCTION BLOCK
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 the high voltage cable connector of the HV battery h2
and k2 from the hybrid battery junction block.
(c) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
k2-1 - Hybrid Battery Carrier
Panel
Power switch off 10 MΩ or higher
h2-1 - Hybrid Battery Carrier
Panel
Power switch off 10 MΩ or higher
NG REPLACE HYBRID BATTERY JUNCTION BLOCK
OK REPLACE HV BATTERY
17. CHECK MOTOR CABLE
CAUTION:
Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) 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.
(c) Disconnect the motor cable from the hybrid vehicle transaxle assembly .

(d) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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:
TESTER CONNECTION SWITCH
CONDITION
SPECIFIED
CONDITION
e1-3 (V) - Body ground and
shielded wire ground
Power switch off 100 MΩ or higher
e1-2 (U) - 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
Text in Illustration
*1 Motor Cable
*2 Shielded Wire Ground
NG REPLACE MOTOR CABLE
OK REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
18. CHECK GENERATOR 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
repair manual because this may cause a malfunction.
(b) Disconnect the generator cable from the hybrid vehicle transaxle assembly .
(c) Using a megohmmeter set to 500 V, measure the resistance
according to the value(s) in the table below.
NOTICE:
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: