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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 532 (HYBRID CONTROL SYSTEM - DIAGNOSIS)DTC P0A94/557: DC/DC CONVERTER PERFORMANCEINSPECTION PROCEDURE
2004 Toyota Matrix XR, FWD, Standard

Inspection Procedure

2004 Toyota Matrix XR, FWD, StandardSECTION Inspection Procedure
WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system.
  • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:

At least 5 minutes is required to discharge the high-voltage condenser inside the inverter.

  1. READ OUTPUT DTC (HV ECU) 
    1. Connect the hand-held tester to the DLC3.
    2. Turn the power switch ON (IG).
    3. Turn the hand-held tester ON.
    4. On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO /CURRENT CODES.
    5. Read DTCs.
      1. Result: DTC listed in the table below is output 
      DTC TROUBLE

      DTC No. INF Code Detection Item
      P0A94 551 or 552 DC/DC Converter Malfunction

    YES: GO TO THE DTC TEST SHOWN IN THE TABLE ABOVE 

    NO: Go to Next Step 

  2. CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Turn the power switch OFF.
    2. Remove the service plug grip (see SERVICE PLUG GRIP ).
      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.
    3. Remove the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM ).
    4. Check the connection condition of the I9 and I10 inverter connectors.
      1. OK: Connectors have been connected securely and there is no poor connection. 
    5. Reinstall the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM ).
    6. Reinstall the service plug grip (see SERVICE PLUG GRIP ).
    Fig 1: Checking Connection Condition Of I9 And I10 Inverter Connector
    G02917785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: CONNECT SECURELY 

    OK: Go to Next Step 

  3. READ OUTPUT DTC (HV ECU) 
    1. Connect the hand-held tester to the DLC3.
    2. Turn the power switch ON (IG).

      HINT:

      DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.

    3. Turn the hand-held tester ON.
    4. On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO /CURRENT CODES.
    5. Read DTCs.
      1. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output 

    NO: REPLACE W/CONVERTER INVERTER ASSY (See  W/CONVERTER INVERTER ASSY  in HYBRID CONTROL SYSTEM ) 

    YE: Go to Next Step 

  4. INSPECT W/CONVERTER INVERTER ASSY (IGCT VOLTAGE) 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Turn the power switch OFF.
    2. Remove the service plug grip (see SERVICE PLUG GRIP ).
      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.
    3. Remove the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM ).
    4. Turn the power switch ON (IG).

      HINT:

      DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.

    5. Measure the voltage between the terminals of the inverter connector.
      1. Standard: 
      VOLTAGE CHECK

      Tester Connection Specified Condition
      IGCT (I9-1) - GND1 (I9-2) 8 V or more
    6. Turn the power switch OFF.
    7. Reinstall the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM ).
    8. Reinstall the service plug grip (see SERVICE PLUG GRIP ).

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Fig 2: Identifying Connector Terminals GNDI (-) And IGCT (+)
    G02917786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE W/CONVERTER INVERTER ASSY (See  W/CONVERTER INVERTER ASSY  in HYBRID CONTROL SYSTEM ) 

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.