A 2013 Toyota Camry HV2 hybrid vehicle with approximately 50,000 km and a 4AR engine. A user reported that engine suddenly lost power while vehicle was moving and vehicle could not move. The message "Please check hybrid system" appeared on multifunction display screen, battery charging warning light came on, and vehicle stopped. side of road to wait for rescue.
Inspection Analysis: Maintenance personnel arrived at site for a preliminary inspection, determined that problem could not be fixed locally, and towed vehicle back to workshop for repair. Check vehicle maintenance history, timely vehicle maintenance, and no collision maintenance record.
Check if fault phenomenon is as reported by user, turn on ignition, "READY" indicator will illuminate for 1 second and then turn off, and fault code will be read as "P0A08-DC/DC Converter Status Circuit", and fault code cannot be cleared. According to analysis of maintenance manual, possible causes of failure are: fuses, wiring harnesses or connectors, inverter water pump assemblies, inverter cooling systems, inverter assemblies, power control units, and transmission assemblies. The service personnel carry out following checks.
① Check DC/DC IGC D fuse in No. 2 relay box in engine room, and make sure everything is OK.
② Check IGCT MAIN fuse in No. 2 relay box in engine room, and make sure everything is OK.
＠ Check DC/DC-S fuse of relay box and junction box in engine room, and make sure everything is OK.
④ Check engine control module connector and make sure there is no problem.
⑥ Check connector of inverter assembly with inverter, no abnormality is found.
⑥ Check DC/DC fuse in fuse box and make sure everything is OK.
⑦Remove top cover of inverter, measure insulation resistance of inverter with a multimeter, and compare it with indicated value, no abnormality is found.
⑧Make sure AMD terminal voltage is same as auxiliary battery voltage, which is in accordance with regulations, check AMD connection line and installation is correct.
⑨Make sure that ground voltage of "A13-3" inverter and car body is same as that of auxiliary battery, which is in accordance with regulations.
⑩Make sure that ground voltage of inverter "A13-1" and car body is same as that of auxiliary battery, which is in accordance with regulations.
11 Measure grounding resistance of Al 3-5 inverter and car body at 130 ohms, which is in accordance with requirements.
12 The auxiliary battery in luggage compartment has a measured voltage of 11.2V and indicated voltage is between 13.01 and 15.0V; If a 12V battery is connected in parallel, car can start and move, but fault indicator does not light up. is still on.
Troubleshooting: According to instructions in service manual, replace inverter assembly, test run is normal, problem is solved.
Overview and summary. Hybrid vehicle maintenance steps still include factory inspection, customer inquiry, fault check, fault code detection, data stream read, plan, check and measure, parts repair, parts replacement, and test run check. . Service personnel must be specially trained for hybrid vehicles. Hybrid vehicle batteries are high voltage, and safety regulations are strictly followed to prevent electric shock.