05–488

DIAGNOSTICS – HYBRID CONTROL SYSTEM 05J9E–01

DTC P0A0F/238 ENGINE FAILED TO START

CIRCUIT DESCRIPTION
The HV control ECU detects this DTC and effects fail–safe control if the engine or transaxle gear has seized
up, or foreign objects have been caught in either of them.
DTC No. INF Code DTC Detection Condition Trouble Area

Engine assembly

HV transaxle assembly (shaft or gear)
Engine does not start even though cranking it
P0A0F 238
Transmission input damper
(transaxle input malfunction [engine system])

Wire harness or connector

HV control ECU

WIRING DIAGRAM

ECM HV Control ECU

1
LG 12
NEO E7 H16 NEO
(Shielded)
33
R 1
NE+ E4 C7
Crankshaft
Position
34 Sensor
G A A G 2
NE– E4
J14
J/C BR A A BR

J12 EC
J/C

A92095

INSPECTION PROCEDURE
1 READ OUTPUT DTC(ENGINE)

(a) Connect the hand–held tester to the DLC3.

(b) Turn the power switch ON (IG).
(c) Turn the hand–held tester ON.
(d) On the hand–held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ENGINE AND
ECT / DTC INFO / TROUBLE CODES.
(e) Read DTCs.
Result: DTCs are output
YES GO TO RELEVANT DTC CHART
(See page 05–55)

NO

2004 Prius – Preliminary Release (RM1075U)

Author: Date: 652

 05–489
DIAGNOSTICS – HYBRID CONTROL SYSTEM

2 CHECK CRANKSHAFT PULLEY REVOLUTION

(a) Turn the power switch OFF.

(b) Jack up the vehicle.
(c) Manually turn the crankshaft pulley to check if the crankshaft rotates.
OK: The crankshaft rotates
NG Go to step 11

OK

3 CHECK HARNESS AND CONNECTOR(ECM – CRANKSHAFT POSITION SENSOR)

(a) Disconnect the E4 ECM connector.

(b) Disconnect the C7 crankshaft position sensor connector.
E4 (c) Check the resistance between the wire harness side con-
nectors.
Standard (Check for open):
Tester Connection Specified Condition
NE+ (E4–33) – Crankshaft position sensor (C7–1) Below 1 Ω
NE–
NE+ NE– (E4–34) – Crankshaft position sensor (C7–2) Below 1 Ω
ECM Connector A65743 Standard (Check for short):
Tester Connection Specified Condition
Wire Harness Side: NE+ (E4–33) or Crankshaft position sensor (C7–1) –
10 kΩ or higher
Body ground
Crankshaft Position Sensor Connector
NE– (E4–34) or Crankshaft position sensor (C7–2) –
10 kΩ or higher
C7 Body ground

(d) Reconnect the crankshaft position sensor connector.

(e) Reconnect the ECM connector.

Front View NG REPAIR OR REPLACE HARNESS OR

A92031 CONNECTOR

OK

2004 Prius – Preliminary Release (RM1075U)

Author: Date: 653

05–490
DIAGNOSTICS – HYBRID CONTROL SYSTEM

4 CHECK HARNESS AND CONNECTOR(HYBRID VEHICLE CONTROL ECU – ECM)

(a) Disconnect the H16 HV control ECU connector.

(b) Disconnect the E7 ECM connector.
H16 (c) Check the resistance between the wire harness side con-
nectors.
Standard (Check for open):
Tester Connection Specified Condition
NEO NEO (H16–12) – NEO (E7–1) Below 1 Ω
Standard (Check for short):
HV Control ECU Connector A65745 Tester Connection Specified Condition
NEO (H16–12) or NEO (E7–1) –Body ground 10 kΩ or higher
(d) Reconnect the ECM connector.
(e) Reconnect the HV control ECU connector.
E7

NEO
ECM Connector NG REPAIR OR REPLACE HARNESS OR
A65744
CONNECTOR

OK

5 CHECK AND CLEAR DTC(HV ECU)

(a) Connect the hand–held tester to the DLC3.

(b) Turn the power switch ON (IG).
(c) Turn the hand–held tester ON.
(d) On the hand–held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / HV ECU /
DTC INFO / TROUBLE CODES.
(e) Check and record the DTCs, the freeze frame data, and the information.
(f) Clear the DTCs of HV ECU.
GO

6 CHECK READY LAMP ON

(a) Connect the hand–held tester to the DLC3.

(b) Turn the power switch ON (IG).
(c) Turn the hand–held tester ON.
(d) On the hand–held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / HV ECU /
DATA LIST.
(e) Read the MG1 REV and ENGINE SPD values.
(f) Turn the power switch ON (READY).
OK: READY lamp turns ON
HINT:
If the READY lamp does not turn ON, and the reading on the hand–held tester shows DTC P0A90 (INF 239)
(HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace
the hybrid vehicle transaxle assembly.
2004 Prius – Preliminary Release (RM1075U)

Author: Date: 654

 05–491
DIAGNOSTICS – HYBRID CONTROL SYSTEM

NG REPLACE HYBRID VEHICLE TRANSAXLE

ASSY (See page 22–11)

OK

7 CHECK ENGINE REV–UP

(a) Connect the hand–held tester to the DLC3.

(b) Turn the power switch ON (IG).
(c) Turn the hand–held tester ON.
(d) On the hand–held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / HV ECU /
DATA LIST.
(e) Read the MG1 REV and ENGINE SPD values.
(f) With the READY lamp turned ON, depress the accelerator pedal for 10 seconds while the shift position
is in the P position.
OK: The engine revs up
HINT:
If the engine does not rev up, and the reading on the hand–held tester shows DTC P0A90 (INF 239) (HV
transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the
hybrid vehicle transaxle assembly.
NG REPLACE HYBRID VEHICLE TRANSAXLE
ASSY (See page 22–11)

OK

8 CHECK CREEP MOVEMENT

(a) Connect the hand–held tester to the DLC3.

(b) Turn the power switch ON (READY).
(c) Jack up the vehicle.
(d) Depress the brake pedal, move the selector lever to the D position, and release the brake pedal.
OK: The wheels turn (creep movement)
HINT:
If the wheels do not turn, and the reading on the hand–held tester shows DTC P0A90 (INF 602) (HV transaxle
output malfunction), replace the hybrid vehicle transaxle assembly.
NG REPLACE HYBRID VEHICLE TRANSAXLE
ASSY (See page 22–11)

OK

9 CHECK ENGINE ACCELERATION SPEED

(a) Connect the hand–held tester to the DLC3.

(b) While driving at the vehicle speed of more than 6 mph (10 km/h), fully depress the accelerator pedal
to raise the engine speed.
OK: The engine speed increases smoothly
HINT:
If the engine over–revs or the reading on the hand–held tester shows DTC P0A90 (INF 241) (HV transaxle
input malfunction [torque limiter slipping]), replace the transmission input damper.

2004 Prius – Preliminary Release (RM1075U)

Author: Date: 655

05–492
DIAGNOSTICS – HYBRID CONTROL SYSTEM

NG REPLACE TRANSMISSION INPUT DAMPER

ASSY

OK

10 CHECK CAUSE OF INCREASE IN REVOLUTION RESISTANCE

(a) Investigate what has caused the revolution resistance of the transaxle and engine to become greater.
(1) Check the engine lubrication system and transaxle lubrication system.
(2) Check the engine coolant and transaxle coolant.
(3) Check for any breakdowns in engine itself and transaxle itself.
Result: There is no fault
NO REPAIR MALFUNCTION PARTS AND
COMPONENTS

YES

PERFORM SIMULATION TEST. IF SYMPTOM IS NOT REPRODUCED, REPLACE ENGINE, HV

TRANSAXLE AND HV CONTROL ECU

11 CHECK FRONT TIRE REVOLUTION

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

(b) Depress the brake pedal, move the selector lever to the N position.
(c) Jack up the vehicle.
(d) Manually turn the crankshaft pulley to check if the front tires rotate.
OK: The front tires rotate
NG REPAIR OR REPLACE ENGINE ASSY

OK

REPAIR OR REPLACE HYBRID VEHICLE TRANSAXLE ASSY

2004 Prius – Preliminary Release (RM1075U)

Author: Date: 656