HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-284

DESCRIPTION

For a description of the inverter, Click here.

If the motor inverter overheats, has a circuit malfunction, or has an internal short, the inverter transmits this information to the MG ECU via the motor inverter fail signal line.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P1CAC-200 Click here.

Refer to the wiring diagram for DTC P324E-788 Click here.

Refer to the wiring diagram for DTC U0110-159 Click here.

CAUTION / NOTICE / HINT

PROCEDURE

1. CHECK DTC OUTPUT (HYBRID CONTROL)

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the power switch on (IG).

   3. Enter the following menus: Powertrain / Hybrid Control / DTC.

   4. Check if DTCs are output.

      Result
      Result Proceed to P0A78-202 is not output. A P0A78-202 is also output. B

      Note

      
      

      • If P0A78-202 is output, troubleshoot it first. After completing the troubleshooting for P0A78-202, return to perform troubleshooting for this DTC.

      • Parts repaired or replaced during troubleshooting for P0A78-202 do not need to be re-inspected in this diagnosis procedure.

   5. Turn the power switch off.

   
   

   B

   GO TO DTC CHART (P0A78-202) Click here

   A

2. CHECK DTC OUTPUT (HYBRID CONTROL)

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the power switch on (IG).

   3. Enter the following menus: Powertrain / Hybrid Control / DTC.

   4. Check if DTCs are output.

      Tech Tips

      
      

      • If P0A78-202 was not output in step 1 of this diagnosis procedure, check Table 1 below.

      • If P0A78-202 was output in step 1 of this diagnosis procedure, repair that DTC first, then check Table 2 below.

      Result
      Result Proceed to P0A78-284 only is output. A Any of the following DTCs are also output. B

      Table 1

      DTC No.	Relevant Diagnosis
      P06B0-163	Sensor Power Supply "A" Circuit/Open
      P06D6-511	Sensor Reference Voltage "F" Circuit/Open
      P06E6-164	Sensor Power Supply "C" Circuit/Open
      P0A1A (all INF codes)*1	Generator Control Module
      P0A1B (all INF codes)*1	Drive Motor "A" Control Module
      P0A1D (all INF codes)*1	Hybrid Powertrain Control Module
      P0A3F-243	Drive Motor "A" Position Sensor Circuit
      P0A40-500, 504, 506, 549, 556, 808	Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245	Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253	Generator Position Sensor Circuit
      P0A4C-513, 518, 811	Generator Position Sensor Circuit Range/Performance
      P0A4D-255	Generator Position Sensor Circuit Low
      P0A78-279, 287, 548, 555, 807	Drive Motor "A" Inverter Performance
      P0A7A-325, 810	Generator Inverter Performance
      P0A90-509	Drive Motor "A" Performance
      P0A92-521	Hybrid Generator Performance
      P0BEA-290	Drive Motor "A" Phase V Current Sensor Circuit Range/Performance
      P0BEE-298	Drive Motor "A" Phase W Current Sensor Circuit Range/Performance
      P0C19-306	Drive Motor "A" Torque Delivered Performance
      P0C73-776	Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523	Hybrid Battery System Discharge Time Too Long
      P0CA3-442	DC/DC Converter Step Up Voltage Performance
      P0D2E-586	Drive Motor "A" Inverter Voltage Sensor Circuit Range/Performance
      P0D2F-266	Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267	Drive Motor "A" Inverter Voltage Sensor Circuit High
      P0E05-328	Generator Phase V Current Sensor Circuit Range/Performance
      P0E09-336	Generator Phase W Current Sensor Circuit Range/Performance
      P0E32-585	DC/DC Converter Voltage Sensor "A" Range/Performance
      P0E33-589	DC/DC Converter Voltage Sensor "A" Low
      P0E34-590	DC/DC Converter Voltage Sensor "A" High
      P0E71-344	Generator Torque Delivered Performance
      P1C2A-155	Generator A/D Converter Circuit
      P1C2B-192	Drive Motor "A" A/D Converter Circuit
      P1C2D-587	Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294	Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302	Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333	Generator Phase V Current Sensor Correlation
      P1C3F-341	Generator Phase W Current Sensor Correlation
      P1C4A-288	Drive Motor "A" Phase V Current Sensor Sub Circuit Range/Performance
      P1C4F-296	Drive Motor "A" Phase W Current Sensor Sub Circuit Range/Performance
      P1C54-326	Generator Phase V Current Sensor Sub Circuit Range/Performance
      P1C59-334	Generator Phase W Current Sensor Sub Circuit Range/Performance
      P1C6D-501	Drive Motor "A" Phase V Current Sensor Offset Range/Performance
      P1C6E-502	Drive Motor "A" Phase W Current Sensor Offset Range/Performance
      P1C71-515	Generator Phase V Current Sensor Offset Range/Performance
      P1C72-516	Generator Phase W Current Sensor Offset Range/Performance
      P1C73-512	Sensor Standard Voltage "F" Circuit/Open
      P1CA6-156	Generator Control Module Malfunction
      P1CA7-193	Drive Motor Control Module Malfunction
      P1CAC-200	Generator Position Sensor Angle Malfunction
      P1CAD-168	Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792	Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795	Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793	Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796	Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3133-659	Communication Error from Generator to Drive Motor "A"
      P3134-661	Communication Error from Drive Motor "A" to Generator
      P314A-828	Inverter Coolant Pump Speed Signal

      Table 2

      DTC No.	Relevant Diagnosis
      P06B0-163	Sensor Power Supply "A" Circuit/Open
      P06D6-511	Sensor Reference Voltage "F" Circuit/Open
      P06E6-164	Sensor Power Supply "C" Circuit/Open
      P0A1A (all INF codes)*1	Generator Control Module
      P0A1B (all INF codes)*1	Drive Motor "A" Control Module
      P0A1D (all INF codes)*1	Hybrid Powertrain Control Module
      P0A3F-243	Drive Motor "A" Position Sensor Circuit
      P0A40-500, 504, 506, 549, 556, 808	Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245	Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253	Generator Position Sensor Circuit
      P0A4C-513, 518, 811	Generator Position Sensor Circuit Range/Performance
      P0A4D-255	Generator Position Sensor Circuit Low
      P0A78-279, 287, 548, 555, 807	Drive Motor "A" Inverter Performance
      P0A7A-325, 810	Generator Inverter Performance
      P0A92-521	Hybrid Generator Performance
      P0C73-776	Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523	Hybrid Battery System Discharge Time Too Long
      P0CA3-442	DC/DC Converter Step Up Voltage Performance
      P0D2E-586	Drive Motor "A" Inverter Voltage Sensor Circuit Range/Performance
      P0D2F-266	Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267	Drive Motor "A" Inverter Voltage Sensor Circuit High
      P0E05-328	Generator Phase V Current Sensor Circuit Range/Performance
      P0E09-336	Generator Phase W Current Sensor Circuit Range/Performance
      P0E32-585	DC/DC Converter Voltage Sensor "A" Range/Performance
      P0E33-589	DC/DC Converter Voltage Sensor "A" Low
      P0E34-590	DC/DC Converter Voltage Sensor "A" High
      P0E71-344	Generator Torque Delivered Performance
      P1C2A-155	Generator A/D Converter Circuit
      P1C2B-192	Drive Motor "A" A/D Converter Circuit
      P1C2D-587	Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294	Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302	Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333	Generator Phase V Current Sensor Correlation
      P1C3F-341	Generator Phase W Current Sensor Correlation
      P1C54-326	Generator Phase V Current Sensor Sub Circuit Range/Performance
      P1C59-334	Generator Phase W Current Sensor Sub Circuit Range/Performance
      P1C71-515	Generator Phase V Current Sensor Offset Range/Performance
      P1C72-516	Generator Phase W Current Sensor Offset Range/Performance
      P1C73-512	Sensor Standard Voltage "F" Circuit/Open
      P1CA6-156	Generator Control Module Malfunction
      P1CA7-193	Drive Motor Control Module Malfunction
      P1CAC-200	Generator Position Sensor Angle Malfunction
      P1CAD-168	Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792	Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795	Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793	Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796	Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3133-659	Communication Error from Generator to Drive Motor "A"
      P3134-661	Communication Error from Drive Motor "A" to Generator
      P314A-828	Inverter Coolant Pump Speed Signal

      Tech Tips

      
      

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • P0A78-284 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table.

   5. Turn the power switch off.

   
   

   B

   GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

   A

3. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

   CAUTION:

   Be sure to wear insulated gloves.

   
   

   1. 

      Check that the service plug grip is not installed.

      Note

      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.

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector does not pull out.

   2. Check the connection of the low voltage connector of the inverter with converter assembly.

      OK
      The connector is connected securely and there are no contact problems.

      Tech Tips

      When connecting the connector, insert it with the locking lever in the raised position. Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage. After the click is heard, pull up on the connector to confirm that it is properly connected.

   
   

   NG

   CONNECT SECURELY

   OK

4. CHECK QUANTITY OF HV COOLANT

   
   

   1. Check the coolant level in the inverter reserve tank.

   2. Check for coolant leaks.

      Result

      Result	Proceed to
      No leaks are found and coolant level in the inverter reserve tank assembly is above the low line.	A
      No leaks are found and coolant level in the inverter reserve tank assembly is below the low line.	B
      Coolant leaks are evident.	C

      Tech Tips

      After repairing the coolant leaks and adding coolant, perform the "Activate the Water Pump" Active Test (HV Active Test item) and the "Control the Electric Cooling Fan" Active Test (Engine Active Test item) and make sure that there are no malfunctions.

   
   

   B

   ADD HV COOLANT

   C

   INSPECT FOR COOLANT LEAK AND ADD COOLANT

   A

5. CHECK COOLANT HOSE

   
   

   1. Check if the hoses of the cooling system are kinked or clogged.

   
   

   NG

   CORRECT THE PROBLEM

   OK

6. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE ELECTRIC COOLING FAN)

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the power switch on (IG).

   3. Enter the following menus: Powertrain / Hybrid Control / DTC.

   4. Clear DTCs and freeze frame data.

   5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Electric Cooling Fan.

   6. Perform the "Control the Electric Cooling Fan" Active Test.

      Result
      Result Proceed to The cooling fan rotates. A The cooling fan does not rotate (for 2ZR-FXE). B The cooling fan does not rotate (for 5ZR-FXE). C

   7. Turn the power switch off.

   
   

   B

   CHECK COOLING FAN SYSTEM (2ZR-FXE) Click here

   C

   CHECK COOLING FAN SYSTEM (5ZR-FXE) Click here

   A

7. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING)

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the power switch on (IG).

   3. Read the freeze frame data Ambient Temperature using the intelligent tester.

   4. Check if the freeze frame data Ambient Temperature is below freezing.

      Result
      Result Proceed to Ambient Temperature value is above freezing temperature of the HV coolant A Ambient Temperature value is below freezing temperature of the HV coolant B

      Tech Tips

      
      

      • HV coolant (SLLC) with a 30% concentration freezes at -15°C (5°F) and HV coolant (SLLC) with a 50% concentration freezes at -35°C (-31°F).

      • If the HV coolant freezes in the HV radiator or inverter water pump assembly, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be set.

      • A DTC is set when the inverter water pump assembly impeller cannot rotate due to freezing of the HV coolant.

      • If a DTC is set due to freezing of HV coolant, the problem cannot be reproduced. Judge whether freezing of HV coolant occurred according to the freeze point of the HV coolant, HV coolant change history and ambient temperature when the DTC was set.

   5. Turn the power switch off.

   
   

   B

   REPLACE HV COOLANT Click here

   A

8. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)

   CAUTION:

   Be sure to wear insulated gloves.

   
   

   1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

   2. Turn the power switch on (IG).

   3. 

      Text in Illustration

      *a	Front view of wire harness connector (to Inverter with Converter Assembly)

      Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Switch Condition Specified Condition D28-11 (GRF) - Body ground Power switch on (IG) Below 1 V D28-12 (GRFG) - Body ground Power switch on (IG) Below 1 V D28-7 (GSN) - Body ground Power switch on (IG) Below 1 V D28-8 (GSNG) - Body ground Power switch on (IG) Below 1 V D28-10 (GCS) - Body ground Power switch on (IG) Below 1 V D28-9 (GCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

   4. Turn the power switch off.

   5. Connect the low voltage connector from the inverter with converter assembly.

   
   

   NG

   REPAIR OR REPLACE HARNESS OR CONNECTOR

   OK

9. CHECK GENERATOR RESOLVER

   
   

   1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

   2. 

      Text in Illustration

      *a	Front view of wire harness connector (to Inverter with Converter Assembly)

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition D28-11 (GRF) - D28-12 (GRFG) Power switch off 7.1 to 21.6 Ω D28-7 (GSN) - D28-8 (GSNG) Power switch off 13.7 to 34.5 Ω D28-10 (GCS) - D28-9 (GCSG) Power switch off 12.8 to 32.4 Ω

      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition D28-11 (GRF) or D28-12 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher D28-7 (GSN) or D28-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher D28-10 (GCS) or D28-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

   3. Connect the inverter with converter assembly connector.

   
   

   NG

   CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

   OK

10. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. 

       Text in Illustration

       *a	Front view of wire harness connector (to Inverter with Converter Assembly)

       Measure the voltage according to the value(s) in the table below.

       Standard Voltage
       Tester Connection Switch Condition Specified Condition D28-1 (MRF) - Body ground Power switch on (IG) Below 1 V D28-2 (MRFG) - Body ground Power switch on (IG) Below 1 V D28-3 (MSN) - Body ground Power switch on (IG) Below 1 V D28-4 (MSNG) - Body ground Power switch on (IG) Below 1 V D28-6 (MCS) - Body ground Power switch on (IG) Below 1 V D28-5 (MCSG) - Body ground Power switch on (IG) Below 1 V

       Note

       Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    4. Turn the power switch off.

    5. Connect the inverter with converter assembly connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

11. CHECK MOTOR RESOLVER

    
    

    1. Disconnect the low voltage connector D28 from the inverter with converter assembly.

    2. 

       Text in Illustration

       *a	Front view of wire harness connector (to Inverter with Converter Assembly)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance (Check for Open)
       Tester Connection Switch Condition Specified Condition D28-1 (MRF) - D28-2 (MRFG) Power switch off 7.1 to 21.6 Ω D28-3 (MSN) - D28-4 (MSNG) Power switch off 13.7 to 34.5 Ω D28-6 (MCS) - D28-5 (MCSG) Power switch off 12.8 to 32.4 Ω

       Standard Resistance (Check for Short)
       Tester Connection Switch Condition Specified Condition D28-1 (MRF) or D28-2 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher D28-3 (MSN) or D28-4 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher D28-6 (MCS) or D28-5 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    3. Connect the inverter with converter assembly connector.

    
    

    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

12. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. 

       Remove the inverter cover from the inverter with converter assembly.

    3. 

       Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

       Specified Condition
       Bolt A
       T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
       Bolt B
       T=9.2 N*m {94 kgf*cm, 81 in.*lbf}

       Note

       
       

       • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

       • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

    4. Disconnect the generator cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts for the generator cable.

       Result

       Result Proceed to The terminals are connected securely and there are no contact problems. There are no arc marks. A The terminals are not connected securely and there is a contact problem. There are arc marks. B The terminals are not connected securely and there is a contact problem. There are no arc marks. C The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the generator cable to the inverter with converter assembly.

    7. Install the inverter cover.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

13. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. 

       Remove the inverter cover from the inverter with converter assembly.

    3. 

       Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

       Specified Condition
       Bolt A
       T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
       Bolt B
       T=9.2 N*m {94 kgf*cm, 81 in.*lbf}

       Note

       
       

       • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

       • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

    4. Disconnect the motor cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts for the motor cable.

       Result

       Result Proceed to The terminals are connected securely and there are no contact problems. There are no arc marks. A The terminals are not connected securely and there is a contact problem. There are arc marks. B The terminals are not connected securely and there is a contact problem. There are no arc marks. C The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the motor cable to the inverter with converter assembly.

    7. Install the inverter cover.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

14. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. 

       Remove the inverter cover from the inverter with converter assembly.

    3. Disconnect the generator cable and motor cable from the inverter with converter assembly.

    4. 

       Text in Illustration

       *1	Generator Cable
       *2	Shield Ground

       Check MG1 for an interphase short using a milliohmmeter.

       
       

       1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

          Tech Tips

          If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

          Standard Resistance
          Tester Connection Switch Condition Specified Condition d3-1 (W) - d3-2 (U) Power switch off 89.5 to 98.9 mΩ d3-2 (U) - d3-3 (V) Power switch off 89.5 to 98.9 mΩ d3-3 (V) - d3-1 (W) Power switch off 89.5 to 98.9 mΩ

          Tech Tips

          To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).

          
          

          • R20 = Rt / {1 + 0.00393 X (T - 20)}

          The calculation is based on the following:

          
          

          • R20: Resistance at 20°C (68°F) (mΩ)

          • Rt: Measured resistance (mΩ)

          • T: Temperature when the resistance is measured (°C)

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

       Note

       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 d3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher d3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher d3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.

    
    

    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) Click here

    OK

15. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. 

       Remove the inverter cover from the inverter with converter assembly.

    3. Disconnect the generator cable and motor cable from the inverter with converter assembly.

    4. 

       Text in Illustration

       *1	Motor Cable
       *2	Shield Ground

       Check MG2 for an interphase short using a milliohmmeter.

       
       

       1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

          Tech Tips

          If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

          Standard Resistance
          Tester Connection Switch Condition Specified Condition c3-1 (W) - c3-2 (U) Power switch off 152.6 to 169.0 mΩ c3-2 (U) - c3-3 (V) Power switch off 157.6 to 174.0 mΩ c3-3 (V) - c3-1 (W) Power switch off 151.6 to 168.0 mΩ

          Tech Tips

          To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).

          
          

          • R20 = Rt / {1 + 0.00393 X (T - 20)}

          The calculation is based on the following:

          
          

          • R20: Resistance at 20°C (68°F) (mΩ)

          • Rt: Measured resistance (mΩ)

          • T: Temperature when the resistance is measured (°C)

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

       Note

       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 c3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher c3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher c3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.

    
    

    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) Click here

    OK

16. CHECK FUSE (PCU)

    
    
    1. 

       Text in Illustration

       *1	Engine Room Junction Block Assembly
       *2	PCU Fuse

       Remove the PCU fuse from the engine room junction block assembly.

    2. Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Condition Specified Condition PCU fuse terminals Always Below 1 Ω

    3. Install the PCU fuse.

    
    

    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) Click here

    OK

17. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. Disconnect connector A62 from the inverter with converter assembly.

    3. 

       Text in Illustration

       *a	Front view of wire harness connector (to Inverter with Converter Assembly)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Switch Condition Specified Condition A62-28 (GND1) - Body ground Power switch off Below 1 Ω A62-27 (GND2) - Body ground Power switch off Below 1 Ω

    4. Turn the power switch on (IG).

    5. Measure the voltage according to the value(s) in the table below.

       Standard Voltage
       Tester Connection Switch Condition Specified Condition A62-10 (+B) - Body ground Power switch on (IG) 11 to 14 V A62-9 (+B2) - Body ground Power switch on (IG) 11 to 14 V

    6. Turn the power switch off.

    7. Connect the inverter with converter assembly connector.

    
    

    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

18. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. Disconnect connector A62 from the inverter with converter assembly.

    3. Disconnect connector A20 from the power management control ECU.

    4. Measure the resistance according to the value(s) in the table below.

       

       Standard Resistance (Check for Open)

       Tester Connection Switch Condition Specified Condition A62-8 (HTM+) - A20-24 (HTM+) Power switch off Below 1 Ω A62-18 (HTM-) - A20-25 (HTM-) Power switch off Below 1 Ω A62-7 (MTH+) - A20-30 (MTH+) Power switch off Below 1 Ω A62-17 (MTH-) - A20-29 (MTH-) Power switch off Below 1 Ω A62-6 (REQ+) - A20-33 (REQ+) Power switch off Below 1 Ω A62-16 (REQ-) - A20-32 (REQ-) Power switch off Below 1 Ω A62-5 (CLK+) - A20-21 (CLK+) Power switch off Below 1 Ω A62-15 (CLK-) - A20-20 (CLK-) Power switch off Below 1 Ω

       Standard Resistance (Check for Short)

       Tester Connection Switch Condition Specified Condition A62-8 (HTM+) or A20-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher A62-18 (HTM-) or A20-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher A62-7 (MTH+) or A20-30 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher A62-17 (MTH-) or A20-29 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher A62-6 (REQ+) or A20-33 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher A62-16 (REQ-) or A20-32 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher A62-5 (CLK+) or A20-21 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher A62-15 (CLK-) or A20-20 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher

       Text in Illustration

       *a	Front view of wire harness connector (to Inverter with Converter Assembly)
       *b	Rear view of wire harness connector (to Power Management Control ECU)

    5. Turn the power switch on (IG).

    6. Measure the voltage according to the value(s) in the table below.

       Standard Voltage

       Tester Connection Switch Condition Specified Condition A62-8 (HTM+) or A20-24 (HTM+) - Body ground Power switch on (IG) Below 1 V A62-18 (HTM-) or A20-25 (HTM-) - Body ground Power switch on (IG) Below 1 V A62-7 (MTH+) or A20-30 (MTH+) - Body ground Power switch on (IG) Below 1 V A62-17 (MTH-) or A20-29 (MTH-) - Body ground Power switch on (IG) Below 1 V A62-6 (REQ+) or A20-33 (REQ+) - Body ground Power switch on (IG) Below 1 V A62-16 (REQ-) or A20-32 (REQ-) - Body ground Power switch on (IG) Below 1 V A62-5 (CLK+) or A20-21 (CLK+) - Body ground Power switch on (IG) Below 1 V A62-15 (CLK-) or A20-20 (CLK-) - Body ground Power switch on (IG) Below 1 V

       Note

       Turning the power switch on (IG) with the power management control ECU and inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.

    8. Connect the power management control ECU connector.

    9. Connect the inverter with converter assembly connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

19. CHECK POWER MANAGEMENT CONTROL ECU

    
    

    1. Disconnect connector A20 from the power management control ECU.

    2. 

       Text in Illustration

       *a	Component without harness connected (Power Management Control ECU)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Switch Condition Specified Condition A20-24 (HTM+) - A20-25 (HTM-) Power switch off 80 to 170 Ω A20-30 (MTH+) - A20-29 (MTH-) Power switch off 80 to 170 Ω A20-33 (REQ+) - A20-32 (REQ-) Power switch off 80 to 170 Ω A20-21 (CLK+) - A20-20 (CLK-) Power switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.

    
    

    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

20. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    
    

    1. 

       Check the connection of the generator resolver connector.

       OK
       The connector is connected securely and there are no contact problems.

    
    

    NG

    CONNECT SECURELY

    OK

21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    
    

    1. 

       Check the connection of the motor resolver connector.

       OK
       The connector is connected securely and there are no contact problems.

    
    

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CONNECT SECURELY

22. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    
    

    1. 

       Check the connection of the generator resolver connector.

       OK
       The connector is connected securely and there are no contact problems.

    
    

    NG

    CONNECT SECURELY

    OK

23. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)

    
    

    1. 

       Disconnect the D7 generator resolver connector.

    2. 

       *a	Component without harness connected (Generator Resolver (Hybrid Vehicle Transaxle Assembly))

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance (Check for Open)
       Tester Connection Switch Condition Specified Condition D7-1(GRF) - D7-5(GRFG) IG OFF 9.5 to 15.5 Ω D7-2(GSN) - D7-6(GSNG) IG OFF 15.0 to 27.0 Ω D7-3(GCS) - D7-7(GCSG) IG OFF 14.0 to 26.0 Ω

       Standard Resistance (Check for Short)

       Tester Connection Switch Condition Specified Condition D7-1 (GRF) - Body ground and other terminals (except D7-5 (GRFG)) Power switch off 1 MΩ or higher D7-5 (GRFG) - Body ground and other terminals (except D7-1 (GRF)) Power switch off 1 MΩ or higher D7-2 (GSN) - Body ground and other terminals (except D7-6 (GSNG)) Power switch off 1 MΩ or higher D7-6 (GSNG) - Body ground and other terminals (except D7-2 (GSN)) Power switch off 1 MΩ or higher D7-3 (GCS) - Body ground and other terminals (except D7-7 (GCSG)) Power switch off 1 MΩ or higher D7-7 (GCSG) - Body ground and other terminals (except D7-3 (GCS)) Power switch off 1 MΩ or higher

       Tech Tips

       The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Connect the D7 generator resolver connector.

    
    

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY Click here

24. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    
    

    1. 

       Check the connection of the motor resolver connector.

       OK
       The connector is connected securely and there are no contact problems.

    
    

    NG

    CONNECT SECURELY

    OK

25. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)

    
    

    1. 

       Disconnect the D1 motor resolver connector.

    2. 

       *a	Component without harness connected (Motor Resolver (Hybrid Vehicle Transaxle Assembly))

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance (Check for Open)
       Tester Connection Condition Specified Condition D1-3 (MRF) - D1-6 (MRFG) Power switch off 9.5 to 15.5 Ω D1-1 (MSN) - D1-4 (MSNG) Power switch off 15.0 to 27.0 Ω D1-2 (MCS) - D1-5 (MCSG) Power switch off 14.0 to 26.0 Ω

       Standard Resistance (Check for Short)

       Tester Connection Condition Specified Condition D1-3 (MRF) - Body ground and other terminals (except D1-6 (MRFG)) Power switch off 1 MΩ or higher D1-6 (MRFG) - Body ground and other terminals (except D1-3 (MRF)) Power switch off 1 MΩ or higher D1-1 (MSN) - Body ground and other terminals (except D1-4 (MSNG)) Power switch off 1 MΩ or higher D1-4 (MSNG) - Body ground and other terminals (except D1-1 (MSN)) Power switch off 1 MΩ or higher D1-2 (MCS) - Body ground and other terminals (except D1-5 (MCSG)) Power switch off 1 MΩ or higher D1-5 (MCSG) - Body ground and other terminals (except D1-2 (MCS)) Power switch off 1 MΩ or higher

       Tech Tips

       The motor resolver is not available separately. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Connect the D1 motor resolver connector.

    
    

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Click here

26. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. Disconnect connector A62 from the inverter with converter assembly.

    3. 

       Text in Illustration

       *a	Front view of wire harness connector (to Inverter with Converter Assembly)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Switch Condition Specified Condition A62-10 (+B) - Body ground Power switch off 10 kΩ or higher A62-9 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Connect the inverter with converter assembly connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

27. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here

    
    

    NEXT

    REPLACE FUSE (PCU)

28. REPAIR OR REPLACE HARNESS OR CONNECTOR

    
    

    NEXT

    REPLACE FUSE (PCU)

29. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. Remove the inverter with converter assembly.

    3. 

       Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

       Specified Condition
       Bolt A
       T=20 N*m {204 kgf*cm, 15 ft.*lbf}
       Bolt B
       T=10 N*m {102 kgf*cm, 7 ft.*lbf}

       Note

       
       

       • Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 and 245 kgf*cm, 12 and 18 ft.*lbf).

       • Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    4. Disconnect the generator cable from the hybrid transaxle assembly.

    5. Check for arc marks at the bolts for the generator cable.

       Result

       Result Proceed to The terminals are connected securely and there are no contact problems. There are no arc marks. A The terminals are not connected securely and there is a contact problem. There are arc marks. B The terminals are not connected securely and there is a contact problem. There are no arc marks. C The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the generator cable to the hybrid transaxle assembly.

    7. Install the inverter with converter assembly.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

30. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. Remove the generator cable.

    3. 

       Text in Illustration

       *1	Generator Cable (Inverter with Converter Assembly Side)
       *2	Shielded Ground
       *3	Generator Cable (Hybrid Vehicle Transaxle Assembly Side)

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

       Note

       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 d3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher d3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher d3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

       Note

       Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

    4. Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Switch Condition Specified Condition d3-1 (W) - d4-3 (W) Power switch off Below 1 Ω d3-2 (U) - d4-2 (U) Power switch off Below 1 Ω d3-3 (V) - d4-1 (V) Power switch off Below 1 Ω d3-1 (W) - d4-2 (U) Power switch off 100 MΩ or higher d3-2 (U) - d4-1 (V) Power switch off 100 MΩ or higher d3-3 (V) - d4-3 (W) Power switch off 100 MΩ or higher

    5. Install the generator cable.

    
    

    OK

    REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

31. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. 

       Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

       Specified Condition
       T=10 N*m {102 kgf*cm, 7 ft.*lbf}

       Note

       Make sure that the tightening torque of the bolts is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    3. Disconnect the motor cable from the hybrid transaxle assembly.

    4. Check for arc marks at the bolts for the motor cable.

       Result

       Result Proceed to The terminals are connected securely and there are no contact problems. There are no arc marks. A The terminals are not connected securely and there is a contact problem. There are arc marks. B The terminals are not connected securely and there is a contact problem. There are no arc marks. C The terminals are connected securely and there are no contact problems. There are arc marks. B

    5. Connect the motor cable to the hybrid transaxle assembly.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

32. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note

       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.

    2. Remove the motor cable.

    3. 

       Text in Illustration

       *1	Motor Cable (Inverter with Converter Assembly Side)
       *2	Shielded Ground
       *3	Motor Cable (Hybrid Vehicle Transaxle Assembly Side)

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

       Note

       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 c3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher c3-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher c3-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

       Note

       Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

    4. Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Switch Condition Specified Condition c3-1 (W) - c4-1 (W) Power switch off Below 1 Ω c3-2 (U) - c4-3 (U) Power switch off Below 1 Ω c3-3 (V) - c4-2 (V) Power switch off Below 1 Ω c3-1 (W) - c4-3 (U) Power switch off 100 MΩ or higher c3-2 (U) - c4-2 (V) Power switch off 100 MΩ or higher c3-3 (V) - c4-1 (W) Power switch off 100 MΩ or higher

    5. Install the motor cable.

    
    

    OK

    REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

33. REPLACE HV COOLANT

    
    

    1. Replace the HV coolant with coolant having an appropriate concentration (appropriate freeze point) for the vehicle usage conditions Click here.

    
    

    NEXT

    COMPLETED