HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-121

DTC Code DTC Name
P0A78-121 Drive Motor "A" Inverter Performance

DESCRIPTION

For a description of the inverter, Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A78 121 Motor inverter overvoltage signal detection (overvoltage due to system malfunction)

  • HV battery junction block

  • Inverter with converter assembly

  • Service plug grip (Electric battery fuse)

  • Frame wire

  • Hybrid vehicle transmission assembly

  • Wire harness or connector

  • Generator cable

  • Motor cable

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AE6-225 Click here.

CAUTION / NOTICE / HINT

CAUTION:


  • 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.

Tech Tips

Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE


  1. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0A78-121 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      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 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 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes) *1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes) *1 Drive Motor "A" Phase W Current
      P0A72 (all INF codes) *1 Generator Phase V Current
      P0A75 (all INF codes) *1 Generator Phase W Current
      P0A78-113, 128, 266, 267, 279, 284, 286, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-172, 442, 547, 548, 549, 553, 554, 555, 556, 557, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 Power Cable Malfunction

      Tech Tips


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

      • P0A78-121 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. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.


    B

    GO TO DTC CHART Click here

    A

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


    1. Remove the service plug grip. Click here

      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.

      • Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector cannot be pulled 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

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Disconnect the low voltage connector from the inverter with converter assembly.

    3. Turn the power switch on (IG).

    4. A00106EE02

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

      Standard voltage
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A79-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A79-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A79-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A79-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A79-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A88-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A88-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A88-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A88-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A88-6 (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.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  4. CHECK GENERATOR RESOLVER


    1. A00106EE02

      Turn the power switch off.

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

      Standard resistance (Check for open)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) - A79-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A79-18 (GSN) - A79-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A79-17 (GCS) - A79-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) - A88-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A88-18 (GSN) - A88-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A88-17 (GCS) - A88-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      Standard resistance (Check for short)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) or A79-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-18 (GSN) or A79-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-17 (GCS) or A79-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) or A88-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-18 (GSN) or A88-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-17 (GCS) or A88-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

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


    1. Turn the power switch on (IG).

    2. A000UOIE02

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

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

      Standard voltage
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A79-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A79-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A79-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A79-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A79-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A88-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A88-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A88-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A88-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A88-27 (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.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. CHECK MOTOR RESOLVER


    1. A000UOIE02

      Turn the power switch off.

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

      Standard resistance (Check for open)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) - A79-29 (MRFG) Power switch off 4.5 to 16.8 Ω
      A79-39 (MSN) - A79-28 (MSNG) Power switch off 9.3 to 27.8 Ω
      A79-38 (MCS) - A79-27 (MCSG) Power switch off 12.4 to 30.7 Ω
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) - A88-29 (MRFG) Power switch off 4.5 to 16.8 Ω
      A88-39 (MSN) - A88-28 (MSNG) Power switch off 9.3 to 27.8 Ω
      A88-38 (MCS) - A88-27 (MCSG) Power switch off 12.4 to 30.7 Ω
      Standard resistance (Check for short)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) or A79-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-39 (MSN) or A79-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-38 (MCS) or A79-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) or A88-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-39 (MSN) or A88-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-38 (MCS) or A88-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

  7. 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.

    2. Remove the inverter terminal cover from the inverter with converter assembly.


      • For LHD vehicles, use the following procedures Click here.

      • For RHD vehicles, use the following procedures Click here.

      Note

      Lift the inverter terminal cover horizontally so that it does not tilt. Failure to do so may break the inverter cover guide pins.

      A000TY6E01
      *1 for LHD:
      *2 for RHD:

    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.

      A000YYUE01
      *1 for LHD:
      *2 for RHD:
      Specified Condition
      T=8.0 N*m {82 kgf*cm, 71 in.*lbf}

      Note

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

    4. 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

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  8. 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.

      A000V3GE01
      *1 for LHD:
      *2 for RHD:

    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=8.0 N*m {82 kgf*cm, 71 in.*lbf}

      Note

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

    3. 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

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  9. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1)

    CAUTION:

    Be sure to wear insulated gloves.


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

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

      Tech Tips

      For the removal and installation procedures related to the generator cable and motor cable, (See page for LHD, Click here for RHD).

    3. Check MG1 for an interphase short using a milliohmmeter.

      A000WF5E01
      *1 Generator Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
        LHD
        Tester Connection Switch Condition Specified Condition
        U - V Power switch off 32.4 to 35.8 mΩ
        V - W Power switch off 31.3 to 34.6 mΩ
        W - U Power switch off 31.4 to 34.7 mΩ
        RHD
        Tester Connection Switch Condition Specified Condition
        U - V Power switch off 32.3 to 35.7 mΩ
        V - W Power switch off 31.2 to 34.5 mΩ
        W - U Power switch off 31.3 to 34.6 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)

    4. 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
      U - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      V - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      W - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

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

    OK

  10. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG2)

    CAUTION:

    Be sure to wear insulated gloves.


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

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

      Tech Tips

      For the removal and installation procedures related to the generator cable and motor cable, (See page for LHD, Click here for RHD).

    3. Check MG2 for an interphase short using a milliohmmeter.

      A000WF5E02
      *1 Motor Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
        LHD
        Tester Connection Switch Condition Specified Condition
        U - V Power switch off 46.9 to 51.8 mΩ
        V - W Power switch off 47.1 to 52.1 mΩ
        W - U Power switch off 46.8 to 51.8 mΩ
        RHD
        Tester Connection Switch Condition Specified Condition
        U - V Power switch off 47.2 to 52.2 mΩ
        V - W Power switch off 47.4 to 52.4 mΩ
        W - U Power switch off 47.2 to 52.1 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)

    4. 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
      U - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      V - Body ground and shielded wire ground Power switch off 100 MΩ or higher
      W - Body ground and shielded wire ground Power switch off 100 MΩ or higher

    NG

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

    OK

  11. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. Check the connection condition of the generator resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

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

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  12. 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

  13. CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH-VOLTAGE CONNECTOR CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. Remove the connector cover from the inverter with converter assembly.

      A000YZ3E01
      *1 for LHD:
      *2 for RHD:

    3. Check the connection of the high-voltage DC connector of the inverter with converter assembly.

      A000VIJE01
      *1 for LHD:
      *2 for RHD:
      OK
      The connector is connected securely and there are no contact problems.

    4. Check for arc marks on the terminals of the high-voltage DC connector of the inverter with converter assembly.

      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

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  14. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK
      Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  15. CHECK SERVICE PLUG GRIP


    1. A000WIIE02
      *1 Service Plug Grip

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

      Standard resistance
      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  16. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000VQNE02
      *1 Frame Wire (HV Battery Junction Block Side)

      Disconnect the frame wire from the HV battery junction block.

    3. Disconnect the frame wire (high-voltage DC connector) from the inverter with converter assembly.

      A000VIJE01
      *1 for LHD:
      *2 for RHD:
    4. A000YDHE03
      *1 Frame Wire (Inverter with Converter Assembly Side)
      *2 Frame Wire (HV Battery Junction Block Side)
      *3 Shielded Wire Ground

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      g2-1 - g1-1 (CBI) (Positive terminal) Power switch off Below 1 Ω
      g3-1 - g1-2 (CEI) (Negative terminal) Power switch off Below 1 Ω
    5. A000ZE2E03
      *1 Frame Wire (HV Battery Junction Block Side)
      *2 Red Mark
      *3 Shielded Wire Ground

      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
      g2-1 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      g3-1 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      g2-1 - g3-1 Power switch off 10 MΩ or higher
      Result
      Result Proceed to
      OK A
      NG (for LHD) B
      NG (for RHD) C

    B

    REPLACE FRAME WIRE Click here

    C

    REPLACE FRAME WIRE Click here

    A

  17. INSPECT HV BATTERY JUNCTION BLOCK (SMRB)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. Remove the HV battery junction block from the vehicle. Click here

    3. A000YP1E01
      *1 HV Battery Junction Block

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      g2-1 - z30-1 Auxiliary battery voltage is not applied between terminals z38-3 (SMRB) and z38-2 (GND) 10 MΩ or higher
      g2-1 - z30-1 Auxiliary battery voltage is applied between terminals z38-3 (SMRB) and z38-2 (GND) Below 1 Ω

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

      Standard resistance
      Tester Connection Condition Specified Condition
      z38-3 (SMRB) - z38-2 (GND)

      -35 to 80°C

      (-31 to 176° F)

      		 18.8 to 32.1 Ω

    NG

    REPLACE HV BATTERY JUNCTION BLOCK Click here

    OK

  18. INSPECT HV BATTERY JUNCTION BLOCK (SMRG)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000UTDE01
      *1 HV Battery Junction Block

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      g3-1 - z34-1 Auxiliary battery voltage is not applied between terminals z38-1 (SMRG) and z38-2 (GND) 10 MΩ or higher
      g3-1 - z34-1 Auxiliary battery voltage is applied between terminals z38-1 (SMRG) and z38-2 (GND) Below 1 Ω

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

      Standard resistance
      Tester Connection Condition Specified Condition
      z38-1 (SMRG) - z38-2 (GND)

      -35 to 80°C

      (-31 to 176° F)

      		 18.8 to 32.1 Ω
      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    REPLACE HV BATTERY JUNCTION BLOCK Click here

  19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. Check the connection condition of the generator resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

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

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY (MG ECU) - GENERATOR RESOLVER)


    1. Disconnect the generator resolver connector.

    2. A000WPZE02

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

      Standard resistance (Check for open)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) - E62-1 (GRF) Power switch off Below 1 Ω
      A79-9 (GRFG) - E62-5 (GRFG) Power switch off Below 1 Ω
      A79-18 (GSN) - E62-2 (GSN) Power switch off Below 1 Ω
      A79-7 (GSNG) - E62-6 (GSNG) Power switch off Below 1 Ω
      A79-17 (GCS) - E62-3 (GCS) Power switch off Below 1 Ω
      A79-6 (GCSG) - E62-7 (GCSG) Power switch off Below 1 Ω
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) - E62-1 (GRF) Power switch off Below 1 Ω
      A88-9 (GRFG) - E62-5 (GRFG) Power switch off Below 1 Ω
      A88-18 (GSN) - E62-2 (GSN) Power switch off Below 1 Ω
      A88-7 (GSNG) - E62-6 (GSNG) Power switch off Below 1 Ω
      A88-17 (GCS) - E62-3 (GCS) Power switch off Below 1 Ω
      A88-6 (GCSG) - E62-7 (GCSG) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) or E62-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-9 (GRFG) or E62-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-18 (GSN) or E62-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-7 (GSNG) or E62-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-17 (GCS) or E62-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-6 (GCSG) or E62-7 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) or E62-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-9 (GRFG) or E62-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-18 (GSN) or E62-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-7 (GSNG) or E62-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-17 (GCS) or E62-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-6 (GCSG) or E62-7 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

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


    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. Check the connection condition of the motor resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

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

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  22. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY (MG ECU) - MOTOR RESOLVER)


    1. Disconnect the motor resolver connector.

    2. A000WPZE03

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

      Standard resistance (Check for open)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) - E63-1 (MRF) Power switch off Below 1 Ω
      A79-29 (MRFG) - E63-5 (MRFG) Power switch off Below 1 Ω
      A79-39 (MSN) - E63-2 (MSN) Power switch off Below 1 Ω
      A79-28 (MSNG) - E63-6 (MSNG) Power switch off Below 1 Ω
      A79-38 (MCS) - E63-3 (MCS) Power switch off Below 1 Ω
      A79-27 (MCSG) - E63-7 (MCSG) Power switch off Below 1 Ω
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) - E63-1 (MRF) Power switch off Below 1 Ω
      A88-29 (MRFG) - E63-5 (MRFG) Power switch off Below 1 Ω
      A88-39 (MSN) - E63-2 (MSN) Power switch off Below 1 Ω
      A88-28 (MSNG) - E63-6 (MSNG) Power switch off Below 1 Ω
      A88-38 (MCS) - E63-3 (MCS) Power switch off Below 1 Ω
      A88-27 (MCSG) - E63-7 (MCSG) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) or E63-1 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-29 (MRFG) or E63-5 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-39 (MSN) or E63-2 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-28 (MSNG) or E63-6 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-38 (MCS) or E63-3 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-27 (MCSG) or E63-7 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) or E63-1 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-29 (MRFG) or E63-5 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-39 (MSN) or E63-2 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-28 (MSNG) or E63-6 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-38 (MCS) or E63-3 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-27 (MCSG) or E63-7 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

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


    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  23. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)


    1. A000TAA

      Remove the hybrid vehicle transmission assembly Click here.

    2. 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
      T=8.0 N*m {82 kgf*cm, 71 in.*lbf}

      Note

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

    3. 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

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  24. CHECK GENERATOR CABLE


    1. Remove the generator cable from the hybrid vehicle transmission assembly. Click here

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

      A000WOCE01
      *1 Generator Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher
      U - V Power switch off 100 MΩ or higher
      V - W Power switch off 100 MΩ or higher
      W - U Power switch off 100 MΩ or higher

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

      Standard resistance
      Tester Connection Condition Specified Condition
      U - U Power switch off 1 Ω or less
      V - V Power switch off 1 Ω or less
      W - W Power switch off 1 Ω or less

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  25. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)


    1. A000UQD

      Remove the hybrid vehicle transmission assembly. Click here

    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=8.0 N*m {82 kgf*cm, 71 in.*lbf}

      Note

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

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

      Result
      OK 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

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  26. CHECK MOTOR CABLE


    1. Remove the motor cable from the hybrid vehicle transmission assembly. Click here

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

      A000X8SE01
      *1 Motor Cable
      *2 for LHD:
      *3 for RHD:
      *4 Shielded Wire Ground

      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
      U - Shielded wire ground Power switch off 100 MΩ or higher
      V - Shielded wire ground Power switch off 100 MΩ or higher
      W - Shielded wire ground Power switch off 100 MΩ or higher
      U - V Power switch off 100 MΩ or higher
      V - W Power switch off 100 MΩ or higher
      W - U Power switch off 100 MΩ or higher

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

      Standard resistance
      Tester Connection Condition Specified Condition
      U - U Power switch off 1 Ω or less
      V - V Power switch off 1 Ω or less
      W - W Power switch off 1 Ω or less

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here