HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-122

DTC Code DTC Name
P0A7A-122 Generator Inverter Performance

DESCRIPTION

For a description of the inverter, Click here.

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

If an abnormal amount of current flows through the generator inverter, the MG ECU detects it and sends a signal to inform the hybrid vehicle control ECU of the malfunction.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A7A 122 Generator inverter fail signal detection (overcurrent due to system malfunction)

  • Fuel level

  • Hybrid vehicle transmission assembly

  • Engine

  • Generator cable

  • Inverter with converter assembly

  • Wire harness or connector

  • Motor cable

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
      P3245-203 is output A
      P3245-203 is also output. B

    B

    GO TO DTC CHART Click here

    A

  2. 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
      P0A7A-122 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
      P0A78-266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 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 High Voltage Power Resource

      Tech Tips


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

      • P0A7A-122 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

  3. CHECK AMOUNT OF GASOLINE


    1. Turn the power switch on (IG).

    2. Check the amount of fuel by referring to the fuel gauge in the meter.

      OK
      Adequate amount of fuel is in the tank.

      Tech Tips


      • If the vehicle is driven when there is no fuel in the tank, MG1 will crank the engine but the engine will not start. For this reason, an inoperative condition of MG1 may be detected.

      • Add fuel until the low fuel level warning light turns off.


    NG

    REFUEL VEHICLE

    OK

  4. CHECK ENGINE START


    1. Turn the power switch on (READY).

    2. Check if the engine starts.

      Tech Tips

      Depressing the accelerator pedal with the shift lever in the P position will cause the engine to start.

      Result
      Result Proceed to
      The engine does not start. A
      The engine starts. B

    B

    CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) Click here

    A

  5. INSPECT CRANKSHAFT PULLEY REVOLUTION (P POSITION)


    1. Turn the power switch off.

    2. Move the shift lever to the P position and lift up the vehicle.

    3. Turn the crankshaft pulley using hand tools to check if the crankshaft can rotate smoothly.

      CAUTION:

      Do not turn the power switch on (READY) while performing this inspection. Be sure to turn the power switch off before performing this inspection to prevent the engine from starting.

      Result
      Result Proceed to
      The crankshaft does not rotate smoothly. A
      The crankshaft rotates smoothly. B

    B

    CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) Click here

    A

  6. INSPECT CRANKSHAFT PULLEY REVOLUTION (N POSITION)


    1. Lower the vehicle.

    2. Move the shift lever to the N position and lift up the vehicle.

    3. Turn the crankshaft pulley using hand tools to check if the crankshaft can rotate smoothly.

      CAUTION:

      Do not turn the power switch on (READY) while performing this inspection. Be sure to turn the power switch off before performing this inspection to prevent the engine from starting.

      Result
      Result Proceed to
      The crankshaft does not rotate smoothly. A
      The crankshaft rotates smoothly. B

    A

    REPAIR OR REPLACE ENGINE

    B

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  7. 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

  8. 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

  9. 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

  10. 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

  11. 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

  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.

    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

  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.

      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

  14. 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

  15. 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

  16. 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

  17. 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

  18. CHECK QUANTITY OF HV COOLANT


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

      A000X1ZE01
      *1 for LHD
      *2 for RHD
      *3 Inverter Reserve Tank

    2. Check for coolant leaks.

      Result
      Result Proceed to
      Coolant leaks are not evident. A sufficient amount of coolant remains in the inverter reserve tank. A
      Coolant leaks are not evident. No coolant remains in the inverter reserve tank. 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 ECU active test item) and the "Control the Electric Cooling Fan" active test (Engine ECU active test item) and make sure that there are no malfunctions.


    B

    ADD HV COOLANT

    C

    CHECK FOR COOLANT LEAKS AND ADD COOLANT

    A

  19. CHECK COOLANT HOSE


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


    NG

    CORRECT THE PROBLEM

    OK

  20. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (WATER PUMP)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Select the following menu items: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

    4. Perform the "Activate the Water Pump" active test for at least 1 minute.

    5. Check that there are ripples in the coolant in the inverter reserve tank.

      A000X1ZE01
      *1 for LHD
      *2 for RHD
      *3 Inverter Reserve Tank
      OK
      There are ripples in the coolant in the inverter reserve tank as long as the active test is being performed.

      Note

      In addition to the active test, the water pump with motor and bracket assembly will also operate with the power switch on (READY). However, the water pump with motor and bracket assembly will operate at low speed for 20 seconds after the power switch is turned on (READY).

      Tech Tips

      The water pump with motor and bracket assembly will also operate in inspection mode.


    NG

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (WATER PUMP) Click here

    OK

  21. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (COOLING FAN)


    1. Select the following menu items: Powertrain / Engine and ECT / Active Test / Control the Electric Cooling Fan.

    2. Perform the "Control the Electric Cooling Fan" active test.

      OK
      The cooling fan rotates.

    NG

    CHECK COOLING FAN SYSTEM Click here

    OK

  22. INSPECT COOLING SYSTEM (FOR CLOGGING)


    1. Drain the inverter coolant Click here.

      Note

      Do not reuse the drained coolant because it may contain foreign objects.

      Tech Tips

      Drain the inverter coolant with the inverter reserve tank cap installed.

    2. Install the inverter reserve tank cap.

    3. Remove the drain plug.

    4. A000VFOE04

      Disconnect end A of the No. 3 inverter cooling hose.

      Note


      • Applied air pressure should be 59 kPa (0.6 kgf/cm2, 8.6 psi) or less.

      • Be careful when disconnecting the hose. Coolant may spill out of the hose.

    5. A000YF3E03
      *1 Tape
      *2 Air

      Cover the pipe shown in the illustration with packing tape.

    6. Using an air gun, apply air to the disconnected end of the hose to check for clogging in the coolant path.

      Note

      Be careful when applying air. Applying excessive air may cause coolant to overflow from the inverter reserve tank cap.

      OK
      Coolant and air come out from the drain.
    7. A000VFOE04

      Connect end A of the No. 3 inverter cooling hose and disconnect end B.

    8. A000U9LE03
      *1 Tape
      *2 Air

      Cover the pipe shown in the illustration with packing tape.

    9. Using an air gun, apply air to the disconnected end of the hose to check for clogging in the coolant path.

      Note


      • Applied air pressure should be 59 kPa (0.6 kgf/cm2, 8.6 psi) or less.

      • Be careful when applying air. Applying excessive air may cause coolant to overflow from the inverter reserve tank cap.

      OK
      Coolant and air come out from the drain.
      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    10. After this inspection, check for coolant leaks from the hose with the power switch on (READY).

      Note

      If leaks are found, replace the No. 3 inverter cooling hose and clamps.


    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    REPLACE MALFUNCTIONING PARTS

  23. 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

  24. 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

  25. 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

  26. 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

  27. 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

  28. 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

  29. 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

  30. 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

  31. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (WATER PUMP)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Select the following menu items: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

    4. Perform the "Activate the Water Pump" active test for at least 1 minute.

    5. Check that there are ripples in the coolant in the inverter reserve tank.

      A000X1ZE01
      *1 for LHD
      *2 for RHD
      *3 Inverter Reserve Tank
      OK
      There are ripples in the coolant in the inverter reserve tank as long as the active test is being performed.

      Note

      In addition to the active test, the water pump with motor and bracket assembly will also operate with the power switch on (READY). However, the water pump with motor and bracket assembly will operate at low speed for 20 seconds after the power switch is turned on (READY).

      Tech Tips

      The water pump with motor and bracket assembly will also operate in inspection mode.


    OK

    ADD HV COOLANT

    NG

  32. CHECK FUSE (INV W/P)


    1. A000U8FE01
      *1 Engine Room No. 2 Relay Block
      *2 INV W/P Fuse

      Check if there is an open circuit in the fuse (INV W/P) in the engine room No. 2 relay block.

      OK
      There is no open circuit in the fuse (INV W/P).

      Tech Tips

      If the result is NG, replace the fuse (INV W/P) with a new one.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY CONNECTOR) Click here

    OK

  33. CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY CONNECTOR)


    1. A00104U

      Check the connection of the water pump with motor and bracket assembly connector.

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

    NG

    CONNECT SECURELY

    OK

  34. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)


    1. Check the connections of the hybrid vehicle control ECU connectors.

      OK
      The connectors are connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  35. CHECK HARNESS AND CONNECTOR (WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY)


    1. Disconnect connector A78 from the hybrid vehicle control ECU.

    2. Remove the fuse (INV W/P) from the engine room No. 2 relay block.

    3. Disconnect the water pump with motor and bracket assembly connector.

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

      A000WGVE02
      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      A78-23 (IWP) - zA1-2 (SWP) Power switch off Below 1 Ω
      zA1-3 (GND) - Body ground Power switch off Below 1 Ω
      Engine Room No. 2 Relay Block INV W/P Fuse Terminal 2 - zA1-4 (+BWP) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      A78-23 (IWP) or zA1-2 (SWP) - Body ground and other terminals Power switch off 10 kΩ or higher
      Engine Room No. 2 Relay Block INV W/P Fuse Terminal 2 or zA1-4 (+BWP) - Body ground and other terminals Power switch off 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  36. CHECK WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY


    1. A000U2ZE01
      *1 Engine Room No. 2 Relay Block
      *2 INV W/P Fuse

      Apply 12 V to terminal 2 of the INV W/P fuse holder of the engine room No. 2 relay block and check that the water pump operates.

      OK
      The water pump operates.

    OK

    REPLACE HYBRID VEHICLE CONTROL ECU Click here

    NG

    REPLACE WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY Click here

  37. CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY CONNECTOR)


    1. A00104U

      Check the connection of the water pump with motor and bracket assembly connector.

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

    NG

    CONNECT SECURELY

    OK

  38. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)


    1. Check the connections of the hybrid vehicle control ECU connectors.

      OK
      The connectors are connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  39. CHECK HARNESS AND CONNECTOR (WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY)


    1. Disconnect connector A78 from the hybrid vehicle control ECU.

    2. Remove the fuse (INV W/P) from the engine room No. 2 relay block.

    3. Disconnect the water pump with motor and bracket assembly connector.

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

      A000WGVE02
      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      A78-23 (IWP) - zA1-2 (SWP) Power switch off Below 1 Ω
      zA1-3 (GND) - Body ground Power switch off Below 1 Ω
      Engine Room No. 2 Relay Block INV W/P Fuse Terminal 2 - zA1-4 (+BWP) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      A78-23 (IWP) or zA1-2 (SWP) - Body ground and other terminals Power switch off 10 kΩ or higher
      Engine Room No. 2 Relay Block INV W/P Fuse Terminal 2 or zA1-4 (+BWP) - Body ground and other terminals Power switch off 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  40. CHECK WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY


    1. A000U2ZE01
      *1 Engine Room No. 2 Relay Block
      *2 INV W/P Fuse

      Apply 12 V to terminal 2 of the INV W/P fuse holder of the engine room No. 2 relay block and check that the water pump operates.

      OK
      The water pump operates.

    OK

    REPLACE HYBRID VEHICLE CONTROL ECU Click here

    NG

    REPLACE WATER PUMP WITH MOTOR AND BRACKET ASSEMBLY Click here