HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-113

DTC Code DTC Name
P0A78-113 Drive Motor "A" Inverter Performance

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.

Tech Tips

The term "drive motor A" indicates motor (MG2).

DTC No. DTC Detection Condition Trouble Area
P0A78-113

Motor inverter fail signal detection (System overcurrent)

A malfunction is detected in any of the motor components (motor inverter, motor, MG ECU, etc.).

(1 trip detection logic)

  • Hybrid vehicle transmission assembly

  • Generator cable

  • Motor cable

  • Inverter with converter assembly

  • Power management control ECU

  • IGCT NO. 4 fuse

  • Wire harness or connector

WIRING DIAGRAM

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

Refer to the wiring diagram for DTC P0AA6-526 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

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 removing 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 Click here.

    Tech Tips

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

Note

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


  1. Turn the power switch on (READY) and wait for 5 seconds or more.

  2. Perform a road test according to the freeze frame data "Vehicle Spd" for approximately 10 minutes.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Check for DTCs.

      Result
      Result Proceed to
      P0A78-113 is stored before any of the DTCs in the tables below are stored. A
      Any of the DTCs including pending DTCs in table 1 below are stored before P0A78-113 is stored. B
      Any of the DTCs including pending DTCs in table 2 below are stored before P0A78-113 is stored. C
      Table 1
      Relevant DTC
      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
      P3004-803 High Voltage Power Resource
      Table 2
      Relevant DTC
      P0A9C-123 Hybrid Battery Temperature Sensor "A" Range / Performance
      P0A9D-123 Hybrid Battery Temperature Sensor "A" Circuit Low
      P0A9E-123 Hybrid Battery Temperature Sensor "A" Circuit High
      P0AC0-123 Hybrid Battery Pack Current Sensor Circuit Range / Performance
      P0AC1-123 Hybrid Battery Pack Current Sensor Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor Circuit High
      P0AC6-123 Hybrid Battery Temperature Sensor "B" Range / Performance
      P0AC7-123 Hybrid Battery Temperature Sensor "B" Circuit Low
      P0AC8-123 Hybrid Battery Temperature Sensor "B" Circuit High
      P0ACB-123 Hybrid Battery Temperature Sensor "C" Range / Performance
      P0ACC-123 Hybrid Battery Temperature Sensor "C" Circuit Low
      P0ACD-123 Hybrid Battery Temperature Sensor "C" Circuit High
      P0AFC-123 Hybrid Battery Pack Sensor Module
      P3011-123, P3012-123, P3013-123, P3014-123, P3015-123, P3016-123, P3017-123, P3018-123, P3019-123, P3020-123, P3021-123, P3022-123, P3023-123, P3024-123, P3025-123, P3026-123 Battery Block # Becomes Weak
      P3065-123 Hybrid Battery Temperature Sensor Range / Performance Stuck "A"
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low

      Tech Tips


      • Refer to the freeze frame data to determine the order in which the DTCs were stored.

      • P0A78-113 may be stored due to a malfunction which also causes DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    A

  2. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Check for DTCs.

      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

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Check for DTCs.

      Tech Tips


      • If P0A78-202 was not output in step 2 of this diagnosis procedure, check Table 1 below.

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

      Result
      Result Proceed to
      P0A78-113 only is output, or DTCs except the ones in the tables below are also output. A
      Any of the following DTCs including pending 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-151, 166, 517, 658, 791, 809 Generator Control Module
      P0A1B-198, 503, 505, 547, 554, 786, 794, 806 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
      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
      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
      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
      P3004-803 Power Cable Malfunction
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      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-151, 166, 517, 658, 791, 809 Generator Control Module
      P0A1B-198, 503, 505, 547, 554, 786, 794, 806 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
      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
      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
      P3004-803 Power Cable Malfunction
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator

      Tech Tips


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

      • P0A78-113 may be stored due to a malfunction which also causes DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  4. 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.

    2. Check connection condition of the low voltage connector of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter Click here.

      B002B6BE01
      Text in Illustration
      *A for LHD *B for RHD

      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.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

      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.


    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

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

    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 the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. Connect the cable to the negative (-) auxiliary battery terminal.

    4. Turn the power switch on (IG).

    5. B002BKAE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A38-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A38-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A38-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A38-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A38-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A74-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A74-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A74-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A74-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A74-6 (GCSG) - Body ground Power switch on (IG) Below 1 V

      Note

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

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal.

    8. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. CHECK GENERATOR RESOLVER

    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 the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. B002BKAE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - A38-9 (GRFG) Power switch off 5.8 to 11.8 Ω
      A38-18 (GSN) - A38-7 (GSNG) Power switch off 11.7 to 17.7 Ω
      A38-17 (GCS) - A38-6 (GCSG) Power switch off 11.7 to 17.7 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - A74-9 (GRFG) Power switch off 5.8 to 11.8 Ω
      A74-18 (GSN) - A74-7 (GSNG) Power switch off 11.7 to 17.7 Ω
      A74-17 (GCS) - A74-6 (GCSG) Power switch off 11.7 to 17.7 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) or A38-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-18 (GSN) or A38-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-17 (GCS) or A38-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) or A74-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-18 (GSN) or A74-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-17 (GCS) or A74-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

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

    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 the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. Connect the cable to the negative (-) auxiliary battery terminal.

    4. Turn the power switch on (IG).

    5. B002B4ZE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A38-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A38-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A38-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A38-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A38-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A74-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A74-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A74-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A74-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A74-27 (MCSG) - Body ground Power switch on (IG) Below 1 V

      Note

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

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal.

    8. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. CHECK MOTOR RESOLVER

    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 the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. B002B4ZE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - A38-29 (MRFG) Power switch off 6.0 to 12.0 Ω
      A38-39 (MSN) - A38-28 (MSNG) Power switch off 12.5 to 24.5 Ω
      A38-38 (MCS) - A38-27 (MCSG) Power switch off 12.5 to 24.5 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - A74-29 (MRFG) Power switch off 6.0 to 12.0 Ω
      A74-39 (MSN) - A74-28 (MSNG) Power switch off 12.5 to 24.5 Ω
      A74-38 (MCS) - A74-27 (MCSG) Power switch off 12.5 to 24.5 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) or A38-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-39 (MSN) or A38-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-38 (MCS) or A38-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) or A74-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-39 (MSN) or A74-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-38 (MCS) or A74-27 (MCSG) - Body ground and other terminal Power switch off 1 MΩ or higher

    4. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

  9. 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. B002BL0E02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. B002BUKE03
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. B002BN0E02
      Text in Illustration
      *A for LHD
      *B for RHD
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)

      Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected

      Specified Condition
      T=8.0 N*m (82 kgf*cm, 71 in.*lbf)

      Note

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

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

    6. Check for arc marks at the terminals 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

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

    8. Install the inverter terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  10. 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. B002BL0E02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. B002BUKE03
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. B002C31E02
      Text in Illustration
      *A for LHD
      *B for RHD
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)

      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 bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

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

    6. Check for arc marks at the terminals 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

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

    8. Install the inverter terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  11. CHECK HYBRID VEHICLE TRANSMISSION 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. B002BL0E03
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. B002BUKE04
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. B002BU8E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Motor Cable
      *2 Generator Cable

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

    5. B002BUTE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      Check generator (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 generator (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
        for LHD
        Tester Connection Switch Condition Specified Condition
        v3-3 (W) - v3-1 (U) Power switch off 59.2 to 65.2 mΩ
        v3-2 (V) - v3-3 (W) Power switch off 62.2 to 68.2 mΩ
        v3-1 (U) - v3-2 (V) Power switch off 59.2 to 65.2 mΩ
        for RHD
        Tester Connection Switch Condition Specified Condition
        v3-1 (W) - v3-3 (U) Power switch off 59.0 to 65.0 mΩ
        v3-2 (V) - v3-1 (W) Power switch off 61.9 to 67.9 mΩ
        v3-3 (U) - v3-2 (V) Power switch off 59.0 to 65.0 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)

    6. When checking for a short circuit between motor phases without using a milliohmmeter.

      Note

      The motor generates current when wheels are rotated by hand. Before performing the inspection, wrap the motor cable terminals with insulation tape.

      Tech Tips

      A short circuit between the motor phases can be checked simply without using a milliohmmeter.


      1. Connect the cable to the negative (-) auxiliary battery terminal.

      2. Turn the power switch on (IG).

        Note

        Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

      3. Move the shift lever to N.

      4. Lift up the vehicle.

      5. Rotate the rear wheels in the same direction simultaneously by hand.

        Standard
        Left and right wheels rotate smoothly (No short circuit between phases)

        Tech Tips

        If a short circuit exists between the motor phases, the rear wheels do not rotate smoothly (some resistance is felt).

      6. Lower the vehicle.

      7. Move the shift lever to P.

      8. Turn the power switch off.

      9. Disconnect the cable from the negative (-) auxiliary battery terminal.

    7. 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
      for LHD
      Tester Connection Switch Condition Specified Condition
      v3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

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

      Tech Tips

      Perform this procedure only when checking for a short circuit between motor phases without using a milliohmmeter.

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      v3-3 (W) - v3-2 (V) Power switch off Below 1 Ω
      v3-2 (V) - v3-1 (U) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      v3-1 (W) - v3-2 (V) Power switch off Below 1 Ω
      v3-2 (V) - v3-3 (U) Power switch off Below 1 Ω

    9. Connect the generator cable and motor cable.

    10. Install the inverter terminal cover.


    NG

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

    OK

  12. CHECK HYBRID VEHICLE TRANSMISSION 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. B002BL0E02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. B002BUKE03
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. B002BU8E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Motor Cable
      *2 Generator Cable

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

    5. B002BQ5E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

      Check motor (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 motor (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
        for LHD
        Tester Connection Switch Condition Specified Condition
        u1-3 (W) - u1-1 (U) Power switch off 47.0 to 51.8 mΩ
        u1-2 (V) - u1-3 (W) Power switch off 47.3 to 52.1 mΩ
        u1-1 (U) - u1-2 (V) Power switch off 47.1 to 51.9 mΩ
        for RHD
        Tester Connection Switch Condition Specified Condition
        u3-1 (W) - u3-3 (U) Power switch off 47.0 to 51.8 mΩ
        u3-2 (V) - u3-1 (W) Power switch off 47.3 to 52.1 mΩ
        u3-3 (U) - u3-2 (V) Power switch off 47.1 to 51.9 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)

    6. When checking for a short circuit between motor phases without using a milliohmmeter.

      Note

      The motor generates current when wheels are rotated by hand. Before performing the inspection, wrap the motor cable terminals with insulation tape.

      Tech Tips

      A short circuit between the motor phases can be checked simply without using a milliohmmeter.


      1. Connect the cable to the negative (-) auxiliary battery terminal.

      2. Turn the power switch on (IG).

        Note

        Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

      3. Move the shift lever to N.

      4. Lift up the vehicle.

      5. Rotate the rear wheels in the same direction simultaneously by hand.

        Standard
        Left and right wheels rotate smoothly (No short circuit between phases)

        Tech Tips

        If a short circuit exists between the motor phases, the rear wheels do not rotate smoothly (some resistance is felt).

      6. Lower the vehicle.

      7. Move the shift lever to P.

      8. Turn the power switch off.

      9. Disconnect the cable from the negative (-) auxiliary battery terminal.

    7. 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
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

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

      Tech Tips

      Perform this procedure only when checking for a short circuit between motor phases without using a milliohmmeter.

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - u1-2 (V) Power switch off Below 1 Ω
      u1-2 (V) - u1-1 (U) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - u3-2 (V) Power switch off Below 1 Ω
      u3-2 (V) - u3-3 (U) Power switch off Below 1 Ω

    9. Connect the generator cable and motor cable.

    10. Install the inverter terminal cover.


    NG

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

    OK

  13. CHECK FUSE (IGCT NO. 4)


    1. B002B5LE01
      Text in Illustration
      *1 No. 1 Engine Room Relay Block and Junction Block Assembly
      *2 IGCT NO. 4 Fuse

      Remove the IGCT NO. 4 fuse from the No. 1 engine room relay block and junction block assembly.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      IGCT NO. 4 fuse terminal Always Below 1 Ω

    3. Install the IGCT NO. 4 fuse.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 4 FUSE) Click here

    OK

  14. 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 the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. B002BBFE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-30 (GND1) - Body ground Power switch off Below 1 Ω
      A38-31 (GND2) - Body ground Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-30 (GND1) - Body ground Power switch off Below 1 Ω
      A74-31 (GND2) - Body ground Power switch off Below 1 Ω

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

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

      Standard Voltage
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-10 (+B) - Body ground Power switch on (IG) Same as auxiliary battery voltage
      A38-11 (+B2) - Body ground Power switch on (IG) Same as auxiliary battery voltage
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-10 (+B) - Body ground Power switch on (IG) Same as auxiliary battery voltage
      A74-11 (+B2) - Body ground Power switch on (IG) Same as auxiliary battery voltage

      Note

      Turning the power switch on (IG) with the 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. Disconnect the cable from the negative (-) auxiliary battery terminal.

    9. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

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

    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 the A35 power management control ECU connector.

    3. Disconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    4. B002B4UE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

      Standard Resistance (Check for Open)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-23 (HTM+) - A35-34 (HTM+) Power switch off Below 1 Ω
      A38-22 (HTM-) - A35-33 (HTM-) Power switch off Below 1 Ω
      A38-3 (MTH+) - A35-21 (MTH+) Power switch off Below 1 Ω
      A38-2 (MTH-) - A35-20 (MTH-) Power switch off Below 1 Ω
      A38-34 (REQ+) - A35-32 (REQ+) Power switch off Below 1 Ω
      A38-33 (REQ-) - A35-31 (REQ-) Power switch off Below 1 Ω
      A38-14 (CLK+) - A35-29 (CLK+) Power switch off Below 1 Ω
      A38-13 (CLK-) - A35-28 (CLK-) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-23 (HTM+) - A35-34 (HTM+) Power switch off Below 1 Ω
      A74-22 (HTM-) - A35-33 (HTM-) Power switch off Below 1 Ω
      A74-3 (MTH+) - A35-21 (MTH+) Power switch off Below 1 Ω
      A74-2 (MTH-) - A35-20 (MTH-) Power switch off Below 1 Ω
      A74-34 (REQ+) - A35-32 (REQ+) Power switch off Below 1 Ω
      A74-33 (REQ-) - A35-31 (REQ-) Power switch off Below 1 Ω
      A74-14 (CLK+) - A35-29 (CLK+) Power switch off Below 1 Ω
      A74-13 (CLK-) - A35-28 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-23 (HTM+) or A35-34 (HTM +) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-22 (HTM-) or A35-33 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-3 (MTH+) or A35-21 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-2 (MTH-) or A35-20 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-34 (REQ+) or A35-32 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-33 (REQ-) or A35-31 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-14 (CLK+) or A35-29 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-13 (CLK-) or A35-28 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-23 (HTM+) or A35-34 (HTM +) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-22 (HTM-) or A35-33 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-3 (MTH+) or A35-21 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-2 (MTH-) or A35-20 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-34 (REQ+) or A35-32 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-33 (REQ-) or A35-31 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-14 (CLK+) or A35-29 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-13 (CLK-) or A35-28 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Connect the cable to the negative (-) auxiliary battery terminal.

    6. Turn the power switch on (IG).

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

      Standard Voltage
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-23 (HTM+) or A35-34 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A38-22 (HTM-) or A35-33 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A38-3 (MTH+) or A35-21 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A38-2 (MTH-) or A35-20 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A38-34 (REQ+) or A35-32 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A38-33 (REQ-) or A35-31 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A38-14 (CLK+) or A35-29 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A38-13 (CLK-) or A35-28 (CLK-) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-23 (HTM+) or A35-34 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A74-22 (HTM-) or A35-33 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A74-3 (MTH+) or A35-21 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A74-2 (MTH-) or A35-20 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A74-34 (REQ+) or A35-32 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A74-33 (REQ-) or A35-31 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A74-14 (CLK+) or A35-29 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A74-13 (CLK-) or A35-28 (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 connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    8. Turn the power switch off.

    9. Disconnect the cable from the negative (-) auxiliary battery terminal.

    10. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    11. Reconnect the A35 power management control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  16. CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect the A35 power management control ECU connector.

    2. B002BUFE02
      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
      A35-34 (HTM+) - A35-33 (HTM-) Power switch off 80 to 170 Ω
      A35-21 (MTH+) - A35-20 (MTH-) Power switch off 80 to 170 Ω
      A35-32 (REQ+) - A35-31 (REQ-) Power switch off 80 to 170 Ω
      A35-29 (CLK+) - A35-28 (CLK-) Power switch off 80 to 170 Ω

    3. Reconnect the A35 power management control ECU connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B002BLJ

      Remove the hybrid vehicle transmission assembly Click here.

    2. 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 Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B002BU6

      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 Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    2. Install the hybrid vehicle transmission assembly.


    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  19. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 4 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 the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. B002BDTE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A38-11 (+B2) - Body ground Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A74-11 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  20. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  21. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  22. CHECK HYBRID VEHICLE TRANSMISSION 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 hybrid vehicle transmission assembly Click here.

    3. B002BPP

      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 bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Disconnect the motor cable from the hybrid vehicle transmission assembly.

    5. Check for arc marks at the terminals 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 hybrid vehicle transmission assembly.

    7. Install the hybrid vehicle transmission assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  23. 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 Click here.

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

      B002B4SE02
      Text in Illustration
      *A for LHD *B for RHD
      *1 Shield ground - -
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

      		 *b

      Motor Cable

      (Hybrid Vehicle Transmission Assembly Side)

      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
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the motor 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
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - u2-1 (U) Power switch off 100 MΩ or higher
      u1-2 (V) - u2-3 (W) Power switch off 100 MΩ or higher
      u1-1 (U) - u2-2 (V) Power switch off 100 MΩ or higher
      u1-3 (W) - u2-3 (W) Power switch off Below 1 Ω
      u1-2 (V) - u2-2 (V) Power switch off Below 1 Ω
      u1-1 (U) - u2-1 (U) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - u2-1 (U) Power switch off 100 MΩ or higher
      u3-2 (V) - u2-3 (W) Power switch off 100 MΩ or higher
      u3-3 (U) - u2-2 (V) Power switch off 100 MΩ or higher
      u3-1 (W) - u2-3 (W) Power switch off Below 1 Ω
      u3-2 (V) - u2-2 (V) Power switch off Below 1 Ω
      u3-3 (U) - u2-1 (U) Power switch off Below 1 Ω

    5. Install the motor cable.


    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  24. CHECK HYBRID VEHICLE TRANSMISSION 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 hybrid vehicle transmission assembly Click here.

    3. B002BHI

      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 bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Disconnect the generator cable from the hybrid vehicle transmission assembly.

    5. Check for arc marks at the terminals 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 vehicle transmission assembly.

    7. Install the hybrid vehicle transmission assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  25. 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 Click here.

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

      B002B7ME03
      Text in Illustration
      *A for LHD *B for RHD
      *1 Shield ground - -
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      		 *b

      Generator Cable

      (Hybrid Vehicle Transmission Assembly Side)

      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
      for LHD
      Tester Connection Switch Condition Specified Condition
      v3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the generator 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
      for LHD
      Tester Connection Switch Condition Specified Condition
      v3-3 (W) - v4-3 (U) Power switch off 100 MΩ or higher
      v3-2 (V) - v4-1 (W) Power switch off 100 MΩ or higher
      v3-1 (U) - v4-2 (V) Power switch off 100 MΩ or higher
      v3-3 (W) - v4-1 (W) Power switch off Below 1 Ω
      v3-2 (V) - v4-2 (V) Power switch off Below 1 Ω
      v3-1 (U) - v4-3 (U) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      v3-1 (W) - v4-3 (U) Power switch off 100 MΩ or higher
      v3-2 (V) - v4-1 (W) Power switch off 100 MΩ or higher
      v3-3 (U) - v4-2 (V) Power switch off 100 MΩ or higher
      v3-1 (W) - v4-1 (W) Power switch off Below 1 Ω
      v3-2 (V) - v4-2 (V) Power switch off Below 1 Ω
      v3-3 (U) - v4-3 (U) Power switch off Below 1 Ω

    5. Install the generator cable.


    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  26. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. Remove the hybrid vehicle transmission assembly Click here.

    2. B002BU6

      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 Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  27. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR RESOLVER)


    1. Disconnect the resolver connector.

    2. B002B72C14
      *a

      Component without harness connected

      (Motor Resolver (Hybrid Vehicle Transmission Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      1 (MRF) - 5 (MRFG) Power switch off 6.0 to 12.0 Ω
      2 (MSN) - 6 (MSNG) Power switch off 12.5 to 24.5 Ω
      3 (MCS) - 7 (MCSG) Power switch off 12.5 to 24.5 Ω

      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 (°F).)

      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      1 (MRF) - Body ground and other terminals (except 5 (MRFG)) Power switch off 1 MΩ or higher
      5 (MRFG) - Body ground and other terminals (except 1 (MRF)) Power switch off 1 MΩ or higher
      2 (MSN) - Body ground and other terminals (except 6 (MSNG)) Power switch off 1 MΩ or higher
      6 (MSNG) - Body ground and other terminals (except 2 (MSN)) Power switch off 1 MΩ or higher
      3 (MCS) - Body ground and other terminals (except 7 (MCSG)) Power switch off 1 MΩ or higher
      7 (MCSG) - Body ground and other terminals (except 3 (MCS)) Power switch off 1 MΩ or higher

    3. Reconnect the resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  28. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. Remove the hybrid vehicle transmission assembly Click here.

    2. B002BLJ

      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 Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  29. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR RESOLVER)


    1. Disconnect the resolver connector.

    2. B002B72C15
      *a

      Component without harness connected

      (Generator resolver (Hybrid Vehicle Transmission Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      1 (GRF) - 5 (GRFG) Power switch off 5.8 to 11.8 Ω
      2 (GSN) - 6 (GSNG) Power switch off 11.7 to 17.7 Ω
      3 (GCS) - 7 (GCSG) Power switch off 11.7 to 17.7 Ω

      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 (°F).)

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

    3. Reconnect the resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here