HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-203

DTC Code DTC Name
P0A7A-203 Generator Inverter Performance

DESCRIPTION

For a description of the inverter Click here.

DTC No. DTC Detection Condition Trouble Area
P0A7A-203

Generator inverter short circuit

Current flowing to any of the phases exceeds a certain level after a DTC (indicates a generator inverter malfunction: overheating, overcurrent or circuit malfunction) is stored and the generator inverter is shutdown.

(1 trip detection logic)

  • Inverter with converter assembly

  • Hybrid vehicle transmission assembly

  • Generator cable

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AA6-526 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.

  • DTC P0A7A-203 is stored after any of DTCs P0A1A-517, P0A4C-518, P0A7A-122, 322, 324 and 325 are stored. After troubleshooting and repairing the malfunction which caused DTC P0A7A-203 to be stored, be sure to troubleshoot all the other DTCs.

  • Depending on the conditions in which the vehicle is being operated when a short circuit occurs in the inverter with converter assembly, the hybrid vehicle transmission assembly may be affected. As this DTC is stored if a short circuit occurs in the inverter with converter assembly, it is necessary to perform a road test to check the hybrid vehicle transmission assembly. If problems are found, replace the malfunctioning parts.

  • After completing the repair, including the repair of previously output DTCs, drive the vehicle at a speed of approximately 40 km/h (25 mph) for 1 minute and check that DTC P0A92-261 (Hybrid Generator Performance) is not output. If DTC P0A92-261 (Hybrid Generator Performance) is output, replace the hybrid vehicle transmission assembly.

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. Drive the vehicle for approximately 10 minutes mainly using the engine.

PROCEDURE


  1. 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 GENERATOR CABLE Click here

    OK

  2. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A1A-517 Generator Control Module
      P0A4C-518 Generator Position Sensor Circuit Range / Performance
      P0A7A-122, 322, 324, 325 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A1A-517, P0A4C-518, P0A7A-122, 322, 324 and 325 are stored. After troubleshooting and repairing the malfunction which caused DTC P0A7A-203 to be stored, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  4. 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.


    NG

    CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1) Click here

    OK

  5. REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here


    NEXT

  6. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

  7. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A1A-517 Generator Control Module
      P0A4C-518 Generator Position Sensor Circuit Range / Performance
      P0A7A-122, 322, 324, 325 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A1A-517, P0A4C-518, P0A7A-122, 322, 324 and 325 are stored. After troubleshooting and repairing the malfunction which caused DTC P0A7A-203 to be stored, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  8. 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. Disconnect the generator cable from the hybrid vehicle transmission assembly Click here.

    3. A000PCSE02
      Text in Illustration
      *a

      Component without generator cable connected

      (Hybrid Vehicle Transmission Assembly)

      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
        Tester Connection Switch Condition Specified Condition
        v4-3 (U) - v4-2 (V) Power switch off 56.0 to 62.0 mΩ
        v4-2 (V) - v4-1 (W) Power switch off 59.0 to 65.0 mΩ
        v4-1 (W) - v4-3 (U) Power switch off 56.0 to 62.0 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 x 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
      v4-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      v4-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v4-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    5. Connect the generator cable.


    NG

    REPLACE GENERATOR CABLE Click here

    OK

  9. REPLACE GENERATOR CABLE

    Click here


    NEXT

  10. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

  11. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A1A-517 Generator Control Module
      P0A4C-518 Generator Position Sensor Circuit Range / Performance
      P0A7A-122, 322, 324, 325 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A1A-517, P0A4C-518, P0A7A-122, 322, 324 and 325 are stored. After troubleshooting and repairing the malfunction which caused DTC P0A7A-203 to be stored, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  12. REPLACE GENERATOR CABLE

    Click here


    NEXT

  13. REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here


    NEXT

  14. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

  15. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A1A-517 Generator Control Module
      P0A4C-518 Generator Position Sensor Circuit Range / Performance
      P0A7A-122, 322, 324, 325 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A1A-517, P0A4C-518, P0A7A-122, 322, 324 and 325 are stored. After troubleshooting and repairing the malfunction which caused DTC P0A7A-203 to be stored, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here