HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-202

DTC Code DTC Name
P0A78-202 Drive Motor "A" Inverter Performance

DESCRIPTION

For a description of the inverter Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A78 202 Malfunction (short circuit) in the motor inverter inside the inverter with converter assembly

  • Inverter with converter assembly

  • Hybrid vehicle transmission assembly

  • Motor 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 P0A78-202 is stored after any of DTCs P0A1B-505, P0A40-506, P0A78-113, 284, 286 and/or 287 are stored. After troubleshooting and repairing DTC P0A78-202, 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 P0A90-251 (Drive Motor "A" Performance) is not output. If DTC P0A90-251 (Drive Motor "A" Performance) is output, replace the hybrid vehicle transmission assembly.

PROCEDURE


  1. 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. B002BDIE01
      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. B002BUQE03
      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. B002BY0E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Generator Cable
      *2 Motor Cable

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

    5. B002C4VE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

      Check MG2 for an interphase short using a milliohmmeter.


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

        Tech Tips

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

        Standard Resistance
        for LHD
        Tester Connection Switch Condition Specified Condition
        u1-3 (W) - u1-1 (U) Power switch off 46.7 to 51.6 mΩ
        u1-2 (V) - u1-3 (W) Power switch off 47.0 to 51.9 mΩ
        u1-1 (U) - u1-2 (V) Power switch off 46.9 to 51.6 mΩ
        for RHD
        Tester Connection Switch Condition Specified Condition
        u3-1 (W) - u3-3 (U) Power switch off 46.9 to 51.9 mΩ
        u3-2 (V) - u3-1 (W) Power switch off 47.2 to 52.2 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. 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

    7. Connect the generator cable and motor cable.

    8. Install the inverter terminal cover.


    NG

    CHECK MOTOR CABLE Click here

    OK

  2. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

  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 the other DTCs that were output together with DTC P0A78-202.

      Result
      DTC No. Relevant Diagnosis
      P0A1B-505 Drive Motor "A" Control Module
      P0A40-506 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A78-113, 284, 286, 287 Drive Motor "A" Inverter Performance

      Note

      DTC P0A78-202 is stored after any of DTCs P0A1B-505, P0A40-506, P0A78-113, 284, 286 and/or 287 are stored. After troubleshooting and repairing DTC P0A78-202, be sure to troubleshoot all the other DTCs.

    5. Turn the power switch off.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  4. 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.

      B002B8JE02
      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 terminals of the motor cable with insulating tape to prevent them from coming into contact with the 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) - u2-3 (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
      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
      for RHD
      Tester Connection Switch Condition Specified Condition
      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
      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

    5. Install the motor cable.


    NG

    CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG2) 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. 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 the other DTCs that were output together with DTC P0A78-202.

      Result
      DTC No. Relevant Diagnosis
      P0A1B-505 Drive Motor "A" Control Module
      P0A40-506 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A78-113, 284, 286, 287 Drive Motor "A" Inverter Performance

      Note

      DTC P0A78-202 is stored after any of DTCs P0A1B-505, P0A40-506, P0A78-113, 284, 286 and/or 287 are stored. After troubleshooting and repairing DTC P0A78-202, be sure to troubleshoot all the other DTCs.

    5. Turn the power switch off.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

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

    3. A000S6JE02
      Text in Illustration
      *a

      Component without motor cable connected

      (Hybrid Vehicle Transmission Assembly)

      Check MG2 for an interphase short using a milliohmmeter.


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

        Tech Tips

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

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        u2-1 (U) - u2-2 (V) Power switch off 45.0 to 49.8 mΩ
        u2-2 (V) - u2-3 (W) Power switch off 45.1 to 50.1 mΩ
        u2-3 (W) - u2-1 (U) Power switch off 44.8 to 49.8 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
      u2-1 (U) - Body ground Power switch off 100 MΩ or higher
      u2-2 (V) - Body ground Power switch off 100 MΩ or higher
      u2-3 (W) - Body ground Power switch off 100 MΩ or higher

    5. Connect the motor cable.


    NG

    REPLACE MOTOR CABLE Click here

    OK

  9. REPLACE MOTOR CABLE

    Click here


    NEXT

  10. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

  11. 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 the other DTCs that were output together with DTC P0A78-202.

      Result
      DTC No. Relevant Diagnosis
      P0A1B-505 Drive Motor "A" Control Module
      P0A40-506 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A78-113, 284, 286, 287 Drive Motor "A" Inverter Performance

      Note

      DTC P0A78-202 is stored after any of DTCs P0A1B-505, P0A40-506, P0A78-113, 284, 286 and/or 287 are stored. After troubleshooting and repairing DTC P0A78-202, be sure to troubleshoot all the other DTCs.

    5. Turn the power switch off.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  12. REPLACE MOTOR 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. 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 the other DTCs that were output together with DTC P0A78-202.

      Result
      DTC No. Relevant Diagnosis
      P0A1B-505 Drive Motor "A" Control Module
      P0A40-506 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A78-113, 284, 286, 287 Drive Motor "A" Inverter Performance

      Note

      DTC P0A78-202 is stored after any of DTCs P0A1B-505, P0A40-506, P0A78-113, 284, 286 and/or 287 are stored. After troubleshooting and repairing DTC P0A78-202, be sure to troubleshoot all the other DTCs.

    5. Turn the power switch off.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here