HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-130

DESCRIPTION

For a description of the inverter Click here.

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

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

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 if DTCs are output.

      Result
      Result Proceed to P0A7A-203 is not output. A P0A7A-203 is also output. B

      Note

      
      

      • If P0A7A-203 is output, troubleshoot it first. After completing the troubleshooting for P0A7A-203, return to perform troubleshooting for this DTC.

      • Parts repaired or replaced during troubleshooting for P0A7A-203 do not need to be re-inspected in this diagnosis procedure.

   5. Turn the power switch off.

   
   

   B

   GO TO DTC CHART (P0A7A-203) 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 if DTCs are output.

      Tech Tips

      
      

      • If P0A7A-203 was not output in step 1 of this diagnosis procedure, check Table 1 below.

      • If P0A7A-203 was output in step 1 of this diagnosis procedure, repair that DTC first, then check Table 2 below.

      Result
      Result Proceed to P0A7A-130 only is output. A Any of the following 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
      P0A90-509	Drive Motor "A" 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
      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
      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
      P1C6D-501	Drive Motor "A" Phase V Current Sensor Offset Range/Performance
      P1C6E-502	Drive Motor "A" 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.

      • P0A7A-130 may be output due to a malfunction which also causes DTCs in the preceding table to be output. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

   5. Turn the power switch off.

   
   

   B

   GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

   A

3. 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 the connector connections and contact pressure of the low voltage connectors of the inverter with converter assembly Click here.

      Note

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

      

      Text in Illustration

      *A

      for LHD

      *B

      for RHD

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

      Tech Tips

      When connecting the connector, insert it with the locking lever in the raised position. Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage. After the click is heard, pull up on the connector to confirm that it is properly connected.

   
   

   NG

   CONNECT SECURELY

   OK

4. 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 connector from the inverter with converter assembly.

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

   4. Turn the power switch on (IG).

   5. 

      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 low voltage connector of 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. Connect the inverter with converter assembly connector.

   
   

   NG

   REPAIR OR REPLACE HARNESS OR CONNECTOR

   OK

5. 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 connector from the inverter with converter assembly.

   3. 

      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. Connect the inverter with converter assembly connector.

   
   

   NG

   CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

   OK

6. 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 connector from the inverter with converter assembly.

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

   4. Turn the power switch on (IG).

   5. 

      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 low voltage connector of 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. Connect the inverter with converter assembly connector.

   
   

   NG

   REPAIR OR REPLACE HARNESS OR CONNECTOR

   OK

7. 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 connector from the inverter with converter assembly.

   3. 

      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 terminals Power switch off 1 MΩ or higher

   4. Connect the inverter with converter assembly connector.

   
   

   NG

   CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

   OK

8. 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. 

      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. 

      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. 

      Text in Illustration

      *A	for LHD
      *B	for RHD
      *1	Generator Cable

      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).

   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

9. 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. 

      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. 

      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. 

      Text in Illustration

      *A	for LHD
      *B	for RHD
      *1	Motor Cable

      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

10. 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. 

       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. 

       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. 

       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. 

       Text in Illustration

       *A	for LHD
       *B	for RHD
       *1	Shield Ground
       *a	Generator Cable (Inverter with Converter Assembly Side)

       Check 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 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 v1-3 (W) - v1-1 (U) Power switch off 31.9 to 35.0 mΩ v1-2 (V) - v1-3 (W) Power switch off 31.8 to 34.9 mΩ v1-1 (U) - v1-2 (V) Power switch off 33.0 to 36.1 mΩ
          for RHD Tester Connection Switch Condition Specified Condition v1-1 (W) - v1-3 (U) Power switch off 31.4 to 34.6 mΩ v1-2 (V) - v1-1 (W) Power switch off 31.3 to 34.5 mΩ v1-3 (U) - v1-2 (V) Power switch off 32.5 to 35.7 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 v1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher v1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
       for RHD Tester Connection Switch Condition Specified Condition v1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher v1-3 (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 HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) Click here

    OK

11. 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. 

       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. 

       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. 

       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. 

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

    OK

12. CHECK FUSE (IGCT NO. 4)

    
    
    1. 

       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

13. 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 connector from the inverter with converter assembly.

    3. 

       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. Connect the inverter with converter assembly connector.

    
    

    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

14. 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 connector from the inverter with converter assembly.

    3. Disconnect the connector from the power management control ECU.

    4. 

       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 connector 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. Connect the power management control ECU connector.

    11. Connect the inverter with converter assembly connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

15. CHECK POWER MANAGEMENT CONTROL ECU

    
    

    1. Disconnect the connector from the power management control ECU.

    2. 

       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. Connect the power management control ECU connector.

    
    

    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

16. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    
    

    1. 

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

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

       Note

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

    
    

    NG

    CONNECT SECURELY

    OK

17. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    
    

    1. 

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

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

       Note

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

    
    

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    NG

    CONNECT SECURELY

18. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    
    

    1. 

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

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

       Note

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

    
    

    NG

    CONNECT SECURELY

    OK

19. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR RESOLVER)

    
    

    1. Disconnect the resolver connector.

    2. 

       *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

20. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    
    

    1. 

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

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

       Note

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

    
    

    NG

    CONNECT SECURELY

    OK

21. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR RESOLVER)

    
    

    1. Disconnect the resolver connector.

    2. 

       *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

22. 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 connector from the inverter with converter assembly.

    3. 

       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. Connect the inverter with converter assembly connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

23. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here

    
    

    NEXT

    REPLACE FUSE (IGCT NO. 4)

24. REPAIR OR REPLACE HARNESS OR CONNECTOR

    
    

    NEXT

    REPLACE FUSE (IGCT NO. 4)

25. 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. 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

26. 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.

       

       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 v1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher v1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
       for RHD Tester Connection Switch Condition Specified Condition v1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher v1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

       Note

       Wrap the terminals of the generator 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 v1-3 (W) - v2-1 (W) Power switch off Below 1 Ω v1-2 (V) - v2-2 (V) Power switch off Below 1 Ω v1-1 (U) - v2-3 (U) Power switch off Below 1 Ω v1-3 (W) - v2-3 (U) Power switch off 100 MΩ or higher v1-2 (V) - v2-1 (W) Power switch off 100 MΩ or higher v1-1 (U) - v2-2 (V) Power switch off 100 MΩ or higher
       for RHD Tester Connection Switch Condition Specified Condition v1-1 (W) - v2-1 (W) Power switch off Below 1 Ω v1-2 (V) - v2-2 (V) Power switch off Below 1 Ω v1-3 (U) - v2-3 (U) Power switch off Below 1 Ω v1-1 (W) - v2-3 (U) Power switch off 100 MΩ or higher v1-2 (V) - v2-1 (W) Power switch off 100 MΩ or higher v1-3 (U) - v2-2 (V) Power switch off 100 MΩ or higher

    5. Install the generator cable.

    
    

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

27. 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. 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

28. 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.

       

       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.

    
    

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here