HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-324

DTC Code DTC Name
P0A7A-324 Generator Inverter Performance

DESCRIPTION

For a description of the inverter Click here.

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

DTC No. INF Code DTC Detection Condition Trouble Area
P0A7A 324 Generator inverter fail signal detection (circuit malfunction)

  • Inverter cooling system

  • Cooling fan system

  • Power management control ECU

  • Inverter with converter assembly

  • Hybrid vehicle transmission assembly

  • Generator cable

  • Motor cable

  • Wire harness or connector

  • IGCT No. 4 fuse

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.

  • After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly as the inverter with converter assembly may have been broken or damaged due to overheating.

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-324 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
      P0A78-113, 128, 279, 284, 287, 548, 555, 807 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 325, 810 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      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
      P0C73-776 Motor Electronics Coolant Pump "A" Control 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
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      P314A-828 Inverter Coolant Pump Speed Signal
      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
      P0A78-113, 128, 279, 284, 287, 548, 555, 807 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 325, 810 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      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
      P0C73-776 Motor Electronics Coolant Pump "A" Control 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
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      P314A-828 Inverter Coolant Pump Speed Signal

      Tech Tips


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

      • P0A7A-324 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. After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

    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.

      B002BBWE01
      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 QUANTITY OF HV COOLANT


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

    2. Check for HV coolant leaks.

      Result
      Result Proceed to
      No leaks are found and coolant level in the inverter reserve tank assembly is above the low line. A
      No leaks are found and coolant level in the inverter reserve tank assembly is below the low line. B
      HV coolant leaks are evident. C

      Note

      The inverter water pump with motor assembly has a protection function that activates when there is an HV coolant leak. Therefore, it is not necessary to replace the inverter water pump with motor assembly unless the cause of the HV coolant leak is the inverter water pump with motor assembly.

      Tech Tips

      After repairing the HV coolant leaks and adding coolant, perform the "Activate the (Inverter) Water Pump" Active Test (HV Active Test item) and the "Control the Electric Cooling Fan" Active Test (Engine Active Test item) and make sure that there are no malfunctions.


    B

    ADD HV COOLANT

    C

    INSPECT FOR HV COOLANT LEAK AND ADD COOLANT

    A

  5. CHECK COOLANT HOSE


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


    NG

    CORRECT THE PROBLEM

    OK

  6. PERFORM ACTIVE TEST USING GTS (CONTROL THE ELECTRIC COOLING FAN)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Electric Cooling Fan.

    4. Perform the "Control the Electric Cooling Fan" Active Test.

      OK
      The cooling fan rotates.

    5. Turn the power switch off.


    NG

    CHECK COOLING FAN SYSTEM Click here

    OK

  7. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING)


    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. Read the freeze frame data Ambient Temperature using the GTS.

    5. Check if the freeze frame data Ambient Temperature is below freezing.

      Result
      Result Proceed to
      Ambient Temperature value is above freezing temperature of the HV coolant. A
      Ambient Temperature value is below freezing temperature of the HV coolant. B

      Tech Tips


      • HV coolant (SLLC) with a 30% concentration freezes at -15°C (5°F) and HV coolant (SLLC) with a 50% concentration freezes at -35°C (-31°F).

      • If the HV coolant freezes in the HV radiator or HV water pump, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be stored.

      • A DTC is stored when the HV water pump impeller cannot rotate due to freezing of the HV coolant.

      • If a DTC is stored due to freezing of HV coolant, the problem cannot be reproduced. Judge whether freezing of HV coolant occurred according to the freeze point of the HV coolant, HV coolant change history and ambient temperature when the DTC was stored.

    6. Turn the power switch off.


    B

    REPLACE HV COOLANT Click here

    A

  8. 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. 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 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

  9. 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. 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. Connect the inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

  10. 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. 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 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

  11. 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. 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 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

  12. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      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. B002BK6E01
      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

  13. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      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. B002BGME01
      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

  14. 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. 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. B002BYSE02
      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

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

    OK

  16. 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

  17. 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. 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. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

  18. 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. 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 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

  19. CHECK POWER MANAGEMENT CONTROL ECU


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

    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. Connect the power management control ECU connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  20. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B002BKT

      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

  21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B002B4I

      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

  22. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B002BKT

      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

  23. 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

  24. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B002B4I

      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

  25. 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

  26. 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. 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. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  27. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  28. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  29. 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.

      B002B8E
      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

  30. 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.

      B002BGYE01
      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

  31. 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.

      B002BAA
      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

  32. 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.


    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  33. REPLACE HV COOLANT


    1. Replace the HV coolant with coolant having an appropriate concentration (appropriate freeze point) for the vehicle usage conditions Click here.


    NEXT

    COMPLETED