HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-122

DTC Code DTC Name
P0A7A-122 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. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P0A7A-122 Generator Inverter Performance Generator inverter fail signal detection (overcurrent due to system malfunction)

  • Power management control ECU

  • Inverter with converter assembly

  • Hybrid vehicle generator assembly

  • Hybrid vehicle motor assembly

  • Generator cable

  • Motor cable

  • Wire harness or connector

  • PCU fuse

 Comes on

Master Warning Light:

Comes on

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A1A-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

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Result
      Result Proceed to
      P0A7A-122 is stored before any of the DTCs in the tables below are stored. A
      Any of the DTCs including pending DTCs in table 1 below are stored before P0A7A-122 is stored. B
      Any of the DTCs in table 2 below are stored before P0A7A-122 is stored. C
      Table 1
      DTC No. Relevant Diagnosis
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P3004-803 High Voltage Power Resource
      Table 2
      DTC No. Relevant Diagnosis
      P3011-123, P3012-123, P3013-123, P0314-123, P3015-123, P3016-123, P0317-123, P3018-123, P3019-123, P3020-123, P3021-123, P3022-123, P3023-123, P3024-123 Battery Block # Becomes Weak
      P0A9C-123 Hybrid Battery Temperature Sensor "A" Range / Performance
      P0A9D-123 Hybrid Battery Temperature Sensor "A" Circuit Low
      P0A9E-123 Hybrid Battery Temperature Sensor "A" Circuit High
      P0AC0-123 Hybrid Battery Pack Current Sensor Circuit Range/Performance
      P0AC1-123 Hybrid Battery Pack Current Sensor Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor Circuit High
      P0AC6-123 Hybrid Battery Temperature Sensor "B" Range/Performance
      P0AC7-123 Hybrid Battery Temperature Sensor "B" Circuit Low
      P0AC8-123 Hybrid Battery Temperature Sensor "B" Circuit High
      P0ACB-123 Hybrid Battery Temperature Sensor "C" Range / Performance
      P0ACC-123 Hybrid Battery Temperature Sensor "C" Circuit Low
      P0ACD-123 Hybrid Battery Temperature Sensor "C" Circuit High
      P0AFC-123 Hybrid Battery Pack Sensor Module
      P3065-123 Hybrid Battery Temperature Sensor Range/Performance Stuck "A"
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low

      Tech Tips


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

      • P0A7A-122 may be stored due to a malfunction which also causes DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    A

  2. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      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, 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

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes

      Tech Tips


      • If P0A7A-203 was not output in step 2 of this diagnosis procedure, check Table 1 below.

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

      Result
      Result Proceed to
      P0A7A-122 only is output, or DTCs except the ones in the tables below are also output. A
      Any of the following DTCs including pending DTCs are also output. B
      Table 1
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 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 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource
      Table 2
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 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 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A72-333 Generator Phase V Current
      P0A75-341 Generator Phase W Current
      P0A78-266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource

      Tech Tips


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

      • P0A7A-122 may be stored due to a malfunction which also causes DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  4. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    Result
    Proceed to
    OK
    NG

    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. A01SFRS

      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 does not pull out.

      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.

      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

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

    Result
    Proceed to
    OK
    NG

    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 B179 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. A0031ZXC08
      *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
      Tester Connection Condition Specified Condition
      B179-11 (GRF) - Body ground Power switch on (IG) Below 1 V
      B179-12 (GRFG) - Body ground Power switch on (IG) Below 1 V
      B179-7 (GSN) - Body ground Power switch on (IG) Below 1 V
      B179-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      B179-10 (GCS) - Body ground Power switch on (IG) Below 1 V
      B179-9 (GCSG) - Body ground Power switch on (IG) Below 1 V

      Note

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

    6. Turn the power switch off.

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

    8. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. CHECK GENERATOR RESOLVER

    Result
    Proceed to
    OK
    NG

    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 B179 inverter with converter assembly connector.

    3. A0031ZXC08
      *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)
      Tester Connection Condition Specified Condition
      B179-11 (GRF) - B179-12 (GRFG) Power switch off 7.1 to 21.6 Ω
      B179-7 (GSN) - B179-8 (GSNG) Power switch off 13.7 to 34.5 Ω
      B179-10 (GCS) - B179-9 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B179-11 (GRF) or B179-12 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-7 (GSN) or B179-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-10 (GCS) or B179-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

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

    Result
    Proceed to
    OK
    NG

    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 B179 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. A0031ZXC07
      *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
      Tester Connection Condition Specified Condition
      B179-1 (MRF) - Body ground Power switch on (IG) Below 1 V
      B179-2 (MRFG) - Body ground Power switch on (IG) Below 1 V
      B179-3 (MSN) - Body ground Power switch on (IG) Below 1 V
      B179-4 (MSNG) - Body ground Power switch on (IG) Below 1 V
      B179-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      B179-5 (MCSG) - Body ground Power switch on (IG) Below 1 V

      Note

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

    6. Turn the power switch off.

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

    8. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. CHECK MOTOR RESOLVER

    Result
    Proceed to
    OK
    NG

    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 B179 inverter with converter assembly connector.

    3. A0031ZXC07
      *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)
      Tester Connection Condition Specified Condition
      B179-1 (MRF) - B179-2 (MRFG) Power switch off 7.1 to 21.6 Ω
      B179-3 (MSN) - B179-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      B179-6 (MCS) - B179-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B179-1 (MRF) or B179-2 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-3 (MSN) or B179-4 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-6 (MCS) or B179-5 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

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

    Result
    Proceed to
    A
    B
    C

    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. A00320Z

      Remove the inverter cover from the inverter with converter assembly.

    3. A00323LN01

      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
      Bolt A
      T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)
      Bolt B
      T = 9.2 N*m (94 kgf*cm, 81 in.*lbf)

      Note


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

      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

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

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

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

    Result
    Proceed to
    A
    B
    C

    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. A00320Z

      Remove the inverter cover from the inverter with converter assembly.

    3. A00324YN01

      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
      Bolt A
      T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)
      Bolt B
      T = 9.2 N*m (94 kgf*cm, 81 in.*lbf)

      Note


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

      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

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

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  11. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

    Result
    Proceed to
    OK
    NG

    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. A00320Z

      Remove the inverter cover from the inverter with converter assembly.

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

    4. A00320GC05
      *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
        Tester Connection Condition Specified Condition
        m1-1 (W) -m1-3 (V) Power switch off 89.5 to 98.9 mΩ
        m1-2 (U) - m1-1 (W) Power switch off 89.5 to 98.9 mΩ
        m1-3 (V) - m1-2 (U) Power switch off 89.5 to 98.9 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)

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

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      m1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.

      Result
      Proceed to
      OK
      NG

    NG

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

    OK

  12. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)

    Result
    Proceed to
    OK
    NG

    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. A00320Z

      Remove the inverter cover from the inverter with converter assembly.

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

    4. A00322XC05
      *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
        Tester Connection Condition Specified Condition
        k1-1 (W) - k1-3 (V) Power switch off 151.6 to 168.0 mΩ
        k1-2 (U) - k1-1 (W) Power switch off 152.6 to 169.0 mΩ
        k1-3 (V) - k1-2 (U) Power switch off 157.6 to 174.0 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68° F).

        R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:

        R20: Resistance at 20°C (68° F) (mΩ)

        Rt: Measured resistance (mΩ)

        T: Temperature when the resistance is measured (°C)

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

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      k1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.

      Result
      Proceed to
      OK
      NG

    NG

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

    OK

  13. CHECK FUSE (PCU)

    Result
    Proceed to
    OK
    NG

    1. A003293C01
      *1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly
      *2 PCU Fuse

      Remove the PCU fuse from the No. 1 engine room relay block and No. 1 junction block assembly.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      PCU fuse terminal Always Below 1 Ω

    3. Install the PCU fuse.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) Click here

    OK

  14. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)

    Result
    Proceed to
    OK
    NG

    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 A143 inverter with converter assembly connector.

    3. A003209C33
      *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
      Tester Connection Condition Specified Condition
      A143-28 (GND1) - Body ground Power switch off Below 1 Ω
      A143-27 (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
      Tester Connection Condition Specified Condition
      A143-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A143-9 (+B2) - Body ground Power switch on (IG) 11 to 14 V

      Note

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

    7. Turn the power switch off.

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

    9. Reconnect the A143 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

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

    Result
    Proceed to
    OK
    NG

    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 A130 power management control ECU connector.

    3. Disconnect the A143 inverter with converter assembly connector.

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

      A00325JC01

      (to Power Management Control ECU)
      *a

      Front view of wire harness connector

      (to Power Management Control ECU)

      		 *b

      Rear view of wire harness connector

      (to Inverter with Converter Assembly)
      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      A143-8 (HTM+) - A130-24 (HTM+) Power switch off Below 1 Ω
      A143-18 (HTM-) - A130-25 (HTM-) Power switch off Below 1 Ω
      A143-7 (MTH+) - A130-30 (MTH+) Power switch off Below 1 Ω
      A143-17 (MTH-) - A130-29 (MTH-) Power switch off Below 1 Ω
      A143-6 (REQ+) - A130-33 (REQ+) Power switch off Below 1 Ω
      A143-16 (REQ-) - A130-32 (REQ-) Power switch off Below 1 Ω
      A143-5 (CLK+) - A130-21 (CLK+) Power switch off Below 1 Ω
      A143-15 (CLK-) - A130-20 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      A143-8 (HTM+) or A130-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A143-18 (HTM-) or A130-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A143-7 (MTH+) or A130-30 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A143-17 (MTH-) or A130-29 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A143-6 (REQ+) or A130-33 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A143-16 (REQ-) or A130-32 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A143-5 (CLK+) or A130-21 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A143-15 (CLK-) or A130-20 (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
      Tester Connection Condition Specified Condition
      A143-8 (HTM+) or A130-24 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A143-18 (HTM-) or A130-25 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A143-7 (MTH+) or A130-30 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A143-17 (MTH-) or A130-29 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A143-6 (REQ+) or A130-33 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A143-16 (REQ-) or A130-32 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A143-5 (CLK+) or A130-21 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A143-15 (CLK-) or A130-20 (CLK-) - Body ground Power switch on (IG) Below 1 V

      Note

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

    8. Turn the power switch off.

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

    10. Reconnect the A143 inverter with converter assembly connector.

    11. Reconnect the A130 power management control ECU connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  16. CHECK POWER MANAGEMENT CONTROL ECU

    Result
    Proceed to
    OK
    NG

    1. Disconnect the A130 power management control ECU connector.

    2. A00327BC04
      *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 Condition Specified Condition
      A130-24 (HTM+) - A130-25 (HTM-) Power switch off 80 to 170 Ω
      A130-30 (MTH+) - A130-29 (MTH-) Power switch off 80 to 170 Ω
      A130-33 (REQ+) - A130-32 (REQ-) Power switch off 80 to 170 Ω
      A130-21 (CLK+) - A130-20 (CLK-) Power switch off 80 to 170 Ω

    3. Reconnect the A130 power management control ECU connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE POWER MANAGEMENT CONTROL ECU for LHD: Click here
    REPLACE POWER MANAGEMENT CONTROL ECU for RHD: Click here

    OK

  17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    Result
    Proceed to
    OK
    NG

    1. A003237

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    Result
    Proceed to
    OK
    NG

    1. A0031Y3

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CONNECT SECURELY

  19. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)

    Result
    Proceed to
    OK
    NG

    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 A143 inverter with converter assembly connector.

    3. A003209C34
      *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
      Tester Connection Condition Specified Condition
      A143-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A143-9 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Reconnect the A143 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  20. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    REPLACE FUSE (PCU)

  21. REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to
    NEXT

    NEXT

    REPLACE FUSE (PCU)

  22. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    Result
    Proceed to
    A
    B
    C

    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. A003285

      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 = 10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note

      Make sure that the tightening torque of the bolt is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    3. Disconnect the motor cable from the hybrid vehicle transaxle assembly.

    4. 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

    5. Connect the motor cable to the hybrid vehicle transaxle assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  23. CHECK MOTOR CABLE

    Result
    Proceed to
    OK
    NG

    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. A0031YJC03
      *1 Shield ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)
      *b

      Motor Cable

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      k1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      k1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the motor cable with insulating tape to prevent them from coming into contact with body ground.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      k1-1 (W) - k2-3 (U) Power switch off 100 MΩ or higher
      k1-2 (U) - k2-2 (V) Power switch off 100 MΩ or higher
      k1-3 (V) - k2-1 (W) Power switch off 100 MΩ or higher
      k1-1 (W) - k2-1 (W) Power switch off Below 1 Ω
      k1-2 (U) - k2-3 (U) Power switch off Below 1 Ω
      k1-3 (V) - k2-2 (V) Power switch off Below 1 Ω

    5. Install the motor cable.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  24. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    Result
    Proceed to
    A
    B
    C

    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 inverter with converter assembly.

      Click here

    3. A0032ALN01

      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
      Bolt A
      T = 20 N*m (204 kgf*cm, 15 ft.*lbf)
      Bolt B
      T = 10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note


      • Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 to 245 kgf*cm, 12 to 18 ft.*lbf).

      • Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

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

    7. Install the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  25. CHECK GENERATOR CABLE

    Result
    Proceed to
    OK
    NG

    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. A003244C04
      *1 Shield ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)
      *b

      Generator Cable

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      m1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      m1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the generator cable with insulating tape to prevent them from coming into contact with body ground.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      m1-1 (W) - m2-2 (U) Power switch off 100 MΩ or higher
      m1-2 (U) - m2-1 (V) Power switch off 100 MΩ or higher
      m1-3 (V) - m2-3 (W) Power switch off 100 MΩ or higher
      m1-1 (W) - m2-3 (W) Power switch off Below 1 Ω
      m1-2 (U) - m2-2 (U) Power switch off Below 1 Ω
      m1-3 (V) - m2-1 (V) Power switch off Below 1 Ω

    5. Install the generator cable.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  26. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    Result
    Proceed to
    OK
    NG

    1. A0031Y3

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  27. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)

    Result
    Proceed to
    OK
    NG

    1. A0031Y3N01

      Disconnect the B168 motor resolver connector.

    2. A00324EC01
      *a

      Component without harness connected

      (Motor Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      B168-3 (MRF) - B168-6 (MRFG) Power switch off 7.1 to 21.6 Ω
      B168-1 (MSN) - B168-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      B168-2 (MCS) - B168-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B168-3 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-6 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-1 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-4 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-2 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-5 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

      The motor resolver is not available as a supply part. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Reconnect the B168 motor resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Click here

  28. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    Result
    Proceed to
    OK
    NG

    1. A003237

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  29. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)

    Result
    Proceed to
    OK
    NG

    1. A003237N01

      Disconnect the B166 generator resolver connector.

    2. A00328TC03
      *a

      Component without harness connected

      (Generator Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      B166-1 (GRF) - B166-5 (GRFG) Power switch off 7.1 to 21.6 Ω
      B166-2 (GSN) - B166-6 (GSNG) Power switch off 13.7 to 34.5 Ω
      B166-3 (GCS) - B166-7 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B166-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-7 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

      The generator resolver is not available as a supply part. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Reconnect the B166 generator resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY Click here