HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-122

DESCRIPTION

For a description of the inverter.

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WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A1A-200.

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Refer to the wiring diagram for DTC P0AA6-526.

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Refer to the wiring diagram for DTC P324E-788.

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Refer to the wiring diagram for DTC U0110-159.

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CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   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.

      
      
      1. Powertrain > Hybrid Control > Trouble Codes
      2. 
         
      3. 
         

      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 including pending DTCs in table 2 below are stored before P0A7A-122 is stored. C

      Table 1. Table 1

      Relevant DTC
      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. Table 2

      Relevant DTC
      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
      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, P3025-123, P3026-123	Battery Block # Becomes Weak
      P3065-123	Hybrid Battery Temperature Sensor Range/Performance Stuck "A"
      P308A-123	Hybrid Battery Voltage Sensor All Circuits Low

      Tip:
      

      • 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.

   
   
   • AClick here
   • B

     GO TO DTC CHART (HYBRID CONTROL SYSTEM)Click here

   • C

     GO TO DTC CHART (HYBRID BATTERY SYSTEM)Click here

2. Click here

   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.

      
      
      1. Powertrain > Hybrid Control > Trouble Codes
      2. 
         
      3. 
         

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

      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.

   
   
   • P0A7A-203 is not output.Click here
   • P0A7A-203 is also output.

     GO TO DTC CHART (P0A7A-203)Click here

3. Click here

   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.

      
      
      1. Powertrain > Hybrid Control > Trouble Codes
      2. 
         
      3. 
         
      Tip:
      

      • 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 3. Table 1

      Relevant DTC
      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 4. Table 2

      Relevant DTC
      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

      Tip:
      

      • *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.

   
   
   • AClick here
   • B

     GO TO DTC CHART (HYBRID CONTROL SYSTEM)Click here

4. Click here

   CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

   Result
   Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) 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. 

      *A

      for LHD

      *B

      for RHD

      Check connection condition of the low voltage connector of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

      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 connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.

      Result
      Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

      Tip:

      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.

   
   
   • AClick here
   • B

     CONNECT SECURELY

   • C

     REPAIR OR REPLACE HARNESS OR CONNECTOR

5. Click here

   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 A28*1 orA29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

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

   4. Turn the power switch on (IG).

   5. 

      *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
      Table 5. for LHD Tester Connection Condition Specified Condition A28-20 (GRF) - Body ground Power switch on (IG) Below 1 V A28-9 (GRFG) - Body ground Power switch on (IG) Below 1 V A28-18 (GSN) - Body ground Power switch on (IG) Below 1 V A28-7 (GSNG) - Body ground Power switch on (IG) Below 1 V A28-17 (GCS) - Body ground Power switch on (IG) Below 1 V A28-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      Table 6. for RHD Tester Connection Condition Specified Condition A29-20 (GRF) - Body ground Power switch on (IG) Below 1 V A29-9 (GRFG) - Body ground Power switch on (IG) Below 1 V A29-18 (GSN) - Body ground Power switch on (IG) Below 1 V A29-7 (GSNG) - Body ground Power switch on (IG) Below 1 V A29-17 (GCS) - Body ground Power switch on (IG) Below 1 V A29-6 (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 A28*1 or A29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

      Result
      Proceed to OK NG

   
   
   • OKClick here
   • NG

     REPAIR OR REPLACE HARNESS OR CONNECTOR

6. Click here

   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 A28*1 orA29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

   3. 

      *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
      Table 7. for LHD Tester Connection Condition Specified Condition A28-20 (GRF) - A28-9 (GRFG) Power switch off 4.2 to 12.5 Ω A28-18 (GSN) - A28-7 (GSNG) Power switch off 9.8 to 20.1 Ω A28-17 (GCS) - A28-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      Table 8. for RHD Tester Connection Condition Specified Condition A29-20 (GRF) - A29-9 (GRFG) Power switch off 4.2 to 12.5 Ω A29-18 (GSN) - A29-7 (GSNG) Power switch off 9.8 to 20.1 Ω A29-17 (GCS) - A29-6 (GCSG) Power switch off 9.8 to 20.1 Ω

      Tip:

      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)
      Table 9. for LHD Tester Connection Condition Specified Condition A28-20 (GRF) or A28-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A28-18 (GSN) or A28-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A28-17 (GCS) or A28-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 10. for RHD Tester Connection Condition Specified Condition A29-20 (GRF) or A29-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A29-18 (GSN) or A29-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A29-17 (GCS) or A29-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

   4. Reconnect the A28*1 or A29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

      Result
      Proceed to OK NG

   
   
   • OKClick here
   • NGClick here
7. Click here

   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 A28*1 orA29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

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

   4. Turn the power switch on (IG).

   5. 

      *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
      Table 11. for LHD Tester Connection Condition Specified Condition A28-40 (MRF) - Body ground Power switch on (IG) Below 1 V A28-29 (MRFG) - Body ground Power switch on (IG) Below 1 V A28-39 (MSN) - Body ground Power switch on (IG) Below 1 V A28-28 (MSNG) - Body ground Power switch on (IG) Below 1 V A28-38 (MCS) - Body ground Power switch on (IG) Below 1 V A28-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      Table 12. for RHD Tester Connection Condition Specified Condition A29-40 (MRF) - Body ground Power switch on (IG) Below 1 V A29-29 (MRFG) - Body ground Power switch on (IG) Below 1 V A29-39 (MSN) - Body ground Power switch on (IG) Below 1 V A29-28 (MSNG) - Body ground Power switch on (IG) Below 1 V A29-38 (MCS) - Body ground Power switch on (IG) Below 1 V A29-27 (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 A28*1 or A29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

      Result
      Proceed to OK NG

   
   
   • OKClick here
   • NG

     REPAIR OR REPLACE HARNESS OR CONNECTOR

8. Click here

   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 A28*1 orA29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

   3. 

      *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
      Table 13. for LHD Tester Connection Condition Specified Condition A28-40 (MRF) - A28-29 (MRFG) Power switch off 4.2 to 12.5 Ω A28-39 (MSN) - A28-28 (MSNG) Power switch off 9.8 to 24.8 Ω A28-38 (MCS) - A28-27 (MCSG) Power switch off 9.8 to 24.8 Ω
      Table 14. for RHD Tester Connection Condition Specified Condition A29-40 (MRF) - A29-29 (MRFG) Power switch off 4.2 to 12.5 Ω A29-39 (MSN) - A29-28 (MSNG) Power switch off 9.8 to 24.8 Ω A29-38 (MCS) - A29-27 (MCSG) Power switch off 9.8 to 24.8 Ω

      Tip:

      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)
      Table 15. for LHD Tester Connection Condition Specified Condition A28-40 (MRF) or A28-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A28-39 (MSN) or A28-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A28-38 (MCS) or A28-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 16. for RHD Tester Connection Condition Specified Condition A29-40 (MRF) or A29-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A29-39 (MSN) or A29-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A29-38 (MCS) or A29-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

   4. Reconnect the A28*1 or A29*2 inverter with converter assembly connector.

      
      

      • *1: for LHD

      • *2: for RHD

      Result
      Proceed to OK NG

   
   
   • OKClick here
   • NGClick here
9. Click here

   CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

   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

   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. 

      *A	for LHD
      *B	for RHD

      for Type A:

      
      

      1. Remove the inverter cover from the inverter with converter assembly.

   3. 

      *A	for LHD
      *B	for RHD

      for Type B:

      
      

      1. Remove the inverter cover from the inverter with converter assembly.

   4. 

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

      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 cover.

   
   
   • AClick here
   • B

     REPLACE MALFUNCTIONING PARTS

   • C

     CONNECT SECURELY

10. Click here

    CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    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

    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. 

       *A	for LHD
       *B	for RHD

       for Type A:

       
       

       1. Remove the inverter cover from the inverter with converter assembly.

    3. 

       *A	for LHD
       *B	for RHD

       for Type B:

       
       

       1. Remove the inverter cover from the inverter with converter assembly.

    4. 

       *A	for LHD
       *B	for RHD
       *1	Motor Cable (Inverter with Converter Assembly Side)

       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 cover.

    
    
    • AClick here
    • B

      REPLACE MALFUNCTIONING PARTS

    • C

      CONNECT SECURELY

11. Click here

    CHECK HYBRID VEHICLE TRANSMISSION 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. 

       *A	for LHD
       *B	for RHD

       for Type A:

       
       

       1. Remove the inverter cover from the inverter with converter assembly.

    3. 

       *A	for LHD
       *B	for RHD

       for Type B:

       
       

       1. Remove the inverter cover from the inverter with converter assembly.

    4. 

       *A	for LHD
       *B	for RHD
       *1	Motor Cable (Inverter with Converter Assembly Side)
       *2	Generator Cable (Inverter with Converter Assembly Side)

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

    5. 

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

       Check generator (MG1) for an interphase short using a milliohmmeter.

       
       

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

          Tip:

          If the generator (MG1) temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

          Standard Resistance
          Table 17. for LHD Tester Connection Condition Specified Condition n1-3 (W) -n1-1 (U) Power switch off 59.2 to 65.2 mΩ n1-2 (V) - n1-3 (W) Power switch off 62.2 to 68.2 mΩ n1-1 (U) - n1-2 (V) Power switch off 59.2 to 65.2 mΩ
          Table 18. for RHD Tester Connection Condition Specified Condition n1-1 (W) -n1-3 (U) Power switch off 59.0 to 65.0 mΩ n1-2 (V) - n1-1 (W) Power switch off 61.9 to 67.9 mΩ n1-3 (U) - n1-2 (V) Power switch off 59.0 to 65.0 mΩ

          Tip:

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

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

          The calculation is based on the following:

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

          Rt: Measured resistance (mΩ)

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

    6. When checking for a short circuit between motor phases without using a milliohmmeter.

       Note:

       The motor generates current when wheels are rotated by hand. Before performing the inspection, wrap the motor cable terminals with insulation tape.

       Tip:

       A short circuit between the motor phases can be checked simply without using a milliohmmeter.

       
       

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

       2. Turn the power switch on (IG).

          Note:

          Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

       3. Move the shift lever to N.

       4. Lift up the vehicle.

       5. Rotate the rear wheels in the same direction simultaneously by hand.

          Standard
          Left and right wheels rotate smoothly (No short circuit between phases)

          Tip:

          If a short circuit exists between the motor phases, the rear wheels do not rotate smoothly (some resistance is felt).

       6. Move the shift lever to P.

       7. Lower the vehicle.

       8. Turn the power switch off.

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

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

       Note:

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

       Standard Resistance
       Table 19. for LHD Tester Connection Condition Specified Condition n1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher n1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
       Table 20. for RHD Tester Connection Condition Specified Condition n1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher n1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

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

       Tip:

       Perform this procedure only when checking for a short circuit between motor phases without using a milliohmmeter.

       Standard Resistance
       Table 21. for LHD Tester Connection Condition Specified Condition n1-3(W) - n1-2(V) Power switch off Below 1 Ω n1-2(V) - n1-1(U) Power switch off Below 1 Ω
       Table 22. for RHD Tester Connection Condition Specified Condition n1-1(W) - n1-2(V) Power switch off Below 1 Ω n1-2(V) - n1-3(U) Power switch off Below 1 Ω

    9. Connect the generator cable and motor cable.

    10. Install the inverter cover.

        Result
        Proceed to OK NG

    
    
    • OKClick here
    • NGClick here
12. Click here

    CHECK HYBRID VEHICLE TRANSMISSION 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. 

       *A	for LHD
       *B	for RHD

       for Type A:

       
       

       1. Remove the inverter cover from the inverter with converter assembly.

    3. 

       *A	for LHD
       *B	for RHD

       for Type B:

       
       

       1. Remove the inverter cover from the inverter with converter assembly.

    4. 

       *A	for LHD
       *B	for RHD
       *1	Motor Cable (Inverter with Converter Assembly Side)
       *2	Generator Cable (Inverter with Converter Assembly Side)

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

    5. 

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

       Check motor (MG2) for an interphase short using a milliohmmeter.

       
       

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

          Tip:

          If the motor (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
          Table 23. for LHD Tester Connection Condition Specified Condition m3-3 (W) - m3-1 (U) Power switch off 47.0 to 51.8 mΩ m3-2 (V) - m3-3 (W) Power switch off 47.3 to 52.1 mΩ m3-1 (U) - m3-2 (V) Power switch off 47.1 to 51.9 mΩ
          Table 24. for RHD Tester Connection Condition Specified Condition m1-1 (W) - m1-3 (U) Power switch off 47.0 to 51.8 mΩ m1-2 (V) - m1-1 (W) Power switch off 47.3 to 52.1 mΩ m1-3 (U) - m1-2 (V) Power switch off 47.1 to 51.9 mΩ

          Tip:

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

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

          The calculation is based on the following:

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

          Rt: Measured resistance (mΩ)

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

    6. When checking for a short circuit between motor phases without using a milliohmmeter.

       Note:

       The motor generates current when wheels are rotated by hand. Before performing the inspection, wrap the motor cable terminals with insulation tape.

       Tip:

       A short circuit between the motor phases can be checked simply without using a milliohmmeter.

       
       

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

       2. Turn the power switch on (IG).

          Note:

          Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

       3. Move the shift lever to N.

       4. Lift up the vehicle.

       5. Rotate the rear wheels in the same direction simultaneously by hand.

          Standard
          Left and right wheels rotate smoothly (No short circuit between phases)

          Tip:

          If a short circuit exists between the motor phases, the rear wheels do not rotate smoothly (some resistance is felt).

       6. Move the shift lever to P.

       7. Lower the vehicle.

       8. Turn the power switch off.

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

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

       Note:

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

       Standard Resistance
       Table 25. for LHD Tester Connection Condition Specified Condition m3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher m3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher m3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
       Table 26. for RHD Tester Connection Condition Specified Condition m1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher m1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher m1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

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

       Tip:

       Perform this procedure only when checking for a short circuit between motor phases without using a milliohmmeter.

       Standard Resistance
       Table 27. for LHD Tester Connection Condition Specified Condition m3-3(W) - m3-2(V) Power switch off Below 1 Ω m3-2(V) - m3-1(U) Power switch off Below 1 Ω
       Table 28. for RHD Tester Connection Condition Specified Condition m1-1(W) - m1-2(V) Power switch off Below 1 Ω m1-2(V) - m1-3(U) Power switch off Below 1 Ω

    9. Connect the generator cable and motor cable.

    10. Install the inverter cover.

        Result
        Proceed to OK NG

    
    
    • OKClick here
    • NGClick here
13. Click here

    CHECK FUSE (IGCT NO. 2)

    Result
    Proceed to OK NG

    
    
    1. 

       *1	No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly
       *2	IGCT NO. 2 Fuse

       Remove the IGCT NO. 2 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 IGCT NO. 2 fuse terminal Always Below 1 Ω

    3. Install the IGCT NO. 2 fuse.

       Result
       Proceed to OK NG

    
    
    • OKClick here
    • NGClick here
14. Click here

    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 A28*1 or A29*2 inverter with converter assembly connector.

       
       

       • *1: for LHD

       • *2: for RHD

    3. 

       *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
       Table 29. for LHD Tester Connection Condition Specified Condition A28-30 (GND1) - Body ground Power switch off Below 1 Ω A28-31 (GND2) - Body ground Power switch off Below 1 Ω
       Table 30. for RHD Tester Connection Condition Specified Condition A29-30 (GND1) - Body ground Power switch off Below 1 Ω A29-31 (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
       Table 31. for LHD Tester Connection Condition Specified Condition A28-10 (+B) - Body ground Power switch on (IG) 11 to 14 V A28-11 (+B2) - Body ground Power switch on (IG) 11 to 14 V
       Table 32. for LHD Tester Connection Condition Specified Condition A29-10 (+B) - Body ground Power switch on (IG) 11 to 14 V A29-11 (+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 A28*1 or A29*2 inverter with converter assembly connector.

       
       

       • *1: for LHD

       • *2: for RHD

       Result
       Proceed to OK NG

    
    
    • OKClick here
    • NG

      REPAIR OR REPLACE POWER SOURCE CIRCUIT

15. Click here

    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 A62 power management control ECU connector.

    3. Disconnect the A28*1 or A29*2 inverter with converter assembly connector.

       
       

       • *1: for LHD

       • *2: for RHD

    4. 

       *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)
       Table 33. for LHD Tester Connection Condition Specified Condition A28-23 (HTM+) - A62-34 (HTM+) Power switch off Below 1 Ω A28-22 (HTM-) - A62-33 (HTM-) Power switch off Below 1 Ω A28-3 (MTH+) - A62-21 (MTH+) Power switch off Below 1 Ω A28-2 (MTH-) - A62-20 (MTH-) Power switch off Below 1 Ω A28-34 (REQ+) - A62-32 (REQ+) Power switch off Below 1 Ω A28-33 (REQ-) - A62-31 (REQ-) Power switch off Below 1 Ω A28-14 (CLK+) - A62-29 (CLK+) Power switch off Below 1 Ω A28-13 (CLK-) - A62-28 (CLK-) Power switch off Below 1 Ω
       Table 34. for RHD Tester Connection Condition Specified Condition A29-23 (HTM+) - A62-34 (HTM+) Power switch off Below 1 Ω A29-22 (HTM-) - A62-33 (HTM-) Power switch off Below 1 Ω A29-3 (MTH+) - A62-21 (MTH+) Power switch off Below 1 Ω A29-2 (MTH-) - A62-20 (MTH-) Power switch off Below 1 Ω A29-34 (REQ+) - A62-32 (REQ+) Power switch off Below 1 Ω A29-33 (REQ-) - A62-31 (REQ-) Power switch off Below 1 Ω A29-14 (CLK+) - A62-29 (CLK+) Power switch off Below 1 Ω A29-13 (CLK-) - A62-28 (CLK-) Power switch off Below 1 Ω

       Standard Resistance (Check for Short)
       Table 35. for LHD Tester Connection Condition Specified Condition A28-23 (HTM+) or A62-34 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-22 (HTM-) or A62-33 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher A28-3 (MTH+) or A62-21 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-2 (MTH-) or A62-20 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher A28-34 (REQ+) or A62-32 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-33 (REQ-) or A62-31 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher A28-14 (CLK+) or A62-29 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-13 (CLK-) or A62-28 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
       Table 36. for RHD Tester Connection Condition Specified Condition A29-23 (HTM+) or A62-34 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-22 (HTM-) or A62-33 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher A29-3 (MTH+) or A62-21 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-2 (MTH-) or A62-20 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher A29-34 (REQ+) or A62-32 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-33 (REQ-) or A62-31 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher A29-14 (CLK+) or A62-29 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-13 (CLK-) or A62-28 (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
       Table 37. for LHD Tester Connection Condition Specified Condition A28-23 (HTM+) or A62-34 (HTM+) - Body ground Power switch on (IG) Below 1 V A28-22 (HTM-) or A62-33 (HTM-) - Body ground Power switch on (IG) Below 1 V A28-3 (MTH+) or A62-21 (MTH+) - Body ground Power switch on (IG) Below 1 V A28-2 (MTH-) or A62-20 (MTH-) - Body ground Power switch on (IG) Below 1 V A28-34 (REQ+) or A62-32 (REQ+) - Body ground Power switch on (IG) Below 1 V A28-33 (REQ-) or A62-31 (REQ-) - Body ground Power switch on (IG) Below 1 V A28-14 (CLK+) or A62-29 (CLK+) - Body ground Power switch on (IG) Below 1 V A28-13 (CLK-) or A62-28 (CLK-) - Body ground Power switch on (IG) Below 1 V
       Table 38. for RHD Tester Connection Condition Specified Condition A29-23 (HTM+) or A62-34 (HTM+) - Body ground Power switch on (IG) Below 1 V A29-22 (HTM-) or A62-33 (HTM-) - Body ground Power switch on (IG) Below 1 V A29-3 (MTH+) or A62-21 (MTH+) - Body ground Power switch on (IG) Below 1 V A29-2 (MTH-) or A62-20 (MTH-) - Body ground Power switch on (IG) Below 1 V A29-34 (REQ+) or A62-32 (REQ+) - Body ground Power switch on (IG) Below 1 V A29-33 (REQ-) or A62-31 (REQ-) - Body ground Power switch on (IG) Below 1 V A29-14 (CLK+) or A62-29 (CLK+) - Body ground Power switch on (IG) Below 1 V A29-13 (CLK-) or A62-28 (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 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 A28*1 or A29*2 inverter with converter assembly connector.

        
        

        • *1: for LHD

        • *2: for RHD

    11. Reconnect the A62 power management control ECU connector.

        Result
        Proceed to OK NG

    
    
    • OKClick here
    • NG

      REPAIR OR REPLACE HARNESS OR CONNECTOR

16. Click here

    CHECK POWER MANAGEMENT CONTROL ECU

    Result
    Proceed to OK NG

    
    

    1. Disconnect the A62 power management control ECU connector.

    2. 

       *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 A62-34 (HTM+) - A62-33 (HTM-) Power switch off 80 to 162 Ω A62-21 (MTH+) - A62-20 (MTH-) Power switch off 80 to 162 Ω A62-32 (REQ+) - A62-31 (REQ-) Power switch off 80 to 162 Ω A62-29 (CLK+) - A62-28 (CLK-) Power switch off 80 to 162 Ω

    3. Reconnect the A62 power management control ECU connector.

       Result
       Proceed to OK NG

    
    
    • OKClick here
    • NG

      REPLACE POWER MANAGEMENT CONTROL ECUClick here

17. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    Result
    Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    
    

    1. Remove the hybrid vehicle transmission assembly.

       Click here

    2. 

       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.
       - The terminals are not deformed and are connected securely.
       - No water or foreign matter in the connector.

       Result
       Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    
    
    • AClick here
    • B

      CONNECT SECURELY

    • C

      REPAIR OR REPLACE HARNESS OR CONNECTOR

18. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    Result
    Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    
    
    1. 

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

       Click here

       OK
       - The connector is connected securely.
       - The terminals are not deformed and are connected securely.
       - No water or foreign matter in the connector.

       Result
       Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    2. Install the hybrid vehicle transmission assembly.

    
    
    • A

      REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here

    • B

      CONNECT SECURELY

    • C

      REPAIR OR REPLACE HARNESS OR CONNECTOR

19. Click here

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 2 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 A28*1 or A29*2 inverter with converter assembly connector.

       
       

       • *1: for LHD

       • *2: for RHD

    3. 

       *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
       Table 39. for LHD Tester Connection Condition Specified Condition A28-10 (+B) - Body ground Power switch off 10 kΩ or higher A28-11 (+B2) - Body ground Power switch off 10 kΩ or higher
       Table 40. for RHD Tester Connection Condition Specified Condition A29-10 (+B) - Body ground Power switch off 10 kΩ or higher A29-11 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Reconnect the A28*1 or A29*2 inverter with converter assembly connector.

       
       

       • *1: for LHD

       • *2: for RHD

       Result
       Proceed to OK NG

    
    
    • OKClick here
    • NGClick here
20. Click here

    REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here

    Result
    Proceed to NEXT

    
    
    • NEXT

      REPLACE FUSE (IGCT NO. 2)

21. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to NEXT

    
    
    • NEXT

      REPLACE FUSE (IGCT NO. 2)

22. Click here

    CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    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

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note:

       After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the hybrid vehicle transmission assembly.

       Click here

    3. 

       Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

       Specified Condition
       T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

       Note:

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

    4. Disconnect the motor cable from the hybrid vehicle transmission assembly.

    5. Check for arc marks at the terminals for the motor cable.

       Result

       Result Proceed to The terminals are connected securely and there are no contact problems. There are no arc marks. A The terminals are not connected securely and there is a contact problem. There are arc marks. B The terminals are not connected securely and there is a contact problem. There are no arc marks. C The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the motor cable to the hybrid vehicle transmission assembly.

    7. Install the hybrid vehicle transmission assembly.

    
    
    • AClick here
    • B

      REPLACE MALFUNCTIONING PARTS

    • C

      CONNECT SECURELY

23. Click here

    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. 

       *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)

       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
       Table 41. for LHD Tester Connection Condition Specified Condition m3-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher m3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher m3-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
       Table 42. for RHD Tester Connection Condition Specified Condition m1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher m1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher m1-3 (U) - 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
       Table 43. for LHD Tester Connection Condition Specified Condition m3-3 (W) - m2-3 (U) Power switch off 100 MΩ or higher m3-2 (V) - m2-1 (W) Power switch off 100 MΩ or higher m3-1 (U) - m2-2 (V) Power switch off 100 MΩ or higher m3-3 (W) - m2-1 (W) Power switch off Below 1 Ω m3-2 (V) - m2-2 (V) Power switch off Below 1 Ω m3-1 (U) - m2-3 (U) Power switch off Below 1 Ω
       Table 44. for RHD Tester Connection Condition Specified Condition m1-1 (W) - m2-3 (U) Power switch off 100 MΩ or higher m1-2 (V) - m2-1 (W) Power switch off 100 MΩ or higher m1-3 (U) - m2-2 (V) Power switch off 100 MΩ or higher m1-1 (W) - m2-1 (W) Power switch off Below 1 Ω m1-2 (V) - m2-2 (V) Power switch off Below 1 Ω m1-3 (U) - m2-3 (U) Power switch off Below 1 Ω

    5. Install the motor cable.

       Result
       Proceed to OK NG

    
    
    • OK

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here

    • NG

      REPLACE MOTOR CABLEClick here

24. Click here

    CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    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

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note:

       After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the hybrid vehicle transmission assembly.

       Click here

    3. 

       Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

       Specified Condition
       T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

       Note:

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

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

    5. Check for arc marks at the terminals for the generator cable.

       Result

       Result Proceed to The terminals are connected securely and there are no contact problems. There are no arc marks. A The terminals are not connected securely and there is a contact problem. There are arc marks. B The terminals are not connected securely and there is a contact problem. There are no arc marks. C The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the generator cable to the hybrid vehicle transmission assembly.

    7. Install the hybrid vehicle transmission assembly.

    
    
    • AClick here
    • B

      REPLACE MALFUNCTIONING PARTS

    • C

      CONNECT SECURELY

25. Click here

    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. 

       *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)

       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
       Table 45. for LHD Tester Connection Condition Specified Condition n1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher n1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
       Table 46. for RHD Tester Connection Condition Specified Condition n1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher n1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

       Note:

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

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

       Standard Resistance
       Table 47. for LHD Tester Connection Condition Specified Condition n1-3 (W) - n2-1 (U) Power switch off 100 MΩ or higher n1-2 (V) - n2-3 (W) Power switch off 100 MΩ or higher n1-1 (U) - n2-2 (V) Power switch off 100 MΩ or higher n1-3 (W) - n2-3 (W) Power switch off Below 1 Ω n1-2 (V) - n2-2 (V) Power switch off Below 1 Ω n1-1 (U) - n2-1 (U) Power switch off Below 1 Ω
       Table 48. for RHD Tester Connection Condition Specified Condition n1-1 (W) - n2-1 (U) Power switch off 100 MΩ or higher n1-2 (V) - n2-3 (W) Power switch off 100 MΩ or higher n1-3 (U) - n2-2 (V) Power switch off 100 MΩ or higher n1-1 (W) - n2-3 (W) Power switch off Below 1 Ω n1-2 (V) - n2-2 (V) Power switch off Below 1 Ω n1-3 (U) - n2-1 (U) Power switch off Below 1 Ω

    5. Install the generator cable.

       Result
       Proceed to OK NG

    
    
    • OK

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here

    • NG

      REPLACE GENERATOR CABLEClick here

26. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    Result
    Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    
    

    1. Remove the hybrid vehicle transmission assembly.

       Click here

    2. 

       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.
       - The terminals are not deformed and are connected securely.
       - No water or foreign matter in the connector.

       Result
       Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    
    
    • AClick here
    • B

      CONNECT SECURELY

    • C

      REPAIR OR REPLACE HARNESS OR CONNECTOR

27. Click here

    INSPECT HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR RESOLVER)

    Result
    Proceed to OK NG

    
    
    1. 

       Disconnect the F51 motor resolver connector.

    2. 

       *a	Component without harness connected (Motor Resolver (Hybrid Vehicle Transmission Assembly))

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

       Standard Resistance
       Tester Connection Condition Specified Condition F51-1 (MRF) - F51-5 (MRFG) Power switch off 6.0 to 12.0 Ω F51-2 (MSN) - F51-6 (MSNG) Power switch off 12.5 to 24.5 Ω F51-3 (MCS) - F51-7 (MCSG) Power switch off 12.5 to 24.5 Ω

       Tip:

       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 F51-1 (MRF) - Body ground and other terminals (except 5 (MRFG)) Power switch off 1 MΩ or higher F51-5 (MRFG) - Body ground and other terminals (except 1 (MRF)) Power switch off 1 MΩ or higher F51-2 (MSN) - Body ground and other terminals (except 6 (MSNG)) Power switch off 1 MΩ or higher F51-6 (MSNG) - Body ground and other terminals (except 2 (MSN)) Power switch off 1 MΩ or higher F51-3 (MCS) - Body ground and other terminals (except 7 (MCSG)) Power switch off 1 MΩ or higher F51-7 (MCSG) - Body ground and other terminals (except 3 (MCS)) Power switch off 1 MΩ or higher

       Tip:

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

    3. Reconnect the F51 motor resolver connector.

       Result
       Proceed to OK NG

    
    
    • OK

      REPAIR OR REPLACE HARNESS OR CONNECTOR

    • NG

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here

28. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

    Result
    Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    
    

    1. Remove the hybrid vehicle transmission assembly.

       Click here

    2. 

       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.
       - The terminals are not deformed and are connected securely.
       - No water or foreign matter in the connector.

       Result
       Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    
    
    • AClick here
    • B

      CONNECT SECURELY

    • C

      REPAIR OR REPLACE HARNESS OR CONNECTOR

29. Click here

    INSPECT HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR RESOLVER)

    Result
    Proceed to OK NG

    
    
    1. 

       Disconnect the F50 generator resolver connector.

    2. 

       *a	Component without harness connected (Generator Resolver (Hybrid Vehicle Transmission Assembly))

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

       Standard Resistance
       Tester Connection Condition Specified Condition F50-1 (GRF) - F50-5 (GRFG) Power switch off 5.8 to 11.8 Ω F50-2 (GSN) - F50-6 (GSNG) Power switch off 11.7 to 17.7 Ω F50-3 (GCS) - F50-7 (GCSG) Power switch off 11.7 to 17.7 Ω

       Tip:

       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 F50-1 (GRF) - Body ground and other terminals (except 5 (GRFG)) Power switch off 1 MΩ or higher F50-5 (GRFG) - Body ground and other terminals (except 1 (GRF)) Power switch off 1 MΩ or higher F50-2 (GSN) - Body ground and other terminals (except 6 (GSNG)) Power switch off 1 MΩ or higher F50-6 (GSNG) - Body ground and other terminals (except 2 (GSN)) Power switch off 1 MΩ or higher F50-3 (GCS) - Body ground and other terminals (except 7 (GCSG)) Power switch off 1 MΩ or higher F50-7 (GCSG) - Body ground and other terminals (except 3 (GCS)) Power switch off 1 MΩ or higher

       Tip:

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

    3. Reconnect the F50 generator resolver connector.

       Result
       Proceed to OK NG

    
    
    • OK

      REPAIR OR REPLACE HARNESS OR CONNECTOR

    • NG

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here