HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-113

DESCRIPTION

For a description of the inverter.

Click here

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

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

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 P0A78-113 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 P0A78-113 is stored. B Any of the DTCs including pending DTCs in table 2 below are stored before P0A78-113 is stored. C

      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

      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, P3014-123, P3015-123, P3016-123, P3017-123, 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

      Tech Tips

      
      

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

      • P0A78-113 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
      Proceed to P0A78-202 is not output. P0A78-202 is also output.

      Note

      
      

      • If P0A78-202 is output, troubleshoot it first. After completing the troubleshooting for P0A78-202, perform troubleshooting for this DTC.

      • Parts repaired or replaced during troubleshooting for P0A78-202 do not need to be re-inspected in this diagnosis procedure.

   5. Turn the power switch off.

   
   

   P0A78-202 is also output.

   GO TO DTC CHART (P0A78-202) Click here

   P0A78-202 is not output.

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 P0A78-202 was not output in step 2 of this diagnosis procedure, check Table 1 below.

      • If P0A78-202 was output in step 2 of this diagnosis procedure, diagnose that DTC first, then check Table 2 below.

      Result
      Result Proceed to P0A78-113 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

      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 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
      P0A60-294	Drive Motor "A" Phase V Current
      P0A63-302	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, 503, 504, 505, 506, 586, 806, 807, 808	Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811	Generator Inverter 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

      Tech Tips

      
      

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

      • P0A78-113 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
   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. 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

      

      *A

      for LHD

      *B

      for RHD

      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

      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.

   
   

   B

   CONNECT SECURELY

   C

   REPAIR OR REPLACE HARNESS OR CONNECTOR

   A

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 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
      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
      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

   
   

   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 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
      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
      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

      Tech Tips

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

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

      The calculation is based on the following:

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

      Rt: Measured resistance (mΩ)

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

      Standard Resistance (Check for Short)
      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
      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

   
   

   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 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
      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
      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

   
   

   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 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
      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
      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

      Tech Tips

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

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

      The calculation is based on the following:

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

      Rt: Measured resistance (mΩ)

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

      Standard Resistance (Check for Short)
      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
      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

   
   

   NG

   CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

   OK

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

   CAUTION:

   Be sure to wear insulated gloves.

   
   

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

      Note

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

   2. 

      *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.

   
   

   B

   REPLACE MALFUNCTIONING PARTS

   C

   CONNECT SECURELY

   A

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

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. 

       *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.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

11. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. 

       *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.

          Tech Tips

          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
          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
          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

          Tech Tips

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

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

          The calculation is based on the following:

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

          Rt: Measured resistance (mΩ)

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

    6. 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.

       Tech Tips

       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)

          Tech Tips

          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
       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
       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.

       Tech Tips

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

       Standard Resistance
       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
       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

    
    

    NG

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

    OK

12. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG2)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. 

       *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.

          Tech Tips

          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
          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
          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

          Tech Tips

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

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

          The calculation is based on the following:

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

          Rt: Measured resistance (mΩ)

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

    6. 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.

       Tech Tips

       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)

          Tech Tips

          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
       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
       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.

       Tech Tips

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

       Standard Resistance
       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
       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

    
    

    NG

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

    OK

13. CHECK FUSE (IGCT NO. 2)

    
    
    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

    
    

    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 2 FUSE) Click here

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. Disconnect the 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
       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
       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
       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
       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

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. Disconnect the 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)
       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
       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)
       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
       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
       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
       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

    
    

    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

16. CHECK POWER MANAGEMENT CONTROL ECU

    
    

    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

    
    

    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

17. 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

    
    

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

18. 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.

    
    

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

19. INSPECT INVERTER WITH CONVERTER ASSEMBLY

    
    

    1. Check the inverter with converter assembly for interphase short circuit.

       
       

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

          Note

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

       2. Check that the motor cable and generator cable are connected securely.

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

       4. 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.

       5. Move the shift lever to N.

       6. Lift up the vehicle.

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

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

          Tech Tips

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

       8. Move the shift lever to P.

       9. Lower the vehicle.

       10. Turn the power switch off.

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

       Result
       Proceed to OK NG

    
    

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY AND MOTOR CABLE

20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 2 FUSE)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. Disconnect the 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
       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
       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

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

21. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here

    Result
    Proceed to NEXT

    
    

    NEXT

    REPLACE FUSE (IGCT NO. 2)

22. REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to NEXT

    
    

    NEXT

    REPLACE FUSE (IGCT NO. 2)

23. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. Remove the hybrid vehicle transmission assembly.

       Click here

    3. 

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

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

       Note

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

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

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

       Result

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

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

    7. Install the hybrid vehicle transmission assembly.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

24. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. Remove the motor cable.

       Click here

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

       

       *A	for LHD	*B	for RHD
       *1	Shield ground	-	-
       *a	Motor Cable (Inverter with Converter Assembly Side)	*b	Motor Cable (Hybrid Vehicle Transmission Assembly Side)

       Note

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

       Standard Resistance
       for LHD Tester Connection 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
       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
       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
       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 ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

25. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. Remove the hybrid vehicle transmission assembly.

       Click here

    3. 

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

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

       Note

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

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

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

       Result

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

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

    7. Install the hybrid vehicle transmission assembly.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

26. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.

    
    

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

       Note

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

    2. Remove the generator cable.

       Click here

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

       Note

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

       Standard Resistance
       for LHD Tester Connection 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
       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

       

       *A	for LHD	*B	for RHD
       *1	Shield ground	-	-
       *a	Generator Cable (Inverter with Converter Assembly Side)	*b	Generator Cable (Hybrid Vehicle Transmission Assembly Side)

       Note

       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
       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
       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 ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

27. 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

    
    

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

28. 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

       Tech Tips

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

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

       The calculation is based on the following:

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

       Rt: Measured resistance (mΩ)

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

       Standard Resistance (Check for Short)

       Tester Connection Condition Specified Condition 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

       Tech Tips

       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 ASSEMBLY Click here

29. 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

    
    

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

30. 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

       Tech Tips

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

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

       The calculation is based on the following:

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

       Rt: Measured resistance (mΩ)

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

       Standard Resistance (Check for Short)

       Tester Connection Condition Specified Condition 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

       Tech Tips

       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 ASSEMBLY Click here