HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A94-557

DESCRIPTION

For a description of the boost converter.

Click here

If a malfunction occurs in the boost converter, the MG ECU detects it and transmits this information to the hybrid vehicle control ECU assembly.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P1CAC-200.

Click here

Refer to the wiring diagram for DTC P0AA6-526.

Click here

Refer to the wiring diagram for DTC P324E-788.

Click here

Refer to the wiring diagram for DTC U0110-159.

Click here

CAUTION / NOTICE / HINT

PROCEDURE

1. CHECK DTC OUTPUT (HYBRID CONTROL)

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the power switch on (IG).

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

   4. Check for DTCs.

      
      Powertrain > Hybrid Control > Trouble Codes

      Result
      Result Proceed to P0A94-557 only is output, or DTCs except the ones in the table below are also output. A Any of the following DTCs are also output. B

      Relevant DTC
      P06B0-163	Sensor Power Supply "A" Circuit / Open
      P06D6-511	Sensor Reference Voltage "F" Circuit / Open
      P06E6-164	Sensor Power Supply "C" Circuit / Open
      P0A1A-151, 166, 517, 658, 791, 809	Generator Control Module
      P0A1B-198, 503, 505, 547, 554, 786, 794, 806	Drive Motor "A" Control Module
      P0A1D (all INF codes)*1	Hybrid Powertrain Control Module
      P0A3F-243	Drive Motor "A" Position Sensor Circuit
      P0A40-500, 504, 506, 549, 556, 808	Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245	Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253	Generator Position Sensor Circuit
      P0A4C-513, 518, 811	Generator Position Sensor Circuit Range / Performance
      P0A4D-255	Generator Position Sensor Circuit Low
      P0A78-113, 128, 279, 284, 286, 287, 548, 555, 807	Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 810	Generator Inverter Performance
      P0A90-509	Drive Motor "A" Performance
      P0A92-521	Hybrid Generator Performance
      P0A94-172, 553	DC / DC Converter Performance
      P0BEA-290	Drive Motor "A" Phase V Current Sensor Circuit Range / Performance
      P0BEE-298	Drive Motor "A" Phase W Current Sensor Circuit Range / Performance
      P0C19-306	Drive Motor "A" Torque Delivered Performance
      P0C73-776	Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523	Hybrid Battery System Discharge Time Too Long
      P0CA3-442	DC/DC Converter Step Up Voltage Performance
      P0D2E-586	Drive Motor "A" Inverter Voltage Sensor Circuit Range / Performance
      P0D2F-266	Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267	Drive Motor "A" Inverter Voltage Sensor Circuit High
      P0E05-328	Generator Phase V Current Sensor Circuit Range / Performance
      P0E09-336	Generator Phase W Current Sensor Circuit Range / Performance
      P0E32-585	DC/DC Converter Voltage Sensor "A" Range / Performance
      P0E33-589	DC/DC Converter Voltage Sensor "A" Low
      P0E34-590	DC/DC Converter Voltage Sensor "A" High
      P0E71-344	Generator Torque Delivered Performance
      P1C2A-155	Generator A/D Converter Circuit
      P1C2B-192	Drive Motor "A" A/D Converter Circuit
      P1C2D-587	Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294	Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302	Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333	Generator Phase V Current Sensor Correlation
      P1C3F-341	Generator Phase W Current Sensor Correlation
      P1C4A-288	Drive Motor "A" Phase V Current Sensor Sub Circuit Range / Performance
      P1C4F-296	Drive Motor "A" Phase W Current Sensor Sub Circuit Range / Performance
      P1C54-326	Generator Phase V Current Sensor Sub Circuit Range / Performance
      P1C59-334	Generator Phase W Current Sensor Sub Circuit Range / Performance
      P1C6D-501	Drive Motor "A" Phase V Current Sensor Offset Range / Performance
      P1C6E-502	Drive Motor "A" Phase W Current Sensor Offset Range / Performance
      P1C71-515	Generator Phase V Current Sensor Offset Range / Performance
      P1C72-516	Generator Phase W Current Sensor Offset Range / Performance
      P1C73-512	Sensor Standard Voltage "F" Circuit / Open
      P1CA6-156	Generator Control Module Malfunction
      P1CA7-193	Drive Motor Control Module Malfunction
      P1CAC-200	Generator Position Sensor Angle Malfunction
      P1CAD-168	Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792	Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795	Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793	Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796	Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3133-659	Communication Error from Generator to Drive Motor "A"
      P3134-661	Communication Error from Drive Motor "A" to Generator
      P314A-828	Inverter Coolant Pump Speed Signal

      Tech Tips

      
      

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

      • P0A94-557 may be stored due to a malfunction which also causes DTCs in the preceding table to be stored. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output. After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

   5. Turn the power switch off.

   
   

   B

   GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

   A

2. 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 the 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

3. CHECK QUANTITY OF HV COOLANT

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

   
   

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

   2. Check for HV coolant leaks.

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

      Tech Tips

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

   
   

   B

   ADD HV COOLANT

   C

   INSPECT FOR HV COOLANT LEAK AND ADD HV COOLANT

   A

4. CHECK COOLANT HOSE

   Result
   Proceed to OK NG

   
   

   1. Check that the cooling system hoses are not kinked or clogged.

      Result
      Proceed to OK NG

   
   

   NG

   REPAIR OR REPLACE COOLANT HOSE

   OK

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

   Result
   Proceed to OK NG

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the power switch on (IG).

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

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

      
      Powertrain > Engine and ECT > Active Test

      Tester Display
      Control the Electric Cooling Fan

      OK
      The cooling fan rotates.

   5. Turn the power switch off.

      Result
      Proceed to OK NG

   
   

   NG

   CHECK COOLING FAN SYSTEM Click here

   OK

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

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

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the power switch on (IG).

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

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

      
      Powertrain > Hybrid Control > Trouble Codes

   5. Check if the freeze frame data item Ambient Temperature is below the freezing temperature of the HV coolant.

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

      Tech Tips

      
      

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

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

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

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

   6. Turn the power switch off.

   
   

   B

   REPLACE HV COOLANT Click here

   A

7. 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

8. 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

9. 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

10. 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

11. 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.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

12. 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.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

13. 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.

          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

14. 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.

          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

15. 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

    
    

    NG

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

    OK

16. 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
       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) Same as auxiliary battery voltage A28-11 (+B2) - Body ground Power switch on (IG) Same as auxiliary battery voltage
       for LHD Tester Connection Condition Specified Condition A29-10 (+B) - Body ground Power switch on (IG) Same as auxiliary battery voltage A29-11 (+B2) - Body ground Power switch on (IG) Same as auxiliary battery voltage

       Note

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

    7. Turn the power switch off.

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

    9. 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 POWER SOURCE CIRCUIT

    OK

17. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - 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 A85 hybrid vehicle control ECU assembly connector.

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

       
       

       • *1: for LHD

       • *2: for RHD

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

       

       *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 Hybrid Vehicle Control ECU Assembly)

       Standard Resistance (Check for Open)
       for LHD Tester Connection Condition Specified Condition A28-23 (HTM+) - A85-24 (HTM+) Power switch off Below 1 Ω A28-22 (HTM-) - A85-25 (HTM-) Power switch off Below 1 Ω A28-3 (MTH+) - A85-23 (MTH+) Power switch off Below 1 Ω A28-2 (MTH-) - A85-22 (MTH-) Power switch off Below 1 Ω A28-34 (REQ+) - A85-31 (REQ+) Power switch off Below 1 Ω A28-33 (REQ-) - A85-30 (REQ-) Power switch off Below 1 Ω A28-14 (CLK+) - A85-33 (CLK+) Power switch off Below 1 Ω A28-13 (CLK-) - A85-32 (CLK-) Power switch off Below 1 Ω
       for RHD Tester Connection Condition Specified Condition A29-23 (HTM+) - A85-24 (HTM+) Power switch off Below 1 Ω A29-22 (HTM-) - A85-25 (HTM-) Power switch off Below 1 Ω A29-3 (MTH+) - A85-23 (MTH+) Power switch off Below 1 Ω A29-2 (MTH-) - A85-22 (MTH-) Power switch off Below 1 Ω A29-34 (REQ+) - A85-31 (REQ+) Power switch off Below 1 Ω A29-33 (REQ-) - A85-30 (REQ-) Power switch off Below 1 Ω A29-14 (CLK+) - A85-33 (CLK+) Power switch off Below 1 Ω A29-13 (CLK-) - A85-32 (CLK-) Power switch off Below 1 Ω

       Standard Resistance (Check for Short)
       for LHD Tester Connection Condition Specified Condition A28-23 (HTM+) or A85-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-22 (HTM-) or A85-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher A28-3 (MTH+) or A85-23 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-2 (MTH-) or A85-22 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher A28-34 (REQ+) or A85-31 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-33 (REQ-) or A85-30 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher A28-14 (CLK+) or A85-33 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher A28-13 (CLK-) or A85-32 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
       for RHD Tester Connection Condition Specified Condition A29-23 (HTM+) or A85-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-22 (HTM-) or A85-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher A29-3 (MTH+) or A85-23 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-2 (MTH-) or A85-22 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher A29-34 (REQ+) or A85-31 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-33 (REQ-) or A85-30 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher A29-14 (CLK+) or A85-33 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher A29-13 (CLK-) or A85-32 (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 A85-24 (HTM+) - Body ground Power switch on (IG) Below 1 V A28-22 (HTM-) or A85-25 (HTM-) - Body ground Power switch on (IG) Below 1 V A28-3 (MTH+) or A85-23 (MTH+) - Body ground Power switch on (IG) Below 1 V A28-2 (MTH-) or A85-22 (MTH-) - Body ground Power switch on (IG) Below 1 V A28-34 (REQ+) or A85-31 (REQ+) - Body ground Power switch on (IG) Below 1 V A28-33 (REQ-) or A85-30 (REQ-) - Body ground Power switch on (IG) Below 1 V A28-14 (CLK+) or A85-33 (CLK+) - Body ground Power switch on (IG) Below 1 V A28-13 (CLK-) or A85-32 (CLK-) - Body ground Power switch on (IG) Below 1 V
       for RHD Tester Connection Condition Specified Condition A29-23 (HTM+) or A85-24 (HTM+) - Body ground Power switch on (IG) Below 1 V A29-22 (HTM-) or A85-25 (HTM-) - Body ground Power switch on (IG) Below 1 V A29-3 (MTH+) or A85-23 (MTH+) - Body ground Power switch on (IG) Below 1 V A29-2 (MTH-) or A85-22 (MTH-) - Body ground Power switch on (IG) Below 1 V A29-34 (REQ+) or A85-31 (REQ+) - Body ground Power switch on (IG) Below 1 V A29-33 (REQ-) or A85-30 (REQ-) - Body ground Power switch on (IG) Below 1 V A29-14 (CLK+) or A85-33 (CLK+) - Body ground Power switch on (IG) Below 1 V A29-13 (CLK-) or A85-32 (CLK-) - Body ground Power switch on (IG) Below 1 V

       Note

       Turning the power switch on (IG) with the hybrid vehicle control ECU assembly 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 A85 hybrid vehicle control ECU assembly connector.

        Result
        Proceed to OK NG

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

18. CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY

    Result
    Proceed to OK NG

    
    

    1. Disconnect the A85 hybrid vehicle control ECU assembly connector.

    2. 

       *a	Component without harness connected (Hybrid Vehicle Control ECU Assembly)

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

       Standard Resistance
       Tester Connection Condition Specified Condition A85-24 (HTM+) - A85-25 (HTM-) Power switch off 80 to 170 Ω A85-23 (MTH+) - A85-22 (MTH-) Power switch off 80 to 170 Ω A85-31 (REQ+) - A85-30 (REQ-) Power switch off 80 to 170 Ω A85-33 (CLK+) - A85-32 (CLK-) Power switch off 80 to 170 Ω

    3. Reconnect the A85 hybrid vehicle control ECU assembly connector.

       Result
       Proceed to OK NG

    
    

    NG

    REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY Click here

    OK

19. 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

20. 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 ASSEMBLY Click here

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

21. 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
       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

22. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here

    Result
    Proceed to NEXT

    
    

    NEXT

    REPLACE FUSE (IGCT NO. 2)

23. REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to NEXT

    
    

    NEXT

    REPLACE FUSE (IGCT NO. 2)

24. 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.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

25. 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. 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

26. 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.

    
    

    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

27. 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. 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

28. 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

29. 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

30. 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

31. 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

32. REPLACE HV COOLANT

    Result
    Proceed to NEXT

    
    

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

       Click here

       Result
       Proceed to NEXT

    
    

    NEXT

    COMPLETED