HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-130

DTC Code DTC Name
P0A7A-130 Generator Inverter Performance

DESCRIPTION

For a description of the inverter Click here.

If an abnormal amount of current flows through the generator inverter, the MG ECU detects it and sends a signal to inform the power management control ECU of the malfunction.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A7A 130 Abnormal MG1 current value detection (system malfunction)

  • Power management control ECU

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • Wire harness or connector

  • PCU fuse

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A1A-200 Click here.

Refer to the wiring diagram for DTC P0AA6-526 Click here.

Refer to the wiring diagram for DTC P324E-788 Click here.

Refer to the wiring diagram for DTC U0110-159 Click here.

CAUTION / NOTICE / HINT

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, turn the ignition switch off and take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work Click here.

    Tech Tips

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

Note

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


  1. Turn the ignition switch to ON (READY) and wait for 5 seconds or more.

  2. Drive the vehicle for approximately 10 minutes mainly using the engine.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

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

    4. Check if DTCs are output.

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

      Note


      • If P0A7A-203 is output, troubleshoot it first. After completing the troubleshooting for P0A7A-203, return to perform troubleshooting for this DTC.

      • Parts repaired or replaced during troubleshooting for P0A7A-203 do not need to be re-inspected in this diagnosis procedure.

    5. Turn the ignition switch off.


    B

    GO TO DTC CHART (P0A7A-203) Click here

    A

  2. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

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

    4. Check if DTCs are output.

      Tech Tips


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

      • If P0A7A-203 was output in step 1 of this diagnosis procedure, repair that DTC first, then check Table 2 below.

      Result
      Result Proceed to
      Only P0A7A-130 is output, or DTCs other than the ones in the table below are also output. A
      Any of the DTCs including pending DTCs are also output. B
      Table 1
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource
      Table 2
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A72-333 Generator Phase V Current
      P0A75-341 Generator Phase W Current
      P0A78-266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource

      Tech Tips


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

      • P0A7A-130 may be set due to a malfunction which also causes DTCs in the preceding table to be set. 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.

    5. Turn the ignition switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01UY1U

      Check the connector connections and contact pressure of the low voltage connectors of the inverter with converter assembly Click here.

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector does not pull out.

      OK
      The connectors are connected securely and there are no contact pressure problems.

      Tech Tips

      When connecting the connector, insert it with the locking lever in the raised position. Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage. After the click is heard, pull up on the connector to confirm that it is properly connected.


    NG

    CONNECT SECURELY

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the inverter with converter assembly connector.

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

    4. Turn the ignition switch to ON (IG).

    5. A004F6DE02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      C28-11 (GRF) - Body ground Ignition switch ON (IG) Below 1 V
      C28-12 (GRFG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-7 (GSN) - Body ground Ignition switch ON (IG) Below 1 V
      C28-8 (GSNG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-10 (GCS) - Body ground Ignition switch ON (IG) Below 1 V
      C28-9 (GCSG) - Body ground Ignition switch ON (IG) Below 1 V

      Note

      Turning the ignition switch to ON (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    6. Turn the ignition switch off.

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

    8. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  5. CHECK GENERATOR RESOLVER

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the inverter with converter assembly connector.

    3. A004F6DE02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      C28-11 (GRF) - C28-12 (GRFG) Ignition switch off 7.1 to 21.6 Ω
      C28-7 (GSN) - C28-8 (GSNG) Ignition switch off 13.7 to 34.5 Ω
      C28-10 (GCS) - C28-9 (GCSG) Ignition switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      C28-11 (GRF) or C28-12 (GRFG) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      C28-7 (GSN) or C28-8 (GSNG) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      C28-10 (GCS) or C28-9 (GCSG) - Body ground and other terminals Ignition switch off 10 kΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the inverter with converter assembly connector.

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

    4. Turn the ignition switch to ON (IG).

    5. A004E74E02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      C28-1 (MRF) - Body ground Ignition switch ON (IG) Below 1 V
      C28-2 (MRFG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-3 (MSN) - Body ground Ignition switch ON (IG) Below 1 V
      C28-4 (MSNG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-6 (MCS) - Body ground Ignition switch ON (IG) Below 1 V
      C28-5 (MCSG) - Body ground Ignition switch ON (IG) Below 1 V

      Note

      Turning the ignition switch to ON (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    6. Turn the ignition switch off.

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

    8. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. CHECK MOTOR RESOLVER

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the inverter with converter assembly connector.

    3. A004E74E02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      C28-1 (MRF) - C28-2 (MRFG) Ignition switch off 7.1 to 21.6 Ω
      C28-3 (MSN) - C28-4 (MSNG) Ignition switch off 13.7 to 34.5 Ω
      C28-6 (MCS) - C28-5 (MCSG) Ignition switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      C28-1 (MRF) or C28-2 (MRFG) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      C28-3 (MSN) or C28-4 (MSNG) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      C28-6 (MCS) or C28-5 (MCSG) - Body ground and other terminals Ignition switch off 10 kΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

  8. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE (FOR MG1) 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZ06

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

    3. A01UXQS

      Remove the inverter cover from the inverter with converter assembly.

    4. A01V0VBE03

      Check that the bolts for the motor cable (for MG1) are tightened to the specified torque, the motor cable (for MG1) is connected securely, and there are no contact problems.

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

      Note

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

    5. Disconnect the motor cable (for MG1) from the inverter with converter assembly.

    6. Check for arc marks at the terminals for the motor cable (for MG1).

      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 (for MG1) to the inverter with converter assembly.

    8. Install the inverter cover.

    9. Install the inverter terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  9. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE (FOR MG2) 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZ06

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

    3. A01UY3HE03

      Check that the bolts for the motor cable (for MG2) are tightened to the specified torque, the motor cable (for MG2) is connected securely, and there are no contact problems.

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

      Note

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

    4. Disconnect the motor cable (for MG2) from the inverter with converter assembly.

    5. Check for arc marks at the terminals for the motor cable (for MG2).

      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 (for MG2) to the inverter with converter assembly.

    7. Install the inverter terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  10. CHECK HYBRID VEHICLE TRANSAXLE 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZ06

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

    3. A01UXQS

      Remove the inverter cover from the inverter with converter assembly.

    4. A01V1DV

      Disconnect the motor cable from the inverter with converter assembly.

    5. A01UZI7E01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (Inverter with Converter Assembly Side)

      Check MG1 for an interphase short using a milliohmmeter.


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

        Tech Tips

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

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        W2-1 (W) - W2-2 (U) Ignition switch off 139.1 to 153.7 mΩ
        W2-2 (U) - W2-3 (V) Ignition switch off 139.1 to 153.7 mΩ
        W2-3 (V) - W2-1 (W) Ignition switch off 139.1 to 153.7 mΩ

        Tech Tips

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


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

        The calculation is based on the following:


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

        • Rt: Measured resistance (mΩ)

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

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W2-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    7. Connect the motor cable.

    8. Install the inverter cover.

    9. Install the inverter terminal cover.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG1) CONNECTION CONDITION) Click here

    OK

  11. CHECK HYBRID VEHICLE TRANSAXLE 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZ06

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

    3. A01UXQS

      Remove the inverter cover from the inverter with converter assembly.

    4. A01V1DV

      Disconnect the motor cable from the inverter with converter assembly.

    5. A01V0VSE01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (Inverter with Converter Assembly Side)

      Check MG2 for an interphase short using a milliohmmeter.


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

        Tech Tips

        If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        W4-1 (W) - W4-2 (U) Ignition switch off 172.5 to 190.7 mΩ
        W4-2 (U) - W4-3 (V) Ignition switch off 172.5 to 190.7 mΩ
        W4-3 (V) - W4-1 (W) Ignition switch off 172.5 to 190.7 mΩ

        Tech Tips

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


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

        The calculation is based on the following:


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

        • Rt: Measured resistance (mΩ)

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

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W4-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

    7. Connect the motor cable.

    8. Install the inverter cover.

    9. Install the inverter terminal cover.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG2) CONNECTION CONDITION) Click here

    OK

  12. CHECK FUSE (PCU)


    1. A01UXTLE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 PCU Fuse

      Remove the PCU fuse from the No. 2 engine room relay block.

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

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

    3. Install the PCU fuse.


    NG

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

    OK

  13. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

    3. A01UZXBE02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A33-28 (GND1) - Body ground Ignition switch off Below 1 Ω
      A33-27 (GND2) - Body ground Ignition switch off Below 1 Ω

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

    5. Turn the ignition switch to ON (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A33-10 (+B) - Body ground Ignition switch ON (IG) 11 to 14 V
      A33-9 (+B2) - Body ground Ignition switch ON (IG) 11 to 14 V

      Note

      Turning the ignition switch to 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 ignition switch off.

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

    9. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

  14. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

    3. Disconnect the power management control ECU connector.

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

      A01UZIAE01
      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A33-8 (HTM+) - A27-24 (HTM+) Ignition switch off Below 1 Ω
      A33-18 (HTM-) - A27-25 (HTM-) Ignition switch off Below 1 Ω
      A33-7 (MTH+) - A27-30 (MTH+) Ignition switch off Below 1 Ω
      A33-17 (MTH-) - A27-29 (MTH-) Ignition switch off Below 1 Ω
      A33-6 (REQ+) - A27-33 (REQ+) Ignition switch off Below 1 Ω
      A33-16 (REQ-) - A27-32 (REQ-) Ignition switch off Below 1 Ω
      A33-5 (CLK+) - A27-21 (CLK+) Ignition switch off Below 1 Ω
      A33-15 (CLK-) - A27-20 (CLK-) Ignition switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A33-8 (HTM+) or A27-24 (HTM+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A33-18 (HTM-) or A27-25 (HTM-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A33-7 (MTH+) or A27-30 (MTH+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A33-17 (MTH-) or A27-29 (MTH-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A33-6 (REQ+) or A27-33 (REQ+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A33-16 (REQ-) or A27-32 (REQ-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A33-5 (CLK+) or A27-21 (CLK+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A33-15 (CLK-) or A27-20 (CLK-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

    6. Turn the ignition switch to ON (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A33-8 (HTM+) or A27-24 (HTM+) - Body ground Ignition switch ON (IG) Below 1 V
      A33-18 (HTM-) or A27-25 (HTM-) - Body ground Ignition switch ON (IG) Below 1 V
      A33-7 (MTH+) or A27-30 (MTH+) - Body ground Ignition switch ON (IG) Below 1 V
      A33-17 (MTH-) or A27-29 (MTH-) - Body ground Ignition switch ON (IG) Below 1 V
      A33-6 (REQ+) or A27-33 (REQ+) - Body ground Ignition switch ON (IG) Below 1 V
      A33-16 (REQ-) or A27-32 (REQ-) - Body ground Ignition switch ON (IG) Below 1 V
      A33-5 (CLK+) or A27-21 (CLK+) - Body ground Ignition switch ON (IG) Below 1 V
      A33-15 (CLK-) or A27-20 (CLK-) - Body ground Ignition switch ON (IG) Below 1 V

      Note

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

    8. Turn the ignition switch off.

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

    10. Connect the power management control ECU connector.

    11. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  15. CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect from the power management control ECU connector.

    2. A01V1X0E02
      Text in Illustration
      *a

      Component without harness connected

      (Power Management Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A27-24 (HTM+) - A27-25 (HTM-) Ignition switch off 80 to 170 Ω
      A27-30 (MTH+) - A27-29 (MTH-) Ignition switch off 80 to 170 Ω
      A27-33 (REQ+) - A27-32 (REQ-) Ignition switch off 80 to 170 Ω
      A27-21 (CLK+) - A27-20 (CLK-) Ignition switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  16. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A004G3E

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  17. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A004G5V

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CONNECT SECURELY

  18. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A004G3E

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

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


    1. A004G3E

      Disconnect the resolver connector.

    2. A004EDMC10
      *a

      Component without harness connected

      (Generator resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      C24-1 (GRF) - C24-5 (GRFG) Ignition switch off 9.5 to 15.5 Ω
      C24-2 (GSN) - C24-6 (GSNG) Ignition switch off 15.0 to 27.0 Ω
      C24-3 (GCS) - C24-7 (GCSG) Ignition switch off 14.0 to 26.0 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
      C24-1 (GRF) - Body ground and other terminals (except C24-5 (GRFG)) Power switch off 1 MΩ or higher
      C24-5 (GRFG) - Body ground and other terminals (except C24-1 (GRF)) Power switch off 1 MΩ or higher
      C24-2 (GSN) - Body ground and other terminals (except C24-6 (GSNG)) Power switch off 1 MΩ or higher
      C24-6 (GSNG) - Body ground and other terminals (except C24-2 (GSN)) Power switch off 1 MΩ or higher
      C24-3 (GCS) - Body ground and other terminals (except C24-7 (GCSG)) Power switch off 1 MΩ or higher
      C24-7 (GCSG) - Body ground and other terminals (except C24-3 (GCS)) Power switch off 1 MΩ or higher

    3. Reconnect the resolver connector.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  20. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A004G5V

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

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


    1. A004G5V

      Disconnect the resolver connector.

    2. A004EWLC03
      *a

      Component without harness connected

      (Motor Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      C26-3 (MRF) - C26-6 (MRFG) Ignition switch off 9.5 to 15.5 Ω
      C26-1 (MSN) - C26-4 (MSNG) Ignition switch off 15.0 to 27.0 Ω
      C26-2 (MCS) - C26-5 (MCSG) Ignition switch off 14.0 to 26.0 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
      C26-3 (MRF) - Body ground and other terminals (except C26-6 (MRFG)) Power switch off 1 MΩ or higher
      C26-6 (MRFG) - Body ground and other terminals (except C26-3 (MRF)) Power switch off 1 MΩ or higher
      C26-1 (MSN) - Body ground and other terminals (except C26-4 (MSNG)) Power switch off 1 MΩ or higher
      C26-4 (MSNG) - Body ground and other terminals (except C26-1 (MSN)) Power switch off 1 MΩ or higher
      C26-2 (MCS) - Body ground and other terminals (except C26-5 (MCSG)) Power switch off 1 MΩ or higher
      C26-5 (MCSG) - Body ground and other terminals (except C26-2 (MCS)) Power switch off 1 MΩ or higher

    3. Reconnect the resolver connector.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  22. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

    3. A01V0J8E02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A33-10 (+B) - Body ground Ignition switch off 10 kΩ or higher
      A33-9 (+B2) - Body ground Ignition switch off 10 kΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  23. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here


    NEXT

    REPLACE FUSE (PCU)

  24. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (PCU)

  25. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG1) 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the inverter with converter assembly Click here.

    3. A01V0HVE03

      Check that the bolts for the motor cable (for MG1) are tightened to the specified torque, the motor cable (for MG1) is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=19.5 N*m (199 kgf*cm, 14 ft.*lbf)
      Bolt B
      T=10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note


      • Make sure that the tightening torque of the bolt A is between 13.5 and 25 N*m (138 and 255 kgf*cm, 10 and 18 ft.*lbf).

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

    4. Disconnect the motor cable (for MG1) from the hybrid vehicle transaxle assembly.

    5. Check for arc marks at the terminals for the motor cable (for MG1).

      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 (for MG1) to the hybrid vehicle transaxle assembly.

    7. Install the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  26. CHECK MOTOR CABLE (FOR 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the motor cable Click here.

    3. A01UYRZE01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (Inverter with Converter Assembly Side)
      *b

      Motor Cable (for MG1)

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W2-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W2-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

      Note

      Wrap the connector W1 terminal of the motor cable (for MG1) with insulating tape to prevent it from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W2-1 (W) - W1-1 (W) Ignition switch off Below 1 Ω
      W2-2 (U) - W1-2 (U) Ignition switch off Below 1 Ω
      W2-3 (V) - W1-3 (V) Ignition switch off Below 1 Ω
      W2-1 (W) - W1-2 (U) Ignition switch off 100 MΩ or higher
      W2-2 (U) - W1-3 (V) Ignition switch off 100 MΩ or higher
      W2-3 (V) - W1-1 (W) Ignition switch off 100 MΩ or higher

    5. Install the motor cable.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here

  27. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG2) 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01UZNOE03

      Check that the bolts for the motor cable (for MG2) are tightened to the specified torque, the motor cable (for MG2) is connected securely, and there are no contact problems.

      Specified Condition
      Bolt A
      T=19.5 N*m (199 kgf*cm, 14 ft.*lbf)
      Bolt B
      T=10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note


      • Make sure that the tightening torque of the bolt A is between 13.5 and 25 N*m (138 and 255 kgf*cm, 10 and 18 ft.*lbf).

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

    3. Disconnect the motor cable (for MG2) from the hybrid vehicle transaxle assembly.

    4. Check for arc marks at the terminals for the motor cable (for MG2).

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

    5. Connect the motor cable (for MG2) to the hybrid vehicle transaxle assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  28. CHECK MOTOR CABLE (FOR 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the motor cable Click here.

    3. A01UYRDE01
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (Inverter with Converter Assembly Side)
      *b

      Motor Cable (for MG2)

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W4-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-2 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      W4-3 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher

      Note

      Wrap the connector W3 terminal of the motor cable (for MG2) with insulating tape to prevent it from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      W4-1 (W) - W3-1 (W) Ignition switch off Below 1 Ω
      W4-2 (U) - W3-3 (U) Ignition switch off Below 1 Ω
      W4-3 (V) - W3-2 (V) Ignition switch off Below 1 Ω
      W4-1 (W) - W3-3 (U) Ignition switch off 100 MΩ or higher
      W4-2 (U) - W3-2 (V) Ignition switch off 100 MΩ or higher
      W4-3 (V) - W3-1 (W) Ignition switch off 100 MΩ or higher

    5. Install the motor cable.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here