HYBRID CONTROL SYSTEM, Diagnostic DTC:U0110-159, U0110-656, U0110-657

DESCRIPTION

• For a description of the inverter Click here.

  The MG ECU located in the inverter with converter assembly controls MG2 based on commands from the power management control ECU. The MG ECU monitors communication data and detects malfunctions.

WIRING DIAGRAM

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

CAUTION / NOTICE / HINT

PROCEDURE

1. CHECK FUSE (PCU)

   
   

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

   2. 

      Text in Illustration

      *1	No. 2 Engine Room Relay Block
      *2	PCU Fuse

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

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

   3. Install the PCU fuse.

   
   

   NG

   REPLACE FUSE (PCU) Click here

   OK

2. CLEAR DTC

   
   

   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. Read and record the DTCs and freeze frame data.

   5. Clear DTCs and freeze frame data.

   6. Turn the ignition switch off.

   
   

   NEXT

3. 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 DTC U0110-159, 656 or 657 is output. A DTC U0110-159, 656 and 657 are not output. B

   5. Turn the ignition switch off.

   
   

   B

   CHECK FOR INTERMITTENT PROBLEMS Click here

   A

4. 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. 

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

   3. 

      Remove the inverter cover from the inverter with converter assembly.

   4. 

      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

5. 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. 

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

   3. 

      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

6. 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. 

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

   3. 

      Remove the inverter cover from the inverter with converter assembly.

   4. 

      Disconnect the motor cable from the inverter with converter assembly.

   5. 

      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

7. 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. 

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

   3. 

      Remove the inverter cover from the inverter with converter assembly.

   4. 

      Disconnect the motor cable from the inverter with converter assembly.

   5. 

      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

8. 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. 

      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 low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

   7. Turn the ignition switch off.

   8. Connect the inverter with converter assembly connector.

   
   

   NG

   REPAIR OR REPLACE HARNESS OR CONNECTOR

   OK

9. CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

   
   

   1. Connect an oscilloscope between the power management control ECU terminals specified in the following table.

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

   3. 

      Text in Illustration

      *a	Component with harness connected (Power Management Control ECU)

      Measure the waveform.

      Item	Contents
      Tester Connection	CH1: A27-21 (CLK+) - F55-6 (E1) CH2: A27-20 (CLK-) - F55-6 (E1)
      Equipment Setting	1 V/DIV., 1 μs/DIV.
      Condition	Ignition switch ON (IG)

      Result
      Result Proceed to The waveform appears as shown in the illustration. A The waveform differs from the one shown in the illustration. B

      Tech Tips

      
      

      • Inspect with the connector connected.

      • If pulses are generated, the shape of the waveform can be assumed to be normal.

      • The shape of the waveform may vary according to communication conditions.

   4. Turn the ignition switch off.

   
   

   B

   CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) Click here

   A

10. CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

    
    

    1. Connect an oscilloscope between the power management control ECU terminals specified in the following table.

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

    3. 

       Text in Illustration

       *a	Component with harness connected (Power Management Control ECU)

       Measure the waveform.

       Item	Contents
       Tester Connection	CH1: A27-33 (REQ+) - F55-6 (E1) CH2: A27-32 (REQ-) - F55-6 (E1)
       Equipment Setting	1 V/DIV., 1 ms/DIV.
       Condition	Ignition switch ON (IG)

       Result
       Result Proceed to The waveform appears as shown in the illustration. A The waveform differs from the one shown in the illustration. B

       Tech Tips

       
       

       • Inspect with the connector connected.

       • If pulses are generated, the shape of the waveform can be assumed to be normal.

       • The shape of the waveform may vary according to communication conditions.

    4. Turn the ignition switch off.

    
    

    B

    CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) Click here

    A

11. CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

    
    

    1. Connect an oscilloscope between the power management control ECU terminals specified in the following table.

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

    3. 

       Text in Illustration

       *a	Component with harness connected (Power Management Control ECU)

       Measure the waveform.

       Item	Contents
       Tester Connection	CH1: A27-30 (MTH+) - F55-6 (E1) CH2: A27-29 (MTH-) - F55-6 (E1)
       Equipment Setting	1 V/DIV., 200 μs/DIV.
       Condition	Ignition switch ON (IG)

       Result
       Result Proceed to The waveform appears as shown in the illustration. A The waveform differs from the one shown in the illustration. B

       Tech Tips

       
       

       • Inspect with the connector connected.

       • If pulses are generated, the shape of the waveform can be assumed to be normal.

       • The shape of the waveform may vary according to communication conditions.

    4. Turn the ignition switch off.

    
    

    A

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    B

    CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) Click here

12. 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 power management control ECU connector.

    3. Disconnect the inverter with converter assembly connector.

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

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

    6. 

       Text in Illustration

       *a	Rear view of wire harness connector (to Power Management Control ECU)
       *b	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 A27-21 (CLK+) - Body ground Ignition switch ON (IG) Below 1 V 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 connector and the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the ignition switch off.

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

       Standard Resistance (Check for Open)
       Tester Connection Switch Condition Specified Condition A27-21 (CLK+) - A33-5 (CLK+) Ignition switch off Below 1 Ω A27-20 (CLK-) - A33-15 (CLK-) Ignition switch off Below 1 Ω

       Standard Resistance (Check for Short)
       Tester Connection Switch Condition Specified Condition A27-21 (CLK+) or A33-5 (CLK+) - Body ground and other terminals Ignition switch off 10 kΩ or higher A27-20 (CLK-) or A33-15 (CLK-) - Body ground and other terminals Ignition switch off 10 kΩ or higher

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

    10. Connect the inverter with converter assembly connector.

    11. Connect the power management control ECU connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

13. CHECK INVERTER WITH CONVERTER ASSEMBLY

    
    

    1. Disconnect the power management control ECU connector.

    2. 

       Text in Illustration

       *a	Rear view of wire harness connector (to Power Management Control ECU)

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

       Standard Resistance
       Tester Connection Switch Condition Specified Condition A27-21 (CLK+) - A27-20 (CLK-) Ignition switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.

    
    

    OK

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

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 power management control ECU connector.

    3. Disconnect the inverter with converter assembly connector.

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

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

    6. 

       Text in Illustration

       *a	Rear view of wire harness connector (to Power Management Control ECU)
       *b	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 A27-33 (REQ+) - Body ground Ignition switch ON (IG) Below 1 V A27-32 (REQ-) - Body ground Ignition switch ON (IG) Below 1 V

       Note

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

    7. Turn the ignition switch off.

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

       Standard Resistance (Check for Open)
       Tester Connection Switch Condition Specified Condition A27-33 (REQ+) - A33-6 (REQ+) Ignition switch off Below 1 Ω A27-32 (REQ-) - A33-16 (REQ-) Ignition switch off Below 1 Ω

       Standard Resistance (Check for Short)
       Tester Connection Switch Condition Specified Condition A27-33 (REQ+) or A33-6 (REQ+) - Body ground and other terminals Ignition switch off 10 kΩ or higher A27-32 (REQ-) or A33-16 (REQ-) - Body ground and other terminals Ignition switch off 10 kΩ or higher

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

    10. Connect the inverter with converter assembly connector.

    11. Connect the power management control ECU connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

15. CHECK INVERTER WITH CONVERTER ASSEMBLY

    
    

    1. Disconnect the power management control ECU connector.

    2. 

       Text in Illustration

       *a	Rear view of wire harness connector (to Power Management Control ECU)

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

       Standard Resistance
       Tester Connection Switch Condition Specified Condition A27-33 (REQ+) - A27-32 (REQ-) Ignition switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.

    
    

    OK

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    NG

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

16. 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 power management control ECU connector.

    3. Disconnect the inverter with converter assembly connector.

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

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

    6. 

       Text in Illustration

       *a	Rear view of wire harness connector (to Power Management Control ECU)
       *b	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 A27-30 (MTH+) - Body ground Ignition switch ON (IG) Below 1 V A27-29 (MTH-) - Body ground Ignition switch ON (IG) Below 1 V

       Note

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

    7. Turn the ignition switch off.

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

       Standard Resistance (Check for Open)
       Tester Connection Switch Condition Specified Condition A27-30 (MTH+) - A33-7 (MTH+) Ignition switch off Below 1 Ω A27-29 (MTH-) - A33-17 (MTH-) Ignition switch off Below 1 Ω

       Standard Resistance (Check for Short)
       Tester Connection Switch Condition Specified Condition A27-30 (MTH+) or A33-7 (MTH+) - Body ground and other terminals Ignition switch off 10 kΩ or higher A27-29 (MTH-) or A33-17 (MTH-) - Body ground and other terminals Ignition switch off 10 kΩ or higher

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

    10. Connect the inverter with converter assembly connector.

    11. Connect the power management control ECU connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

17. CHECK POWER MANAGEMENT CONTROL ECU

    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 from the inverter with converter assembly connector.

    3. 

       Text in Illustration

       *a	Component with 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 A27-30 (MTH+) - A27-29 (MTH-) Ignition switch off 80 to 170 Ω

    4. Connect the inverter with converter assembly connector.

    
    

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

18. REPLACE FUSE (PCU)

    
    
    1. 

       Text in Illustration

       *1	No. 2 Engine Room Relay Block
       *2	PCU Fuse

       Replace the PCU fuse.

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

    3. Check if there is an open circuit in the PCU fuse in the No. 2 engine room relay block.

       OK
       There is no open circuit in the PCU fuse.

       Tech Tips

       If the fuse does not become open again after turning the ignition switch to ON (READY), it can be assumed that the previous fuse failed due to age.

    4. Turn the ignition switch off.

    
    

    OK

    COMPLETED

    NG

19. 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. 

       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.

    3. Disconnect the inverter with converter assembly connector.

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

       

       Text in Illustration

       *1	No. 2 Engine Room Relay Block	*2	PCU Fuse
       *a	Front view of wire harness connector (to Inverter with Converter Assembly)	-	-

       Standard Resistance (Check for Short)
       Tester Connection Switch Condition Specified Condition A33-10 (+B), A33-9 (+B2) or 2 (PCU fuse terminal) - Body ground and other terminals Ignition switch off 10 kΩ or higher

    5. Connect the inverter with converter assembly connector.

    6. Install the PCU fuse.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

20. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS

    Click here

    
    

    NEXT

    REPLACE FUSE (PCU)

21. REPAIR OR REPLACE HARNESS OR CONNECTOR

    
    

    NEXT

    REPLACE FUSE (PCU)

22. 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. 

       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

23. 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. 

       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

24. 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. 

       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

25. 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. 

       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