HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-121

DTC Code DTC Name
P0A78-121 Drive Motor "A" Inverter Performance

DESCRIPTION

For a description of the inverter Click here.

If an overvoltage occurs in the motor inverter or generator inverter, the MG ECU detects it and transmits this information to the power management control ECU.

Tech Tips

The term "drive motor A" indicates MG2.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A78 121 Motor inverter overvoltage signal detection (overvoltage due to system malfunction)

  • Hybrid battery junction block assembly

  • Inverter with converter assembly

  • Service plug grip (EV battery fuse)

  • No. 4 floor wire

  • Hybrid vehicle transmission assembly

  • Generator cable

  • Motor cable

  • Power management control ECU

  • IGCT No. 4 fuse

  • Wire harness or connector

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 P0AE6-225 Click here.

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

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

INSPECTION PROCEDURE

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, 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 power 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.

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 if DTCs are output.

      Result
      Result Proceed to
      P0A78-121 is output before any of the DTCs in the table below are output. A
      Any of the DTCs in the table below are output before P0A78-121 is output. B
      DTC No. Relevant Diagnosis
      P0A9C-123 Hybrid Battery Temperature Sensor "A" Range / Performance
      P0A9D-123 Hybrid Battery Temperature Sensor "A" Circuit Low
      P0A9E-123 Hybrid Battery Temperature Sensor "A" Circuit High
      P0AC0-123 Hybrid Battery Pack Current Sensor Circuit Range / Performance
      P0AC1-123 Hybrid Battery Pack Current Sensor Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor Circuit High
      P0AC6-123 Hybrid Battery Temperature Sensor "B" Range / Performance
      P0AC7-123 Hybrid Battery Temperature Sensor "B" Circuit Low
      P0AC8-123 Hybrid Battery Temperature Sensor "B" Circuit High
      P0ACB-123 Hybrid Battery Temperature Sensor "C" Range / Performance
      P0ACC-123 Hybrid Battery Temperature Sensor "C" Circuit Low
      P0ACD-123 Hybrid Battery Temperature Sensor "C" Circuit High
      P0AE9-123 Hybrid Battery Temperature Sensor "D" Range / Performance
      P0AEA-123 Hybrid Battery Temperature Sensor "D" Circuit Low
      P0AEB-123 Hybrid Battery Temperature Sensor "D" Circuit High
      P0BC3-123 Hybrid Battery Temperature Sensor "E" Range / Performance
      P0BC4-123 Hybrid Battery Temperature Sensor "E" Circuit Low
      P0BC5-123 Hybrid Battery Temperature Sensor "E" Circuit High
      P0AFC-123 Hybrid Battery Pack Sensor Module
      P3011-123, P3012-123, P3013-123, P3014-123, P3015-123, P3016-123, P3017-123, P3018-123, P3019-123, P3020-123, P3021-123, P3022-123, P3023-123, P3024-123, P3025-123, P3026-123, P3027-123, P3028-123, P3029-123, P302F-123 Battery Block # Becomes Weak
      P0C6E-123 Hybrid Battery Temperature Sensor "A" / "B" Correlation
      P306A-123 Hybrid Battery Temperature Sensor Range/Performance Stuck "B"
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low

      Tech Tips


      • Refer to the Freeze Frame data to determine the order in which the DTCs were output.

      • P0A78-121 may be output due to a malfunction which also causes DTCs in the preceding table to be output. 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 power switch off.


    B

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    A

  2. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0A78-121 only is output. A
      Any of the following DTCs are also output. B
      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
      P0A78-113, 128, 266, 267, 279, 284, 286, 287, 306, 503, 504, 505, 506, 565, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A93-346 Inverter Cooling System Performance
      P0A94-172, 442, 547, 548, 549, 553, 554, 555, 556, 557, 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
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource
      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.

      • P0A78-121 may be output due to a malfunction which also causes DTCs in the preceding table to be output. 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 power 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. 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 cannot be pulled out.

      A01FRBVE01
      Text in Illustration
      *A for LHD *B for RHD
      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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the connector from the inverter with converter assembly.

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

    4. Turn the power switch on (IG).

    5. A01FQOWE17
      Text in Illustration
      *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 Switch Condition Specified Condition
      A38-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A38-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A38-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A38-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A38-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A38-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A74-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A74-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A74-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A74-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A74-6 (GCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch 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 power 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the connector from the inverter with converter assembly.

    3. A01FQOWE17
      Text in Illustration
      *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 (Check for Open)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - A38-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A38-18 (GSN) - A38-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A38-17 (GCS) - A38-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - A74-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A74-18 (GSN) - A74-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A74-17 (GCS) - A74-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) or A38-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-18 (GSN) or A38-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-17 (GCS) or A38-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) or A74-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-18 (GSN) or A74-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-17 (GCS) or A74-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the connector from the inverter with converter assembly.

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

    4. Turn the power switch on (IG).

    5. A01FQOWE18
      Text in Illustration
      *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 Switch Condition Specified Condition
      A38-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A38-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A38-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A38-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A38-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A38-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A74-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A74-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A74-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A74-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A74-27 (MCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch 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 power 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the connector from the inverter with converter assembly.

    3. A01FQOWE18
      Text in Illustration
      *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 (Check for Open)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - A38-29 (MRFG) Power switch off 4.2 to 12.5 Ω
      A38-39 (MSN) - A38-28 (MSNG) Power switch off 9.8 to 20.1 Ω
      A38-38 (MCS) - A38-27 (MCSG) Power switch off 9.8 to 20.1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - A74-29 (MRFG) Power switch off 4.2 to 12.5 Ω
      A74-39 (MSN) - A74-28 (MSNG) Power switch off 9.8 to 20.1 Ω
      A74-38 (MCS) - A74-27 (MCSG) Power switch off 9.8 to 20.1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) or A38-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-39 (MSN) or A38-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-38 (MCS) or A38-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) or A74-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-39 (MSN) or A74-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-38 (MCS) or A74-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    Click here

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01FRI1E01
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. A01FV5DE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. A01FTL0E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Generator Cable

      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 terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01FRI1E01
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. A01FV5DE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. A01FR8FE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Motor Cable

      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 terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  10. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01FRI1E01
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. A01FV5DE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. A01FRCRE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Generator Cable
      *2 Motor Cable

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

    5. A01FSH3E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Generator Cable

      (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
        for LHD
        Tester Connection Switch Condition Specified Condition
        v1-3 (W) - v1-1 (U) Power switch off 31.9 to 35.0 mΩ
        v1-2 (V) - v1-3 (W) Power switch off 31.8 to 34.9 mΩ
        v1-1 (U) - v1-2 (V) Power switch off 33.0 to 36.1 mΩ
        for RHD
        Tester Connection Switch Condition Specified Condition
        v1-1 (W) - v1-3 (U) Power switch off 31.4 to 34.6 mΩ
        v1-2 (V) - v1-1 (W) Power switch off 31.3 to 34.5 mΩ
        v1-3 (U) - v1-2 (V) Power switch off 32.5 to 35.7 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
      for LHD
      Tester Connection Switch Condition Specified Condition
      v1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

    7. Connect the generator cable and motor cable.

    8. Install the inverter terminal cover.


    NG

    Click here

    OK

  11. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG2)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01FRI1E01
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type A:


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

    3. A01FV5DE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for Type B:


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

    4. A01FRCRE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Generator Cable
      *2 Motor Cable

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

    5. A01FUB2E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Motor Cable

      (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
        for LHD
        Tester Connection Switch Condition Specified Condition
        u1-3 (W) - u1-1 (U) Power switch off 46.7 to 51.6 mΩ
        u1-2 (V) - u1-3 (W) Power switch off 47.0 to 51.9 mΩ
        u1-1 (U) - u1-2 (V) Power switch off 46.9 to 51.6 mΩ
        for RHD
        Tester Connection Switch Condition Specified Condition
        u3-1 (W) - u3-3 (U) Power switch off 46.9 to 51.9 mΩ
        u3-2 (V) - u3-1 (W) Power switch off 47.2 to 52.2 mΩ
        u3-3 (U) - u3-2 (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. 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 Switch Condition Specified Condition
      u1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

    7. Connect the generator cable and motor cable.

    8. Install the inverter terminal cover.


    NG

    Click here

    OK

  12. CHECK INVERTER WITH CONVERTER ASSEMBLY (NO. 4 FLOOR WIRE CONNECTOR CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. A01FRDPE01
      Text in Illustration
      *A for LHD
      *B for RHD

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

    3. A01FUXUE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Check that the bolt for the No. 4 floor wire is tightened to the specified torque, the No. 4 floor wire is connected securely, and there are no contact problems.

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

    4. Disconnect the connector of the No. 4 floor wire from the inverter with converter assembly.

    5. Check for arc marks at the bolt and terminals for the No. 4 floor wire.

      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 No. 4 floor wire to the inverter with converter assembly.

    7. Install the connector cover assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  13. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK
      Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  14. INSPECT SERVICE PLUG GRIP


    1. A01FQVRE03
      Text in Illustration
      *1 Service plug grip

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  15. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (NO. 4 FLOOR WIRE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the No. 4 hybrid vehicle battery shield sub-assembly Click here.

    3. A01FT15

      Check that the nuts for the No. 4 floor wire are tightened to the specified torque, the No. 4 floor wire is connected securely, and there are no contact problems.

      Specified Condition
      T=9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Check for arc marks on the terminals of the No. 4 floor wire.

      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. Install the No. 4 hybrid vehicle battery shield sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  16. CHECK NO. 4 FLOOR WIRE

    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 No. 4 hybrid vehicle battery shield sub-assembly Click here.

    3. A01FT15

      Remove the No. 4 floor wire from the hybrid battery junction block assembly.

    4. A01FRDPE01
      Text in Illustration
      *A for LHD
      *B for RHD

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

    5. A01FUXUE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Disconnect the connector of the No. 4 floor wire from the inverter with converter assembly.

    6. A01FQE6E01
      Text in Illustration
      *1 Shield Ground
      *2 Red Mark
      *a

      No. 4 Floor Wire

      (Inverter with Converter Assembly Side)
      *b

      No. 4 Floor Wire

      (Hybrid Battery Junction Block Assembly Side)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      V2-1 (CBI) - V5-1 (CBI) (Positive terminal) Power switch off Below 1 Ω
      V2-2 (CEI) - V4-1 (CEI) (Negative terminal) Power switch off Below 1 Ω

    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
      Tester Connection Switch Condition Specified Condition
      V5-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      V4-1 (CEI) - Body ground and shield ground Power switch off 10 MΩor higher
      V5-1 (CBI) - V4-1 (CEI) Power switch off 10 MΩ or higher

    8. Connect the No. 4 floor wire to the hybrid battery junction block assembly.

    9. Connect the No. 4 floor wire to the inverter with converter assembly.

    10. Install the connector cover assembly.

    11. Install the No. 4 hybrid vehicle battery shield sub-assembly.


    NG

    REPLACE NO. 4 FLOOR WIRE Click here

    OK

  17. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    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 battery junction block assembly Click here.

    3. A01FTM0E67
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      y2-1 (+) - V5-1 (CBI) Auxiliary battery voltage is not applied between terminals m3-4 (SMRB) and m3-2 (GND) 10 kΩ or higher
      y2-1 (+) - V5-1 (CBI) Auxiliary battery voltage is applied between terminals m3-4 (SMRB) and m3-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      m3-4 (SMRB) - m3-2 (GND) -40 to 80°C (-40 to 176°F) 18.4 to 36.3 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  18. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

    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 battery junction block assembly Click here.

    3. A01FTM0E68
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      x1-1 (-) - V4-1 (CEI) Auxiliary battery voltage is not applied between terminals m3-1 (SMRG) and m3-2 (GND) 10 kΩ or higher
      x1-1 (-) - V4-1 (CEI) Auxiliary battery voltage is applied between terminals m3-1 (SMRG) and m3-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      m3-1 (SMRG) - m3-2 (GND) -40 to 80°C (-40 to 176°F) 18.4 to 36.3 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  19. CHECK FUSE (IGCT NO. 4)


    1. A01FU51E01
      Text in Illustration
      *1 No. 1 Engine Room Relay Block and Junction Block Assembly
      *2 IGCT No. 4 fuse

      Remove the IGCT No. 4 fuse from the No. 1 engine room relay block and 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. 4 fuse terminal Always Below 1 Ω

    3. Install the IGCT No. 4 fuse.


    NG

    Click here

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the connector from the inverter with converter assembly.

    3. A01FQOWE19
      Text in Illustration
      *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 Switch Condition Specified Condition
      A38-30 (GND1) - Body ground Power switch off Below 1 Ω
      A38-31 (GND2) - Body ground Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-30 (GND1) - Body ground Power switch off Below 1 Ω
      A74-31 (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 Switch Condition Specified Condition
      A38-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A38-11 (+B2) - Body ground Power switch on (IG) 11 to 14 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A74-11 (+B2) - Body ground Power switch on (IG) 11 to 14 V

      Note

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

    7. Turn the power switch off.

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

    9. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the connector from the inverter with converter assembly.

    3. Disconnect the connector from the power management control ECU.

    4. A01FVP8E07
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

      Standard Resistance (Check for Open)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-23 (HTM+) - A35-34 (HTM+) Power switch off Below 1 Ω
      A38-22 (HTM-) - A35-33 (HTM-) Power switch off Below 1 Ω
      A38-3 (MTH+) - A35-21 (MTH+) Power switch off Below 1 Ω
      A38-2 (MTH-) - A35-20 (MTH-) Power switch off Below 1 Ω
      A38-34 (REQ+) - A35-32 (REQ+) Power switch off Below 1 Ω
      A38-33 (REQ-) - A35-31 (REQ-) Power switch off Below 1 Ω
      A38-14 (CLK+) - A35-29 (CLK+) Power switch off Below 1 Ω
      A38-13 (CLK-) - A35-28 (CLK-) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-23 (HTM+) - A35-34 (HTM+) Power switch off Below 1 Ω
      A74-22 (HTM-) - A35-33 (HTM-) Power switch off Below 1 Ω
      A74-3 (MTH+) - A35-21 (MTH+) Power switch off Below 1 Ω
      A74-2 (MTH-) - A35-20 (MTH-) Power switch off Below 1 Ω
      A74-34 (REQ+) - A35-32 (REQ+) Power switch off Below 1 Ω
      A74-33 (REQ-) - A35-31 (REQ-) Power switch off Below 1 Ω
      A74-14 (CLK+) - A35-29 (CLK+) Power switch off Below 1 Ω
      A74-13 (CLK-) - A35-28 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-23 (HTM+) or A35-34 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-22 (HTM-) or A35-33 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-3 (MTH+) or A35-21 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-2 (MTH-) or A35-20 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-34 (REQ+) or A35-32 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-33 (REQ-) or A35-31 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-14 (CLK+) or A35-29 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-13 (CLK-) or A35-28 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-23 (HTM+) or A35-34 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-22 (HTM-) or A35-33 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-3 (MTH+) or A35-21 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-2 (MTH-) or A35-20 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-34 (REQ+) or A35-32 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-33 (REQ-) or A35-31 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-14 (CLK+) or A35-29 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A74-13 (CLK-) or A35-28 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher

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

    6. Turn the power switch on (IG).

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

      Standard Voltage
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-23 (HTM+) or A35-34 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A38-22 (HTM-) or A35-33 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A38-3 (MTH+) or A35-21 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A38-2 (MTH-) or A35-20 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A38-34 (REQ+) or A35-32 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A38-33 (REQ-) or A35-31 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A38-14 (CLK+) or A35-29 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A38-13 (CLK-) or A35-28 (CLK-) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-23 (HTM+) or A35-34 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A74-22 (HTM-) or A35-33 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A74-3 (MTH+) or A35-21 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A74-2 (MTH-) or A35-20 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A74-34 (REQ+) or A35-32 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A74-33 (REQ-) or A35-31 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A74-14 (CLK+) or A35-29 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A74-13 (CLK-) or A35-28 (CLK-) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the power management control ECU and inverter with converter assembly connector 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. Connect the power management control ECU connector.

    11. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  22. CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect the connector from the power management control ECU.

    2. A01FQMYE01
      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
      A35-34 (HTM+) - A35-33 (HTM-) Power switch off 80 to 170 Ω
      A35-21 (MTH+) - A35-20 (MTH-) Power switch off 80 to 170 Ω
      A35-32 (REQ+) - A35-31 (REQ-) Power switch off 80 to 170 Ω
      A35-29 (CLK+) - A35-28 (CLK-) Power switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  23. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A01FSLW

      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 and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  24. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A01FR9I

      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 and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  25. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A01FSLW

      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 and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  26. 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the connector from the inverter with converter assembly.

    3. A01FT2DE03
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to Generator Resolver)
      *b

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      Disconnect the generator resolver connector.

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

      Standard Resistance (Check for Open)
      for LHD
      Tester Connection Switch Condition Specified Condition
      F50-1 (GRF) - A38-20 (GRF) Power switch off Below 1 Ω
      F50-5 (GRFG) - A38-9 (GRFG) Power switch off Below 1 Ω
      F50-2 (GSN) - A38-18 (GSN) Power switch off Below 1 Ω
      F50-6 (GSNG) - A38-7 (GSNG) Power switch off Below 1 Ω
      F50-3 (GCS) - A38-17 (GCS) Power switch off Below 1 Ω
      F50-7 (GCSG) - A38-6 (GCSG) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      F50-1 (GRF) - A74-20 (GRF) Power switch off Below 1 Ω
      F50-5 (GRFG) - A74-9 (GRFG) Power switch off Below 1 Ω
      F50-2 (GSN) - A74-18 (GSN) Power switch off Below 1 Ω
      F50-6 (GSNG) - A74-7 (GSNG) Power switch off Below 1 Ω
      F50-3 (GCS) - A74-17 (GCS) Power switch off Below 1 Ω
      F50-7 (GCSG) - A74-6 (GCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      F50-1 (GRF) or A38-20 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-5 (GRFG) or A38-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-2 (GSN) or A38-18 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-6 (GSNG) or A38-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-3 (GCS) or A38-17 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-7 (GCSG) or A38-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      F50-1 (GRF) or A74-20 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-5 (GRFG) or A74-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-2 (GSN) or A74-18 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-6 (GSNG) or A74-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-3 (GCS) or A74-17 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      F50-7 (GCSG) or A74-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

      The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transmission assembly.

    5. Connect the generator resolver connector.

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  27. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A01FR9I

      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 and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  28. 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the connector from the inverter with converter assembly.

    3. A01FT2DE04
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to Motor Resolver)
      *b

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      Disconnect the motor resolver connector.

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

      Standard Resistance (Check for Open)
      for LHD
      Tester Connection Switch Condition Specified Condition
      F51-1 (MRF) - A38-40 (MRF) Power switch off Below 1 Ω
      F51-5 (MRFG) - A38-29 (MRFG) Power switch off Below 1 Ω
      F51-2 (MSN) - A38-39 (MSN) Power switch off Below 1 Ω
      F51-6 (MSNG) - A38-28 (MSNG) Power switch off Below 1 Ω
      F51-3 (MCS) - A38-38 (MCS) Power switch off Below 1 Ω
      F51-7 (MCSG) - A38-27 (MCSG) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      F51-1 (MRF) - A74-40 (MRF) Power switch off Below 1 Ω
      F51-5 (MRFG) - A74-29 (MRFG) Power switch off Below 1 Ω
      F51-2 (MSN) - A74-39 (MSN) Power switch off Below 1 Ω
      F51-6 (MSNG) - A74-28 (MSNG) Power switch off Below 1 Ω
      F51-3 (MCS) - A74-38 (MCS) Power switch off Below 1 Ω
      F51-7 (MCSG) - A74-27 (MCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      F51-1 (MRF) or A38-40 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-5 (MRFG) or A38-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-2 (MSN) or A38-39 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-6 (MSNG) or A38-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-3 (MCS) or A38-38 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-7 (MCSG) or A38-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      F51-1 (MRF) or A74-40 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-5 (MRFG) or A74-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-2 (MSN) or A74-39 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-6 (MSNG) or A74-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-3 (MCS) or A74-38 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      F51-7 (MCSG) or A74-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

      The motor resolver is not available separately. If it requires replacement, replace the hybrid vehicle transmission assembly.

    5. Connect the motor resolver connector.

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  29. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - IGCT NO. 4 FUSE)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the connector from the inverter with converter assembly.

    3. A01FQOWE20
      Text in Illustration
      *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 Switch Condition Specified Condition
      A38-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A38-11 (+B2) - Body ground Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A74-11 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  30. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  31. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (IGCT NO. 4)

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the hybrid vehicle transmission assembly Click here.

    3. A01FTSA

      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

  33. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the generator cable Click here.

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

      A01FVLBE01
      Text in Illustration
      *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

      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 Switch Condition Specified Condition
      v1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      v1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

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

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

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      v1-3 (W) - v2-1 (W) Power switch off Below 1 Ω
      v1-2 (V) - v2-2 (V) Power switch off Below 1 Ω
      v1-1 (U) - v2-3 (U) Power switch off Below 1 Ω
      v1-3 (W) - v2-3 (U) Power switch off 100 MΩ or higher
      v1-2 (V) - v2-1 (W) Power switch off 100 MΩ or higher
      v1-1 (U) - v2-2 (V) Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      v1-1 (W) - v2-1 (W) Power switch off Below 1 Ω
      v1-2 (V) - v2-2 (V) Power switch off Below 1 Ω
      v1-3 (U) - v2-3 (U) Power switch off Below 1 Ω
      v1-1 (W) - v2-3 (U) Power switch off 100 MΩ or higher
      v1-2 (V) - v2-1 (W) Power switch off 100 MΩ or higher
      v1-3 (U) - v2-2 (V) Power switch off 100 MΩ or higher

    5. Install the generator cable.


    NG

    REPLACE GENERATOR CABLE Click here

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the hybrid vehicle transmission assembly Click here.

    3. A01FQUD

      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

  35. CHECK MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the motor cable Click here.

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

      A01FQROE01
      Text in Illustration
      *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 Switch Condition Specified Condition
      u1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      u3-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

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

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

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      u1-3 (W) - u2-3 (W) Power switch off Below 1 Ω
      u1-2 (V) - u2-2 (V) Power switch off Below 1 Ω
      u1-1 (U) - u2-1 (U) Power switch off Below 1 Ω
      u1-3 (W) - u2-1 (U) Power switch off 100 MΩ or higher
      u1-2 (V) - u2-3 (W) Power switch off 100 MΩ or higher
      u1-1 (U) - u2-2 (V) Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      u3-1 (W) - u2-3 (W) Power switch off Below 1 Ω
      u3-2 (V) - u2-2 (V) Power switch off Below 1 Ω
      u3-3 (U) - u2-1 (U) Power switch off Below 1 Ω
      u3-1 (W) - u2-1 (U) Power switch off 100 MΩ or higher
      u3-2 (V) - u2-3 (W) Power switch off 100 MΩ or higher
      u3-3 (U) - u2-2 (V) Power switch off 100 MΩ or higher

    5. Install the motor cable.


    NG

    REPLACE MOTOR CABLE Click here

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here