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

DTC Code DTC Name
U0110-159 Lost Communication with Drive Motor Control Module "A"
U0110-656 Lost Communication with Drive Motor Control Module "A"
U0110-657 Lost Communication with Drive Motor Control Module "A"

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.

DTC No. INF Code DTC Detection Condition Trouble Area
U0110 159 Error in reception from inverter with converter assembly (MG ECU) via serial communication (out of communication standard)

  • Wire harness or connector

  • Inverter with converter assembly

  • Generator cable

  • Motor cable

  • Hybrid vehicle transmission assembly

  • Power management control ECU

  • IGCT No. 4 fuse
656 Error in reception from inverter with converter assembly (MG ECU) via serial communication (out of communication standard)
657 Error in reception from inverter with converter assembly (MG ECU) via serial communication (no reception)

WIRING DIAGRAM

A01FV72E01

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.

  • If any of the DTCs U0110-159, U0110-656, or U0110-657 was stored due to incomplete engagement of the connectors, and if the system returns to normal when the power switch is turned on (IG) after clearing the DTCs, DTC P324E-788 will be stored. Proceed to troubleshooting without considering DTC P324E-788.

PROCEDURE


  1. CHECK FUSE (IGCT NO. 4)


    1. Remove the IGCT No. 4 fuse from the No. 1 engine room relay block and junction block assembly.

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

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      IGCT No. 4 fuse terminals Always Below 1 Ω

    3. Install the IGCT No. 4 fuse.


    NG

    REPLACE FUSE (IGCT NO. 4) Click here

    OK

  2. CLEAR DTC


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Read and record the DTCs and freeze frame data.

    5. Clear DTCs and freeze frame data.

    6. Turn the power switch off.


    NEXT

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check 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 power switch off.


    B

    CHECK FOR INTERMITTENT PROBLEMS Click here

    A

  4. 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

  5. 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

  6. 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

  7. 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

  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 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 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 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 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 power switch on (IG).

    3. A01FR8JE15
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

      Measure the waveform.

      Item Contents
      Tester Connection

      CH1: A35-29 (CLK+) - N91-6 (E1)

      CH2: A35-28 (CLK-) - N91-6 (E1)
      Equipment Setting 1 V/DIV., 1 μs/DIV.
      Condition Power 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 power 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 power switch on (IG).

    3. A01FRM1E16
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

      Measure the waveform.

      Item Contents
      Tester Connection

      CH1: A35-32 (REQ+) - N91-6 (E1)

      CH2: A35-31 (REQ-) - N91-6 (E1)
      Equipment Setting 1 V/DIV., 1 ms/DIV.
      Condition Power 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 power 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 power switch on (IG).

    3. A01FT59E27
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

      Measure the waveform.

      Item Contents
      Tester Connection

      CH1: A35-21 (MTH+) - N91-6 (E1)

      CH2: A35-20 (MTH-) - N91-6 (E1)
      Equipment Setting 1 V/DIV., 200 μs/DIV.
      Condition Power 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 power switch off.


    B

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

    A

    REPLACE POWER MANAGEMENT CONTROL ECU 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 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. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A01FVP8E09
      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 voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A35-29 (CLK+) - Body ground Power switch on (IG) Below 1 V
      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 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 power switch off.

    8. 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
      A38-14 (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
      A74-14 (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
      A38-14 (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
      A74-14 (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

    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 connector from the power management control ECU.

    2. A01FQSYE34
      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
      A35-29 (CLK+) - A35-28 (CLK-) Power switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.


    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    OK

    REPLACE POWER MANAGEMENT CONTROL ECU 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 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. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A01FVP8E10
      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 voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A35-32 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A35-31 (REQ-) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch 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 power switch off.

    8. 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
      A38-34 (REQ+) - A35-32 (REQ+) Power switch off Below 1 Ω
      A38-33 (REQ-) - A35-31 (REQ-) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-34 (REQ+) - A35-32 (REQ+) Power switch off Below 1 Ω
      A74-33 (REQ-) - A35-31 (REQ-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      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
      for RHD
      Tester Connection Switch Condition Specified Condition
      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

    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 connector from the power management control ECU.

    2. A01FQSYE35
      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
      A35-32 (REQ+) - A35-31 (REQ-) Power switch off 80 to 170 Ω

    3. Connect the power management control ECU connector.


    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    OK

    REPLACE POWER MANAGEMENT CONTROL ECU 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 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. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A01FVP8E11
      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 voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A35-21 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A35-20 (MTH-) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch 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 power switch off.

    8. 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
      A38-3 (MTH+) - A35-21 (MTH+) Power switch off Below 1 Ω
      A38-2 (MTH-) - A35-20 (MTH-) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-3 (MTH+) - A35-21 (MTH+) Power switch off Below 1 Ω
      A74-2 (MTH-) - A35-20 (MTH-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      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
      for RHD
      Tester Connection Switch Condition Specified Condition
      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

    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 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. A01FVOIE24
      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
      A35-21 (MTH+) - A35-20 (MTH-) Power switch off 80 to 170 Ω

    4. Connect the inverter with converter assembly connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  18. REPLACE 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

      Replace the IGCT No. 4 fuse.

    2. Turn the power switch on (READY).

    3. Check if there is an open circuit in the IGCT No. 4 fuse in the No. 1 engine room relay block and junction block assembly.

      OK
      There is no open circuit in the IGCT No. 4 fuse.

      Tech Tips

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

    4. Turn the power switch off.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 1 ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY) Click here

    OK

    COMPLETED

  19. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 1 ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK 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. Remove the IGCT No. 4 fuse from the No. 1 engine room relay block and junction block assembly.

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

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

      A01FUOIE02
      Text in Illustration
      *A for LHD *B for RHD
      *1 No. 1 Engine Room Relay Block and Junction Block Assembly *2 IGCT No. 4 Fuse
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 - -
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-10 (+B), A38-11 (+B2) or 2 (IGCT No. 4 fuse terminal) - Body ground and other terminals Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-10 (+B), A74-11 (+B2) or 2 (IGCT No. 4 fuse terminal) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Connect the inverter with converter assembly connector.

    6. Install the IGCT No. 4 fuse.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  20. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  21. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (IGCT NO. 4)

  22. 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

  23. 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

  24. 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

  25. 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