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HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-286

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DTC Code DTC Name
P0A78-286 Drive Motor "A" Inverter Performance
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DESCRIPTION

For a description of the inverter, (Click here).

If the motor inverter overheats, has a circuit malfunction, or has an internal short, the inverter transmits this information to the MG ECU via the motor inverter fail signal line.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A78 286 Motor inverter fail signal detection (circuit malfunction)

  • Inverter cooling system

  • Cooling fan system

  • Power management control ECU

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Hybrid vehicle generator assembly

  • Wire harness or connector

  • PCU fuse
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WIRING DIAGRAM

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

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

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

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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 disconnecting 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.

Note:

After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

Tip:

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

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PROCEDURE


  1. Click here

    CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester 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
      P0A78-202 is not output A
      P0A78-202 is also output B
      Note:

      • If P0A78-202 is output, troubleshoot it first. After completing the troubleshooting for P0A78-202, return to perform troubleshooting for this DTC.

      • Parts repaired or replaced during troubleshooting for P0A78-202 do not need to be re-inspected in this diagnosis procedure.

    5. Turn the power switch off.


  2. Click here

    CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester 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.

      Tip:

      • If P0A78-202 was not output in step 1 of this diagnosis procedure, check Table 1 below.

      • If P0A78-202 was output in step 1 of this diagnosis procedure, repair that DTC first, then check Table 2 below.

      Result
      Result Proceed to
      P0A78-286 only is output. A
      Any of the following DTCs are also output. B
      Table 1. Table 1
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1C (all INF codes)*1 Drive Motor "B" 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
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-671 Drive Motor "B" Position Sensor Circuit Range/Performance
      P0A47-670 Drive Motor "B" 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
      P0A69 (all INF codes)*1 Drive Motor "B" Phase V Current
      P0A6C (all INF codes)*1 Drive Motor "B" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-113, 118, 119, 120, 128, 266, 267, 279, 284, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-136, 692, 693, 694, 695, 704, 712, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-122, 130, 322, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A91-702 Drive Motor "B" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-124, 125, 126, 169, 170, 171, 442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC/DC Converter Performance
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P314A-828 Inverter Coolant Pump Speed Signal
      Table 2. Table 2
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1C (all INF codes)*1 Drive Motor "B" 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
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-671 Drive Motor "B" Position Sensor Circuit Range/Performance
      P0A47-670 Drive Motor "B" 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
      P0A60-294 Drive Motor "A" Phase V Current
      P0A63-302 Drive Motor "A" Phase W Current
      P0A69 (all INF codes)*1 Drive Motor "B" Phase V Current
      P0A6C (all INF codes)*1 Drive Motor "B" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-113, 118, 119, 120, 128, 266, 267, 279, 284, 287, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-136, 692, 693, 694, 695, 704, 712, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-122, 130, 322, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A91-702 Drive Motor "B" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-124, 125, 126, 169, 170, 171, 442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC/DC Converter Performance
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P314A-828 Inverter Coolant Pump Speed Signal
      Tip:

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

      • P0A78-286 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

    5. Turn the power switch off.


  3. Click here

    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.

      A01NM1T
      Note:

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

    2. Check the connection of the low voltage connector of the inverter with converter assembly.

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

      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.


  4. Click here

    CHECK QUANTITY OF HV COOLANT


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

    2. Check for coolant leaks.

      Table 3. Result
      Result Proceed to
      No leaks are found and coolant level in the inverter reserve tank assembly is above the low line. A
      No leaks are found and coolant level in the inverter reserve tank assembly is below the low line. B
      Coolant leaks are evident. C
      Tip:

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


  5. Click here

    CHECK COOLANT HOSE


    1. Check if the hoses of the cooling system are kinked or clogged.


  6. Click here

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE ELECTRIC COOLING FAN)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

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

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

      OK
      The cooling fan rotates.

    5. Turn the power switch off.


  7. Click here

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


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Read the freeze frame data Ambient Temperature using the intelligent tester.

    4. Check if the freeze frame data Ambient Temperature is below freezing.

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

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

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

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

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

    5. Turn the power switch off.


  8. Click here

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector D44 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. A01NK6NE01

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      D44-1 (GRF) - Body ground Power switch on (IG) Below 1 V
      D44-7 (GRFG) - Body ground Power switch on (IG) Below 1 V
      D44-2 (GSN) - Body ground Power switch on (IG) Below 1 V
      D44-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      D44-3 (GCS) - Body ground Power switch on (IG) Below 1 V
      D44-9 (GCSG) - Body ground Power switch on (IG) Below 1 V
      Table 4. Text in Illustration
      *1

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      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.

    4. Turn the power switch off.

    5. Connect the low voltage connector to the inverter with converter assembly.


  9. Click here

    CHECK GENERATOR RESOLVER


    1. Disconnect the low voltage connector D44 from the inverter with converter assembly.

    2. A01NK6NE01

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D44-1 (GRF) - D44-7 (GRFG) Power switch off 4.2 to 12.5 Ω
      D44-2 (GSN) - D44-8 (GSNG) Power switch off 9.8 to 20.1 Ω
      D44-3 (GCS) - D44-9 (GCSG) Power switch off 9.8 to 20.1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D44-1 (GRF) or D44-7 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D44-2 (GSN) or D44-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D44-3 (GCS) or D44-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 5. Text in Illustration
      *1

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    3. Connect the inverter with converter assembly connector.


  10. Click here

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the low voltage connector D44 from the inverter with converter assembly.

    2. Turn the power switch on (IG).

    3. A01NK6NE02

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      D44-4 (MRF) - Body ground Power switch on (IG) Below 1 V
      D44-11 (MRFG) - Body ground Power switch on (IG) Below 1 V
      D44-5 (MSN) - Body ground Power switch on (IG) Below 1 V
      D44-12 (MSNG) - Body ground Power switch on (IG) Below 1 V
      D44-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      D44-13 (MCSG) - Body ground Power switch on (IG) Below 1 V
      Table 6. Text in Illustration
      *1

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      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.

    4. Turn the power switch off.

    5. Connect the inverter with converter assembly connector.


  11. Click here

    CHECK MOTOR RESOLVER


    1. Disconnect the low voltage connector D44 from the inverter with converter assembly.

    2. A01NK6NE02

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D44-4 (MRF) - D44-11 (MRFG) Power switch off 4.2 to 12.5 Ω
      D44-5 (MSN) - D44-12 (MSNG) Power switch off 9.8 to 20.1 Ω
      D44-6 (MCS) - D44-13 (MCSG) Power switch off 9.8 to 20.1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D44-4 (MRF) or D44-11 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D44-5 (MSN) or D44-12 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D44-6 (MCS) or D44-13 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 7. Text in Illustration
      *1

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    3. Connect the inverter with converter assembly connector.


  12. Click here

    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. A01NKG5

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

    3. A01NMJP

      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 bolts is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Check for arc marks at the bolts 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

    5. Install the inverter terminal cover.


  13. Click here

    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. A01NKG5

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

    3. A01NJJL

      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 bolts is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Check for arc marks at the bolts 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

    5. Install the inverter terminal cover.


  14. Click here

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note:

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

    2. A01NKG5

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

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

    4. A01NIBWE05

      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.

        Tip:

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

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        z36-3 (U) - z36-2 (V) Power switch off 37 to 43 mΩ
        z36-2 (V) - z36-1 (W) Power switch off 36 to 42 mΩ
        z36-1 (W) - z36-3 (U) Power switch off 36 to 42 mΩ
        Table 8. Text in Illustration
        *1 Generator Cable
        *2 Shield Ground
        Tip:

        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)

    5. 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
      z36-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      z36-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      z36-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter terminal cover.


  15. Click here

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note:

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

    2. A01NKG5

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

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

    4. A01NJJ9E04

      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.

        Tip:

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

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        z38-3 (U) - z38-2 (V) Power switch off 52 to 60 mΩ
        z38-2 (V) - z38-1 (W) Power switch off 50 to 58 mΩ
        z38-1 (W) - z38-3 (U) Power switch off 50 to 58 mΩ
        Table 9. Text in Illustration
        *1 Motor Cable
        *2 Shield Ground
        Tip:

        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)

    5. 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
      z38-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      z38-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      z38-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter terminal cover.


  16. Click here

    CHECK FUSE (PCU)


    1. A01NMJ6E02

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

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      PCU fuse Always Below 1Ω
      Table 10. Text in Illustration
      *1 Engine Room Relay Block No. 2
      *2 PCU fuse

    3. Install the PCU fuse.


  17. Click here

    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 connector A79 from inverter with converter assembly.

    3. A01NN9WE03

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A79-10 (GND1) - Body ground Power switch off Below 1 Ω
      A79-11 (GND2) - Body ground Power switch off Below 1 Ω
      Table 11. Text in Illustration
      *1

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    4. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A79-30 (+B) - Body ground Power switch on (IG) Same as auxiliary battery voltage
      A79-31 (+B2) - Body ground Power switch on (IG) Same as auxiliary battery voltage

    6. Turn the power switch off.

    7. Connect the inverter with converter assembly connector.


  18. Click here

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

    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. Turn the power switch off.

    3. Disconnect connector A79 from the inverter with converter assembly.

    4. Disconnect connector A81 from the power management control ECU.

    5. A01NJDCE01

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

      Standard Resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      A81-24 (HTM+) - A79-9 (HTM+) Power switch off Below 1 Ω
      A81-25 (HTM-) - A79-20 (HTM-) Power switch off Below 1 Ω
      A81-30 (MTH+) - A79-8 (MTH+) Power switch off Below 1 Ω
      A81-29 (MTH-) - A79-19 (MTH-) Power switch off Below 1 Ω
      A81-33 (REQ+) - A79-26 (REQ+) Power switch off Below 1 Ω
      A81-32 (REQ-) - A79-37 (REQ-) Power switch off Below 1 Ω
      A81-21 (CLK+) - A79-7 (CLK+) Power switch off Below 1 Ω
      A81-20 (CLK-) - A79-18 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      A81-24 (HTM+) or A79-9 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A81-25 (HTM-) or A79-20 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A81-30 (MTH+) or A79-8 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A81-29 (MTH-) or A79-19 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A81-33 (REQ+) or A79-26 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A81-32 (REQ-) or A79-37 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A81-21 (CLK+) or A79-7 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A81-20 (CLK-) or A79-18 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
      Table 12. Text in Illustration
      *1

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *2

      Rear view of wire harness connector

      (to Power Management Control ECU)

    6. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A81-24 (HTM+) or A79-9 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A81-25 (HTM-) or A79-20 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A81-30 (MTH+) or A79-8 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A81-29 (MTH-) or A79-19 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A81-33 (REQ+) or A79-26 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A81-32 (REQ-) or A79-37 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A81-21 (CLK+) or A79-7 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A81-20 (CLK-) or A79-18 (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. Connect the power management control ECU connector.

    10. Connect the inverter with converter assembly connector.


  19. Click here

    CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect connector A81 from the power management control ECU.

    2. A01NLPLE03

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A81-24 (HTM+) - A81-25 (HTM-) Power switch off 109 to 131Ω
      A81-30 (MTH+) - A81-29 (MTH-) Power switch off 109 to 131Ω
      A81-33 (REQ+) - A81-32 (REQ-) Power switch off 109 to 131Ω
      A81-21 (CLK+) - A81-20 (CLK-) Power switch off 109 to 131Ω
      Table 13. Text in Illustration
      *1

      Component without harness connected

      (Power Management Control ECU)
      Result
      Result Proceed to
      OK A
      NG (for LHD) B
      NG (for RHD) C

    3. Connect the power management control ECU connector.


  20. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A01NIQ6

      Check the connection of the generator resolver connector.

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

  21. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A01NK2V

      Check the connection of the motor resolver connector.

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

  22. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A01NIQ6

      Check the connection of the generator resolver connector.

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

  23. Click here

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


    1. Disconnect the low voltage connector D44 from the inverter with converter assembly.

    2. A01NKHRE01

      Disconnect the generator resolver connector.

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D45-1 (GRF) - D44-1 (GRF) Power switch off Below 1 Ω
      D45-6 (GRFG) - D44-7 (GRFG) Power switch off Below 1 Ω
      D45-2 (GSN) - D44-2 (GSN) Power switch off Below 1 Ω
      D45-7 (GSNG) - D44-8 (GSNG) Power switch off Below 1 Ω
      D45-3 (GCS) - D44-3 (GCS) Power switch off Below 1 Ω
      D45-8 (GCSG) - D44-9 (GCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D45-1 (GRF) or D44-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      D45-6 (GRFG) or D44-7 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D45-2 (GSN) or D44-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      D45-7 (GSNG) or D44-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D45-3 (GCS) or D44-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      D45-8 (GCSG) or D44-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 14. Text in Illustration
      *1

      Front view of wire harness connector

      (to Generator Resolver)
      *2

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      Tip:

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

    4. Connect the generator resolver connector.

    5. Connect the inverter with converter assembly connector.


  24. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A01NK2V

      Check the connection of the motor resolver connector.

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

  25. Click here

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


    1. Disconnect the low voltage connector D44 from the inverter with converter assembly.

    2. A01NJU2E01

      Disconnect the motor resolver connector.

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D46-1 (MRF) - D44-4 (MRF) Power switch off Below 1 Ω
      D46-4 (MRFG) - D44-11 (MRFG) Power switch off Below 1 Ω
      D46-2 (MSN) - D44-5 (MSN) Power switch off Below 1 Ω
      D46-5 (MSNG) - D44-12 (MSNG) Power switch off Below 1 Ω
      D46-3 (MCS) - D44-6 (MCS) Power switch off Below 1 Ω
      D46-6 (MCSG) - D44-13 (MCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D46-1 (MRF) or D44-4 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      D46-4 (MRFG) or D44-11 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D46-2 (MSN) or D44-5 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      D46-5 (MSNG) or D44-12 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D46-3 (MCS) or D44-6 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      D46-6 (MCSG) or D44-13 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 15. Text in Illustration
      *1

      Front view of wire harness connector

      (to Motor Resolver)
      *2

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      Tip:

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

    4. Connect the motor resolver connector.

    5. Connect the inverter with converter assembly connector.


  26. Click here

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note:

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

    2. Disconnect connector A79 from the inverter with converter assembly.

    3. A01NN9WE02

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A79-30 (+B) - Body ground Power switch off 10 kΩ or higher
      A79-31 (+B2) - Body ground Power switch off 10 kΩ or higher
      Table 16. Text in Illustration
      *1

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    4. Connect the inverter with converter assembly connector.


  27. Click here

    REPLACE INVERTER WITH CONVERTER ASSEMBLY


    1. Replace the inverter with converter assembly (Click here).


  28. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR


    1. Repair or replace the harness or connector.


  29. Click here

    REPLACE HV COOLANT


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


  30. Click here

    REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here

  31. Click here

    GO TO DTC CHARTClick here

  32. Click here

    GO TO DTC CHARTClick here

  33. Click here

    REPLACE MALFUNCTIONING PARTS

  34. Click here

    ADD COOLANT

  35. Click here

    INSPECT FOR COOLANT LEAKS AND ADD COOLANT

  36. Click here

    CORRECT THE PROBLEM

  37. Click here

    CHECK COOLING FAN SYSTEMClick here

  38. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  39. Click here

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLYClick here

  40. Click here

    CONNECT SECURELY

  41. Click here

    REPLACE FUSE (PCU)

  42. Click here

    REPLACE POWER MANAGEMENT CONTROL ECU (for LHD)Click here

  43. Click here

    COMPLETED

  44. Click here

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

  45. Click here

    REPLACE POWER MANAGEMENT CONTROL ECU (for RHD)Click here

  46. Click here

    REPLACE HYBRID VEHICLE GENERATOR ASSEMBLYClick here