HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-113

DTC Code DTC Name
P0A78-113 Drive Motor "A" Inverter Performance

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 113

Motor inverter fail signal detection

(System overcurrent)

  • Hybrid vehicle generator assembly

  • Hybrid vehicle motor assembly

  • Generator cable

  • Motor cable

  • Inverter with converter assembly

  • Power management control ECU

  • PCU 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 P324E-788 Click here.

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

CAUTION / NOTICE / HINT

CAUTION:


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

Tech Tips

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


  1. Turn the power switch on (READY) and wait for 5 seconds or more.

  2. Perform a road test according to the freeze frame data "Vehicle Spd" for approximately 10 minutes.

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
      P0A78-113 is set before any of the DTCs in the table below are set. A
      Any of the DTCs including pending DTCs in the table 1 below are set before P0A78-113 is set. B
      Any of the DTCs including pending DTCs in the table 2 below are set before P0A78-113 is set. C
      Table 1
      DTC No. Relevant Diagnosis
      P0AC0-817 Hybrid Battery Pack Current Sensor Circuit Range / Performance
      P3004-131 High Voltage Power Resource
      Table 2
      DTC No. Relevant Diagnosis
      P0A7F-123 Hybrid Battery Pack Deterioration
      P0A80-123 Replace Hybrid Battery Pack
      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
      P0ABF-123 Hybrid Battery Pack Current Sensor Circuit
      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
      P0AFC-123 Hybrid Battery Pack Sensor Module
      P0B10-123 Hybrid Battery Pack Current Sensor "B" Circuit Low
      P0B11-123 Hybrid Battery Pack Current Sensor "B" Circuit High
      P0B13-123 Hybrid Battery Pack Current Sensor "A"/"B" Correlation
      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
      P0C34-123 Hybrid Battery Temperature Sensor "F" Range / Performance
      P0C35-123 Hybrid Battery Temperature Sensor "F" Circuit Low
      P0C36-123 Hybrid Battery Temperature Sensor "F" Circuit High
      P3011-123 Battery Block 1 Becomes Weak
      P3012-123 Battery Block 2 Becomes Weak
      P3013-123 Battery Block 3 Becomes Weak
      P3014-123 Battery Block 4 Becomes Weak
      P3015-123 Battery Block 5 Becomes Weak
      P3016-123 Battery Block 6 Becomes Weak
      P3017-123 Battery Block 7 Becomes Weak
      P3018-123 Battery Block 8 Becomes Weak
      P301A-123 Open in Hybrid Battery Cell Voltage Detection Circuit
      P301B-123 Hybrid Battery Cell Voltage Detection Circuit Range/Performance
      P3065-123 Hybrid Battery Temperature Sensor Range/Performance Stuck "A
      P306A-123 Hybrid Battery Temperature Sensor Range / Performance Stuck "B"
      P31AA-123 Hybrid Battery Cell High Voltage
      P31AB-123 Hybrid Battery Cell Low Voltage
      P31AC-123 Hybrid Battery Cell Extreme High Voltage
      P31B3-123 Hybrid Battery Voltage High
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module

      Tech Tips


      • Refer to the freeze frame data to determine the order in which the DTCs were set.

      • P0A78-113 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    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
      P0A78-202 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.


    B

    GO TO DTC CHART (P0A78-202) Click here

    A

  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.

      Tech Tips


      • If P0A78-202 was not output in step 2 of this diagnosis procedure, check reference 1 below.

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

      Result
      Result Proceed to
      Only P0A78-113 is output, or DTCs other than the ones in the table below are also output. A
      Any of the following DTCs including pending DTCs in the table 1 and 3 below are also output. B
      Any of the following DTCs in the table 2 and 4 below are also output. C
      Table 1 (reference 1)
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC/DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3000-388, 389, 603 HV Battery Malfunction
      P3004-133, 803 High Voltage Power Resource
      Table 2 (reference 1)
      DTC No. Relevant Diagnosis
      P0A95-123 High Voltage Fuse
      P31B4-123 Extreme Charging Current Caused by Hybrid Battery High Voltage
      P31B5-123 Abnormal Current Caused by Continuous Current from Hybrid Battery
      Table 3 (reference 2)
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60-294 Drive Motor "A" Phase V Current
      P0A63-302 Drive Motor "A" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-266, 267, 279, 287, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC/DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3000-388, 389, 603 HV Battery Malfunction
      P3004-133, 803 High Voltage Power Resource
      Table 4 (reference 2)
      DTC No. Relevant Diagnosis
      P0A95-123 High Voltage Fuse
      P31B4-123 Extreme Charging Current Caused by Hybrid Battery High Voltage
      P31B5-123 Abnormal Current Caused by Continuous Current from Hybrid Battery

      Tech Tips


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

      • P0A78-113 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    A

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. A005CAR

      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.

      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.

      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

  5. 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 D29 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. B005XITE03
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      D29-11 (GRF) - Body ground Power switch on (IG) Below 1 V
      D29-12 (GRFG) - Body ground Power switch on (IG) Below 1 V
      D29-7 (GSN) - Body ground Power switch on (IG) Below 1 V
      D29-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      D29-10 (GCS) - Body ground Power switch on (IG) Below 1 V
      D29-9 (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. Disconnect the cable from the negative (-) auxiliary battery terminal.

    7. Turn the power switch off.

    8. Reconnect the D29 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. 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 D29 inverter with converter assembly connector.

    3. B005XITE03
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      D29-11 (GRF) - D29-12 (GRFG) Power switch off 7.1 to 21.6 Ω
      D29-7 (GSN) - D29-8 (GSNG) Power switch off 13.7 to 34.5 Ω
      D29-10 (GCS) - D29-9 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      D29-11 (GRF) or D29-12 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D29-7 (GSN) or D29-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D29-10 (GCS) or D29-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the D29 inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

  7. 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 D29 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. B005ZGNE03
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      D29-1 (MRF) - Body ground Power switch on (IG) Below 1 V
      D29-2 (MRFG) - Body ground Power switch on (IG) Below 1 V
      D29-3 (MSN) - Body ground Power switch on (IG) Below 1 V
      D29-4 (MSNG) - Body ground Power switch on (IG) Below 1 V
      D29-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      D29-5 (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. Disconnect the cable from the negative (-) auxiliary battery terminal.

    7. Turn the power switch off.

    8. Reconnect the D29 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. 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 D29 inverter with converter assembly connector.

    3. B005ZGNE03
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      D29-1 (MRF) - D29-2 (MRFG) Power switch off 7.1 to 21.6 Ω
      D29-3 (MSN) - D29-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      D29-6 (MCS) - D29-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      D29-1 (MRF) or D29-2 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D29-3 (MSN) or D29-4 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D29-6 (MCS) or D29-5 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the D29 inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

  9. 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. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

    3. B005Y1HE14

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

      Note


      • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

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

    4. Disconnect the generator cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts and 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 inverter with converter assembly.

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  10. 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. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

    3. B005ZTIE06

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

      Note


      • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

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

    4. Disconnect the motor cable from the inverter with converter assembly.

    5. Check for arc marks at the bolts and 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 inverter with converter assembly.

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  11. 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. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

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

    4. B005XELE02
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Check MG1 for an interphase short using a milliohmmeter.


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

        Tech Tips

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        f1-1 (W) - f1-2 (U) Power switch off 89.5 to 98.9 mΩ
        f1-2 (U) - f1-3 (V) Power switch off 89.5 to 98.9 mΩ
        f1-3 (V) - f1-1 (W) Power switch off 89.5 to 98.9 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)

    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 Condition Specified Condition
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) Click here

    OK

  12. 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. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

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

    4. B005YCHE02
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Check MG2 for an interphase short using a milliohmmeter.


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

        Tech Tips

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        e1-1 (W) - e1-2 (U) Power switch off 152.6 to 169.0 mΩ
        e1-2 (U) - e1-3 (V) Power switch off 157.6 to 174.0 mΩ
        e1-3 (V) - e1-1 (W) Power switch off 151.6 to 168.0 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)

    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 Condition Specified Condition
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.


    NG

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

    OK

  13. CHECK FUSE (PCU)


    1. B005ZN3E03
      Text in Illustration
      *1 Engine Room Relay Block and Junction Block Assembly
      *2 PCU fuse

      Remove the PCU fuse from the 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
      PCU fuse terminal Always Below 1Ω

    3. Install the PCU fuse.


    NG

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

    OK

  14. 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 A59 inverter with converter assembly connector.

    3. B005Z92E03
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A59-28 (GND1) - Body ground Power switch off Below 1 Ω
      A59-27 (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
      Tester Connection Condition Specified Condition
      A59-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A59-9 (+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. Reconnect the A59 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE POWER SOURCE CIRCUIT

    OK

  15. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - 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 A59 inverter with converter assembly connector.

    3. Disconnect the A22 power management control ECU connector.

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

      B005XGCE03
      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      A59-8 (HTM+) - A22-24 (HTM+) Power switch off Below 1 Ω
      A59-18 (HTM-) - A22-25 (HTM-) Power switch off Below 1 Ω
      A59-7 (MTH+) - A22-30 (MTH+) Power switch off Below 1 Ω
      A59-17 (MTH-) - A22-29 (MTH-) Power switch off Below 1 Ω
      A59-6 (REQ+) - A22-33 (REQ+) Power switch off Below 1 Ω
      A59-16 (REQ-) - A22-32 (REQ-) Power switch off Below 1 Ω
      A59-5 (CLK+) - A22-21 (CLK+) Power switch off Below 1 Ω
      A59-15 (CLK-) - A22-20 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      A59-8 (HTM+) or A22-24 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A59-18 (HTM-) or A22-25 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A59-7 (MTH+) or A22-30 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A59-17 (MTH-) or A22-29 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A59-6 (REQ+) or A22-33 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A59-16 (REQ-) or A22-32 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A59-5 (CLK+) or A22-21 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A59-15 (CLK-) or A22-20 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

    6. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      A59-8 (HTM+) or A22-24 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A59-18 (HTM-) or A22-25 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A59-7 (MTH+) or A22-30 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A59-17 (MTH-) or A22-29 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A59-6 (REQ+) or A22-33 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A59-16 (REQ-) or A22-32 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A59-5 (CLK+) or A22-21 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A59-15 (CLK-) or A22-20 (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. Reconnect the A22 power management control ECU connector.

    11. Reconnect the A59 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  16. CHECK POWER MANAGEMENT CONTROL ECU


    1. Disconnect the A22 power management control ECU connector.

    2. B005YJWE03
      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 Condition Specified Condition
      A22-24 (HTM+) - A22-25 (HTM-) Power switch off 80 to 170 Ω
      A22-30 (MTH+) - A22-29 (MTH-) Power switch off 80 to 170 Ω
      A22-33 (REQ+) - A22-32 (REQ-) Power switch off 80 to 170 Ω
      A22-21 (CLK+) - A22-20 (CLK-) Power switch off 80 to 170 Ω

    3. Reconnect the A22 power management control ECU connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B005Y9J

      Check the connection of the generator resolver connector.

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

    NG

    CONNECT SECURELY

    OK

  18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B005Z3L

      Check the connection of the motor resolver connector.

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

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CONNECT SECURELY

  19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B005Y9J

      Check the connection of the generator resolver connector.

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

    NG

    CONNECT SECURELY

    OK

  20. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)


    1. B005Y9JN03

      Disconnect the D7 generator resolver connector.

    2. B005YPVC15
      *a

      Component without harness connected

      (Generator Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      D7-1(GRF) - D7-5(GRFG) Power switch off 9.5 to 15.5 Ω
      D7-2(GSN) - D7-6(GSNG) Power switch off 15.0 to 27.0 Ω
      D7-3(GCS) - D7-7(GCSG) Power switch off 14.0 to 26.0 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      D7-1 (GRF) - Body ground and other terminals (except D7-5 (GRFG)) Power switch off 1 MΩ or higher
      D7-5 (GRFG) - Body ground and other terminals (except D7-1 (GRF)) Power switch off 1 MΩ or higher
      D7-2 (GSN) - Body ground and other terminals (except D7-6 (GSNG)) Power switch off 1 MΩ or higher
      D7-6 (GSNG) - Body ground and other terminals (except D7-2 (GSN)) Power switch off 1 MΩ or higher
      D7-3 (GCS) - Body ground and other terminals (except D7-7 (GCSG)) Power switch off 1 MΩ or higher
      D7-7 (GCSG) - Body ground and other terminals (except D7-3 (GCS)) Power switch off 1 MΩ or higher

      Tech Tips

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

    3. Connect the D7 generator resolver connector.


    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY Click here

  21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B005Z3L

      Check the connection of the motor resolver connector.

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

    NG

    CONNECT SECURELY

    OK

  22. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)


    1. B005Z3LN03

      Disconnect the D1 motor resolver connector.

    2. B005ZK4C09
      *a

      Component without harness connected

      (Motor Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      D1-3 (MRF) - D1-6 (MRFG) Power switch off 9.5 to 15.5 Ω
      D1-1 (MSN) - D1-4 (MSNG) Power switch off 15.0 to 27.0 Ω
      D1-2 (MCS) - D1-5 (MCSG) Power switch off 14.0 to 26.0 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      D1-3 (MRF) - Body ground and other terminals (except D1-6 (MRFG)) Power switch off 1 MΩ or higher
      D1-6 (MRFG) - Body ground and other terminals (except D1-3 (MRF)) Power switch off 1 MΩ or higher
      D1-1 (MSN) - Body ground and other terminals (except D1-4 (MSNG)) Power switch off 1 MΩ or higher
      D1-4 (MSNG) - Body ground and other terminals (except D1-1 (MSN)) Power switch off 1 MΩ or higher
      D1-2 (MCS) - Body ground and other terminals (except D1-5 (MCSG)) Power switch off 1 MΩ or higher
      D1-5 (MCSG) - Body ground and other terminals (except D1-2 (MCS)) Power switch off 1 MΩ or higher

      Tech Tips

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

    3. Connect the D1 motor resolver connector.


    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Click here

  23. 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 the A59 inverter with converter assembly connector.

    3. B005ZNWE02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A59-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A59-9 (+B2) - Body ground Power switch off 10 kΩ or higher

    4. Reconnect the A59 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  24. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

    REPLACE FUSE (PCU)

  25. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (PCU)

  26. CHECK HYBRID VEHICLE TRANSAXLE 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 inverter with converter assembly.

    3. B005XN6E06

      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
      Bolt A
      T=20 N*m (204 kgf*cm, 15 ft.*lbf)
      Bolt B
      T=10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note


      • Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 and 245 kgf*cm, 12 and 18 ft.*lbf).

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

    4. Disconnect the generator cable from the hybrid vehicle transaxle assembly.

    5. Check for arc marks at the bolts and 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 transaxle assembly.

    7. Install the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  27. 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.

    3. B005YI9E02
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2

      Generator Cable

      (Hybrid Vehicle Transaxle Assembly Side)
      *3 Shield ground

      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 Condition Specified Condition
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-1 (W) - f2-3 (W) Power switch off Below 1 Ω
      f1-2 (U) - f2-2 (U) Power switch off Below 1 Ω
      f1-3 (V) - f2-1 (V) Power switch off Below 1 Ω
      f1-1 (W) - f2-2 (U) Power switch off 100 MΩ or higher
      f1-2 (U) - f2-1 (V) Power switch off 100 MΩ or higher
      f1-3 (V) - f2-3 (W) Power switch off 100 MΩ or higher

    5. Install the generator cable.


    OK

    REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here

  28. CHECK HYBRID VEHICLE TRANSAXLE 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. B005ZGW

      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=10 N*m (102 kgf*cm, 7 ft.*lbf)

      Note

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

    3. Disconnect the motor cable from the hybrid vehicle transaxle assembly.

    4. Check for arc marks at the bolts and 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

    5. Connect the motor cable to the hybrid vehicle transaxle assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  29. 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.

    3. B005XNUE02
      Text in Illustration
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2

      Motor Cable

      (Hybrid Vehicle Transaxle Assembly Side)
      *3 Shield ground

      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 Condition Specified Condition
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      e1-1 (W) - e2-1 (W) Power switch off Below 1 Ω
      e1-2 (U) - e2-3 (U) Power switch off Below 1 Ω
      e1-3 (V) - e2-2 (V) Power switch off Below 1 Ω
      e1-1 (W) - e2-3 (U) Power switch off 100 MΩ or higher
      e1-2 (U) - e2-2 (V) Power switch off 100 MΩ or higher
      e1-3 (V) - e2-1 (W) Power switch off 100 MΩ or higher

    5. Install the motor cable.


    OK

    REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Click here

    NG

    REPLACE MOTOR CABLE Click here