HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A78-121

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

DESCRIPTION

For a description of the inverter Click here.

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

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

  • Hybrid battery junction block assembly

  • Inverter with converter assembly

  • Service plug grip (EV battery fuse)

  • Frame wire

  • Hybrid vehicle generator assembly

  • Hybrid vehicle motor assembly

  • Generator cable

  • Motor cable

  • Power management control ECU

  • PCU fuse

  • Wire harness or connector

WIRING DIAGRAM

Refer to the wiring diagram for DTC P1CAC-200 Click here.

Refer to the wiring diagram for DTC P0AE6-225 Click here.

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

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

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. With the vehicle engine stopped, the power switch on (READY) and park (P) selected, depress the accelerator pedal to start the engine.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0A78-121 is 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 P0A78-121 is set. B
      Any of the DTCs including pending DTCs in the table 2 below are set before P0A78-121 is set. C
      Table 1
      DTC No. Relevant Diagnosis
      P3004-131, 803 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.

      • P0A78-121 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
      Only P0A78-121 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 below are also output. B
      DTC No. Relevant Diagnosis
      P06B0-163 Sensor Power Supply "A" Circuit/Open
      P06D6-511 Sensor Reference Voltage "F" Circuit/Open
      P06E6-164 Sensor Power Supply "C" Circuit/Open
      P0A1A-151, 166, 517, 658, 791, 809 Generator Control Module
      P0A1B-198, 503, 505, 547, 554, 786, 794, 806 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500, 504, 506, 549, 556, 808 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, 518, 811 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A78-113, 128, 279, 284, 286, 287, 548, 555, 807 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 810 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A93-346 Inverter Cooling System Performance
      P0A94-172, 553, 557 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
      P0BEA-290 Drive Motor "A" Phase V Current Sensor Circuit Range/Performance
      P0BEE-298 Drive Motor "A" Phase W Current Sensor Circuit Range/Performance
      P0C19-306 Drive Motor "A" Torque Delivered Performance
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-565, 586 Drive Motor "A" Inverter Voltage Sensor Circuit Range/Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Performance
      P0E05-328 Generator Phase V Current Sensor Circuit Range/Performance
      P0E09-336 Generator Phase W Current Sensor Circuit Range/Performance
      P0E32-585 DC/DC Converter Voltage Sensor "A" Range/Performance
      P0E33-589 DC/DC Converter Voltage Sensor "A" Low
      P0E34-590 DC/DC Converter Voltage Sensor "A" High
      P0E71-344 Generator Torque Delivered Performance
      P1C2A-155 Generator A/D Converter Circuit
      P1C2B-192 Drive Motor "A" A/D Converter Circuit
      P1C2D-587 Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294 Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302 Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333 Generator Phase V Current Sensor Correlation
      P1C3F-341 Generator Phase W Current Sensor Correlation
      P1C4A-288 Drive Motor "A" Phase V Current Sensor Sub Circuit Range/Performance
      P1C4F-296 Drive Motor "A" Phase W Current Sensor Sub Circuit Range/Performance
      P1C54-326 Generator Phase V Current Sensor Sub Circuit Range/Performance
      P1C59-334 Generator Phase W Current Sensor Sub Circuit Range/Performance
      P1C6D-501 Drive Motor "A" Phase V Current Sensor Offset Range/Performance
      P1C6E-502 Drive Motor "A" Phase W Current Sensor Offset Range/Performance
      P1C71-515 Generator Phase V Current Sensor Offset Range/Performance
      P1C72-516 Generator Phase W Current Sensor Offset Range/Performance
      P1C73-512 Sensor Standard Voltage "F" Circuit/Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3004-803 Power Cable Malfunction
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      P314A-828 Inverter Coolant Pump Speed Signal

      Tech Tips


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

      • P0A78-121 may be 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

    A

  3. 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

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the 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

  5. CHECK GENERATOR RESOLVER

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the 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

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the 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

  7. CHECK MOTOR RESOLVER

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Disconnect the 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

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. 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

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. 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

  10. 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

  11. 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

  12. CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH VOLTAGE CONNECTOR CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

    3. B005XKCE11

      Check that the bolts for the frame wire are tightened to the specified torque, the frame wire 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 frame wire from the inverter with converter assembly.

    5. Check for arc marks at the bolts and terminals for the frame wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the frame wire to the inverter with converter assembly.

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  13. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


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

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

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  14. INSPECT SERVICE PLUG GRIP


    1. B005XG7E01
      Text in Illustration
      *1 Service plug grip

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

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

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  15. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

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

    3. B005Z8VE01
      Text in Illustration
      *a

      Frame Wire Connection Condition

      (Hybrid Battery Junction Block Assembly)

      Disconnect the frame wire from the hybrid battery junction block assembly.

    4. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

    5. B005ZUK

      Disconnect the frame wire from the inverter with converter assembly.

    6. B005YLYE02
      Text in Illustration
      *1 Frame Wire (Inverter with Converter Assembly Side)
      *2 Frame Wire (Hybrid Battery Junction Block Assembly Side)
      *3 Shield Ground

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T6-1 (CBI) - T1-2 (CBI) (Positive terminal) Power switch off Below 1 Ω
      T5-1 (CEI) - T1-1 (CEI) (Negative terminal) Power switch off Below 1 Ω

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

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T6-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      T5-1 (CEI) - Body ground and shield ground Power switch off 10 MΩor higher
      T6-1 (CBI) - T5-1 (CEI) Power switch off 10 MΩ or higher

    8. Connect the frame wire to the hybrid battery junction block assembly.

    9. Connect the frame wire to the inverter with converter assembly.

    10. Install the inverter cover.

    11. Install the No. 2 hybrid battery shield sub-assembly.


    NG

    REPLACE FRAME WIRE Click here

    OK

  16. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the hybrid battery junction block assembly Click here.

    3. B005ZM2E02
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      k3-1 (+) - T6-1 (CBI) Auxiliary battery voltage is not applied between terminals c6-4 (SMRB) and c6-2 (GND) 10 kΩ or higher
      k3-1 (+) - T6-1 (CBI) Auxiliary battery voltage is applied between terminals c6-4 (SMRB) and c6-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      c6-4 (SMRB) - c6-2 (GND) -40 to 80°C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  17. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

    CAUTION:

    Be sure to wear insulated gloves.


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

      Note

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

    2. Remove the hybrid battery junction block assembly Click here.

    3. B005Z7TE02
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      h3-1 (-) - T5-1 (CEI) Auxiliary battery voltage is not applied between terminals c6-1 (SMRG) and c6-2 (GND) 10 kΩ or higher
      h3-1 (-) - T5-1 (CEI) Auxiliary battery voltage is applied between terminals c6-1 (SMRG) and c6-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      c6-1 (SMRG) - c6-2 (GND) -40 to 80°C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  18. 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

  19. 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

  20. 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

  21. 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

  22. 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

  23. 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

  24. 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

  25. 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

  26. 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

  27. 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

  28. 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

  29. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


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


    NEXT

    REPLACE FUSE (PCU)

  30. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (PCU)

  31. 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

  32. 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

  33. 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

  34. 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