DTC P0A78-113: Drive Motor "A" Inverter Performance [08/2013 - ]: Procedure

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Check for DTCs.

   Result

   Result	Proceed to
   P0A78-113 is stored before any of the DTCs in the tables below are stored.	A
   Any of the DTCs including pending DTCs in table 1 below are stored before P0A78-113 is stored.	B
   Any of the DTCs in table 2 below are stored before P0A78-113 is stored.	C

   TABLE 1
   
   

   DTC No.	Relevant Diagnosis
   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
   P3004-803	High Voltage Power Resource

   TABLE 2
   
   

   DTC No.	Relevant Diagnosis
   P0A9C-123	Hybrid Battery Temperature Sensor "A" Range / Performance
   P0A9D-123	Hybrid Battery Temperature Sensor "A" Circuit Low
   P0A9E-123	Hybrid Battery Temperature Sensor "A" Circuit High
   P0AC0-123	Hybrid Battery Pack Current Sensor Circuit Range / Performance
   P0AC1-123	Hybrid Battery Pack Current Sensor Circuit Low
   P0AC2-123	Hybrid Battery Pack Current Sensor Circuit High
   P0AC6-123	Hybrid Battery Temperature Sensor "B" Range / Performance
   P0AC7-123	Hybrid Battery Temperature Sensor "B" Circuit Low
   P0AC8-123	Hybrid Battery Temperature Sensor "B" Circuit High
   P0ACB-123	Hybrid Battery Temperature Sensor "C" Range / Performance
   P0ACC-123	Hybrid Battery Temperature Sensor "C" Circuit Low
   P0ACD-123	Hybrid Battery Temperature Sensor "C" Circuit High
   P0AFC-123	Hybrid Battery Pack Sensor Module
   P3011-123, P3012-123, P3013-123, P3014-123, P3015-123, P3016-123, P3017-123, P3018-123, P3019-123, P3020-123, P3021-123, P3022-123, P3023-123, P3024-123, P3025-123, P3026-123, P3027-123	Battery Block # Becomes Weak
   P3065-123	Hybrid Battery Temperature Sensor Range / Performance Stuck "A"
   P308A-123	Hybrid Battery Voltage Sensor All Circuits Low

   HINT: 

   • Refer to the freeze frame data to determine the order in which the DTCs were stored.
   • P0A78-113 may be stored due to a malfunction which also causes DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.
5. Turn the power switch off.

B → See step   32 

C → See step   35 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Check for DTCs.

   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 → See step   30 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Check for DTCs.

   HINT: 

   • If P0A78-202 was not output in step 2 of this diagnosis procedure, check Table 1 below.
   • If P0A78-202 was output in step 2 of this diagnosis procedure, diagnose that DTC first, then check Table 2 below.

   Result

   Result	Proceed to
   P0A78-113 only is output, or DTCs except the ones in the tables below are also output.	A
   Any of the following DTCs including pending DTCs are also output.	B

   TABLE 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
   P3004-803	High Voltage Power Resource

   TABLE 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
   P3004-803	High Voltage Power Resource

   HINT: 

   • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
   • P0A78-113 may be stored due to a malfunction which also causes DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.
5. Turn the power switch off.

B → See step   32 

A: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

NG → See step   19 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

NG → See step   21 

OK: Go to next step 

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 service information because this may cause a malfunction.

2. Remove the upper inverter cover (generator cable side) from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

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

   NOTE:

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

4. Disconnect the generator cable from the inverter with converter assembly.
5. Check for arc marks at the terminals for the generator cable.

   Result

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

6. Connect the generator cable to the inverter with converter assembly.
7. Install the upper inverter cover (generator cable side).

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

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 service information because this may cause a malfunction.

2. Remove the upper inverter cover (motor cable side) from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

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

   NOTE:

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

4. Disconnect the motor cable from the inverter with converter assembly.
5. Check for arc marks at the terminals for the motor cable.

   Result

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

6. Connect the motor cable to the inverter with converter assembly.
7. Install the upper inverter cover (motor cable side).

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

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 service information because this may cause a malfunction.

2. Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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   TEXT IN ILLUSTRATION
   
   

   *1	Generator Cable
   *2	Motor Cable

4. Check MG1 for an interphase short using a milliohmmeter.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      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
      e1-1 (W) - e1-3 (U)	Power switch off	59.1 to 67.5 mΩ
      e1-2 (V) - e1-1 (W)	Power switch off	59.1 to 67.5 mΩ
      e1-3 (U) - e1-2 (V)	Power switch off	62.1 to 70.5 mΩ

      TEXT IN ILLUSTRATION
      
      

      *1	Shield Ground
      *a	Generator Cable (Inverter with Converter Assembly Side)

      HINT: 

      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 (V) - Body ground and shield ground	Power switch off	100 MΩ or higher
   e1-3 (U) - Body ground and shield ground	Power switch off	100 MΩ or higher

6. Connect the generator cable and motor cable.
7. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).

NG → See step   26 

OK: Go to next step 

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 service information because this may cause a malfunction.

2. Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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   TEXT IN ILLUSTRATION
   
   

   *1	Generator Cable
   *2	Motor Cable

4. Check MG2 for an interphase short using a milliohmmeter.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      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
      d1-1 (W) - d1-3 (U)	Power switch off	71.4 to 81.0 mΩ
      d1-2 (V) - d1-1 (W)	Power switch off	71.4 to 81.0 mΩ
      d1-3 (U) - d1-2 (V)	Power switch off	74.4 to 84.1 mΩ

      TEXT IN ILLUSTRATION
      
      

      *1	Shield Ground
      *a	Motor Cable (Inverter with Converter Assembly Side)

      HINT: 

      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
   d1-1 (W) - Body ground and shield ground	Power switch off	100 MΩ or higher
   d1-2 (V) - Body ground and shield ground	Power switch off	100 MΩ or higher
   d1-3 (U) - Body ground and shield ground	Power switch off	100 MΩ or higher

6. Connect the generator cable and motor cable.
7. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).

NG → See step   28 

OK: Go to next step 

1. Remove the INV fuse from the No. 2 engine room relay block.

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

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   INV fuse terminal	Always	Below 1Ω

   TEXT IN ILLUSTRATION
   
   

   *1	No. 2 Engine Room Relay Block
   *2	INV fuse

3. Install the INV fuse.

NG → See step   23 

OK: Go to next step 

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 service information because this may cause a malfunction.

2. Disconnect the A14 inverter with converter assembly connector.
3. Measure the resistance according to the value(s) in the table below.

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   Standard Resistance

   Tester Connection	Condition	Specified Condition
   A14-10 (GND1) - Body ground	Power switch off	Below 1 Ω
   A14-11 (GND2) - Body ground	Power switch off	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Front view of wire harness connector (to Inverter with Converter Assembly)

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
   A14-30 (+B) - Body ground	Power switch on (IG)	11 to 14 V
   A14-31 (+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 A14 inverter with converter assembly connector.

NG → REPAIR OR REPLACE POWER SOURCE CIRCUIT 

OK: Go to next step 

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 service information because this may cause a malfunction.

2. Disconnect the A33 power management control ECU connector.
3. Disconnect the A14 inverter with converter assembly connector.
4. Measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance (Check for Open)

   Tester Connection	Condition	Specified Condition
   A33-24 (HTM+) - A14-9 (HTM+)	Power switch off	Below 1 Ω
   A33-25 (HTM-) - A14-20 (HTM-)	Power switch off	Below 1 Ω
   A33-30 (MTH+) - A14-8 (MTH+)	Power switch off	Below 1 Ω
   A33-29 (MTH-) - A14-19 (MTH-)	Power switch off	Below 1 Ω
   A33-33 (REQ+) - A14-26 (REQ+)	Power switch off	Below 1 Ω
   A33-32 (REQ-) - A14-37 (REQ-)	Power switch off	Below 1 Ω
   A33-21 (CLK+) - A14-7 (CLK+)	Power switch off	Below 1 Ω
   A33-20 (CLK-) - A14-18 (CLK-)	Power switch off	Below 1 Ω

   Standard Resistance (Check for Short)

   Tester Connection	Condition	Specified Condition
   A33-24 (HTM+) or A14-9 (HTM+) - Body ground and other terminals	Power switch off	10 kΩ or higher
   A33-25 (HTM-) or A14-20 (HTM-) - Body ground and other terminals	Power switch off	10 kΩ or higher
   A33-30 (MTH+) or A14-8 (MTH+) - Body ground and other terminals	Power switch off	10 kΩ or higher
   A33-29 (MTH-) or A14-19 (MTH-) - Body ground and other terminals	Power switch off	10 kΩ or higher
   A33-33 (REQ+) or A14-26 (REQ+) - Body ground and other terminals	Power switch off	10 kΩ or higher
   A33-32 (REQ-) or A14-37 (REQ-) - Body ground and other terminals	Power switch off	10 kΩ or higher
   A33-21 (CLK+) or A14-7 (CLK+) - Body ground and other terminals	Power switch off	10 kΩ or higher
   A33-20 (CLK-) or A14-18 (CLK-) - Body ground and other terminals	Power switch off	10 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *a	Rear view of wire harness connector (to Power Management Control ECU)
   *b	Front view of wire harness connector (to Inverter with Converter Assembly)

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
   A33-24 (HTM+) or A14-9 (HTM+) - Body ground	Power switch on (IG)	Below 1 V
   A33-25 (HTM-) or A14-20 (HTM-) - Body ground	Power switch on (IG)	Below 1 V
   A33-30 (MTH+) or A14-8 (MTH+) - Body ground	Power switch on (IG)	Below 1 V
   A33-29 (MTH-) or A14-19 (MTH-) - Body ground	Power switch on (IG)	Below 1 V
   A33-33 (REQ+) or A14-26 (REQ+) - Body ground	Power switch on (IG)	Below 1 V
   A33-32 (REQ-) or A14-37 (REQ-) - Body ground	Power switch on (IG)	Below 1 V
   A33-21 (CLK+) or A14-7 (CLK+) - Body ground	Power switch on (IG)	Below 1 V
   A33-20 (CLK-) or A14-18 (CLK-) - Body ground	Power switch on (IG)	Below 1 V

   NOTE:

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

8. Turn the power switch off.
9. Disconnect the cable from the negative (-) auxiliary battery terminal.
10. Reconnect the A14 inverter with converter assembly connector.
11. Reconnect the A33 power management control ECU connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Disconnect the A33 power management control ECU connector.
2. Measure the resistance according to the value(s) in the table below.

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   Standard Resistance

   Tester Connection	Condition	Specified Condition
   A33-24 (HTM+) - A33-25 (HTM-)	Power switch off	80 to 170 Ω
   A33-30 (MTH+) - A33-29 (MTH-)	Power switch off	80 to 170 Ω
   A33-33 (REQ+) - A33-32 (REQ-)	Power switch off	80 to 170 Ω
   A33-21 (CLK+) - A33-20 (CLK-)	Power switch off	80 to 170 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Component without harness connected (Power Management Control ECU)

3. Reconnect the A33 power management control ECU connector.

NG → See step   33 

OK: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → CONNECT SECURELY 

OK → See step   34 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   31 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   31 

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 service information because this may cause a malfunction.

2. Disconnect the A14 inverter with converter assembly connector.
3. Measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   A14-30 (+B) - Body ground	Power switch off	10 kΩ or higher
   A14-31 (+B2) - Body ground	Power switch off	10 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *a	Front view of wire harness connector (to Inverter with Converter Assembly)

4. Reconnect the A14 inverter with converter assembly connector.

NG → See step   25 

OK: Go to next step 

Refer to COMPONENTS [08/2013 - ]

NEXT → REPLACE FUSE (INV) 

NEXT → REPLACE FUSE (INV) 

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 service information because this may cause a malfunction.

2. Remove the inverter with converter assembly. Refer to COMPONENTS [08/2013 - ] .
3. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

   T = 8.5 N*m (87 kgf*cm, 75 in.*lbf)

   NOTE:

   Make sure that the tightening torque of the bolt is between 6.4 and 10.5 N*m (65 and 107 kgf*cm, 5 and 8 ft.*lbf).

4. Disconnect the generator cable from the hybrid vehicle transaxle assembly.
5. Check for arc marks at the terminals for the generator cable.

   Result

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

6. Connect the generator cable to the hybrid vehicle transaxle assembly.
7. Install the inverter with converter assembly.

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

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 service information because this may cause a malfunction.

2. Remove the generator cable. Refer to COMPONENTS [08/2013 - ] .
3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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 (V) - Body ground and shield ground	Power switch off	100 MΩ or higher
   e1-3 (U) - Body ground and shield ground	Power switch off	100 MΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shield ground
   *a	Generator Cable (Inverter with Converter Assembly Side)
   *b	Generator Cable (Hybrid Vehicle Transaxle Assembly Side)

   NOTE:

   Wrap the terminal of the generator 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 (V) - e2-2 (V)	Power switch off	Below 1 Ω
   e1-3 (U) - e2-3 (U)	Power switch off	Below 1 Ω
   e1-1 (W) - e2-3 (U)	Power switch off	100 MΩ or higher
   e1-2 (V) - e2-1 (W)	Power switch off	100 MΩ or higher
   e1-3 (U) - e2-2 (V)	Power switch off	100 MΩ or higher

5. Install the generator cable.

NG → See step   36 

OK → See step   31 

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 service information because this may cause a malfunction.

2. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

   T = 8.5 N*m (87 kgf*cm, 75 in.*lbf)

   NOTE:

   Make sure that the tightening torque of the bolt is between 6.4 and 10.5 N*m (65 and 107 kgf*cm, 5 and 8 ft.*lbf).

3. Disconnect the motor cable from the hybrid vehicle transaxle assembly.
4. Check for arc marks at the terminals for the motor cable.

   Result

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

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

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

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 service information because this may cause a malfunction.

2. Remove the motor cable. Refer to COMPONENTS [08/2013 - ] .
3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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
   d1-1 (W) - Body ground and shield ground	Power switch off	100 MΩ or higher
   d1-2 (V) - Body ground and shield ground	Power switch off	100 MΩ or higher
   d1-3 (U) - Body ground and shield ground	Power switch off	100 MΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shield ground
   *a	Motor Cable (Inverter with Converter Assembly Side)
   *b	Motor Cable (Hybrid Vehicle Transaxle Assembly Side)

   NOTE:

   Wrap the terminal of the motor 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
   d1-1 (W) - d2-3 (W)	Power switch off	Below 1 Ω
   d1-2 (V) - d2-2 (V)	Power switch off	Below 1 Ω
   d1-3 (U) - d2-1 (U)	Power switch off	Below 1 Ω
   d1-1 (W) - d2-1 (U)	Power switch off	100 MΩ or higher
   d1-2 (V) - d2-3 (W)	Power switch off	100 MΩ or higher
   d1-3 (U) - d2-2 (V)	Power switch off	100 MΩ or higher

5. Install the motor cable.

NG → See step   37 

OK → See step   31