Inspection Procedure

CAUTION:

Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are working on the high-voltage system.
After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:

At least 5 minutes is required to discharge the high-voltage capacitor inside the w/ converter inverter assembly.

READ OUTPUT DTC (HV)

Connect the intelligent tester to the DLC3.
Turn the ignition switch to the ON position.
Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES.

Read output DTC. (See DTC CHECK / CLEAR )

Result:

The DTCs shown in the table below are output

OUTPUT DTC (HV)

DTC No.	Relevant Diagnosis
P0A1D	HV ECU circuit malfunction
P0A2B, P0A2C, P0A2D	Motor temperature sensor circuit
P0A37, P0A38, P0A39	Generator temperature sensor circuit
P0A3F, P0A40, P0A41	Motor resolver circuit
P0A4B, P0A4C, P0A4D	Generator resolver circuit
P0A60, P0A63	Motor current sensor circuit
P0A72, P0A75	Generator current sensor circuit
P0A78	Motor inverter function malfunction
P0A7A	Generator inverter function malfunction
P0A90	Motor function malfunction
P0A92	Generator function malfunction
P0A94	(Except for 554 and 555) Boost converter circuit
P0AA1, P0AA2, P0AA4, P0AA5	System main relay circuit
P0AA6, P3004	High-voltage system
P0A79	Rear motor inverter function malfunction
P0A45, P0A46, P0A47	Rear motor resolver malfunction
P0A69, P0A6C, P0A55	Rear motor current sensor circuit
P0AF8	Hybrid battery system voltage

HINT:

Turning the ignition switch to the ON position with the service plug grip and inverter cover removed causes interlock switch system DTC P0A0D-350 to be output.
P0A94-554 and P0A94-505 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

YES: GO TO DIAGNOSTIC TROUBLE CODE CHART

NO: GO TO NEXT STEP

CHECK CONNECTION CONDITION OF MG ECU CONNECTOR (LOOSENESS AND POOR CONTACT)
CAUTION: Be sure to wear insulated gloves.
1. Turn the ignition switch off and remove the service plug grip. (See PRECAUTION )
  NOTE: Do not put the vehicle into the READY-on state with the service plug grip removed as this may cause a malfunction.
2. Remove the inverter cover. (See INVERTER WITH CONVERTER )
  NOTE:
  - Wrap the interlock round terminal for the inverter cover with vinyl tape to prevent it from shorting to ground.
  - Prevent water in the reservoir tank from entering the inverter.
  - Removing the inverter cover causes the MG ECU board to be exposed. Therefore, temporarily install the inverter cover for each area to be inspected.
3. Check the connections of the MG ECU connectors.
  OK:
  
  Connectors are connected securely and there is no poor connection.
NG: CONNECT SECURELY

OK: GO TO NEXT STEP

INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR)

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the three-phase AC cable for Motor from the w/ converter inverter assembly.

Fig 2: Identifying Three-Phase AC Cable For Motor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR) (USING MILLIOHMMETER)

Tester Connection	Specified Condition
U - V	48 to 59 mΩ (20°C)
V - W	48 to 59 mΩ (20°C)
W - U	48 to 59 mΩ (20°C)

Fig 3: Identifying Three-Phase AC Cable For Motor (Shielded Wire Ground)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: If the Motor temperature is too high, the resistance changes greatly. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

To correct the resistance varying depending on the temperature, use the following formula to calculate the resistance at 20°C.
HINT:
- R20 = Rt / {1 + 0.00393 X (T - 20)}
- R20: Resistance at 20°C (mΩ)
- Rt: Measured resistance (mΩ)
- T: Temperature when the resistance is measured (°C)
Calculate the difference between the maximum and minimum resistance.
Standard Resistance:

Difference is 5 mΩ or less

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

Standard Resistance

HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR) (USING MEGOHMMETER)

Tester Connection	Specified Condition
U - Body ground and shielded wire ground	10 MΩ or higher
V - Body ground and shielded wire ground	10 MΩ or higher
W - Body ground and shielded wire ground	10 MΩ or higher

NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK: GO TO NEXT STEP

INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR)

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the three-phase AC cable for Generator from the w/ converter inverter assembly.

Fig 4: Identifying Three-Phase AC Cable Of Generator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR) (MILLIOHMMETER)

Tester Connection	Specified Condition
U - V	109 mΩ or less (20°C)
V - W	109 mΩ or less (20°C)
W - U	109 mΩ or less (20°C)

NOTE: If the Generator temperature is too high, the resistance varies greatly. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

Fig 5: Identifying Three-Phase AC Cable For Generator (Shielded Wire Ground)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

To correct the resistance varying depending on the temperature, use the following formula to calculate the resistance at 20°C.
HINT:
- R20 = Rt / {1 + 0.00393 X (T - 20)}
- R20: Resistance at 20 °C (mΩ)
- Rt: Measured resistance (mΩ)
- T: Temperature when the resistance is measured (°C)
Calculate the difference between the maximum and minimum resistance.
Standard Resistance:

Difference is 3 mΩ or less

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

Standard Resistance

HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR) (MEGOHMMETER)

Tester Connection	Specified Condition
U - Body ground and shielded wire ground	10 MΩ or higher
V - Body ground and shielded wire ground	10 MΩ or higher
W - Body ground and shielded wire ground	10 MΩ or higher

NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK: GO TO NEXT STEP

INSPECT REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the three-phase AC cable for Rear Motor from the w/ converter inverter assembly.

Fig 6: Identifying Three-Phase AC Cable For Rear Motor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR) (USING MILLIOHMMETER)

Tester Connection	Specified Condition
U - V	109 mΩ or less (20°C)
V - W	109 mΩ or less (20°C)
W - U	109 mΩ or less (20°C)

NOTE: If the Rear Motor temperature is too high, the resistance varies greatly. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

Fig 7: Identifying Three-Phase AC Cable For Rear Motor Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

To correct the resistance varying depending on the temperature, use the following formula to calculate the resistance at 20°C.
HINT:
- R20 = Rt / {1 + 0.00393 X (T - 20)}
- R20: Resistance at 20°C (mΩ)
- Rt: Measured resistance (mΩ)
- T: Temperature when the resistance is measured (°C)
Calculate the difference between the maximum and minimum resistance.
Standard Resistance:

Difference is 5 mΩ or less

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

Standard Resistance

HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR) (USING MEGOHMMETER)

Tester Connection	Specified Condition
U - Body ground and shielded wire ground	10 MΩ or higher
V - Body ground and shielded wire ground	10 MΩ or higher
W - Body ground and shielded wire ground	10 MΩ or higher

NG: Go to step 16

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - MOTOR RESOLVER)

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the I22 connector from the MG ECU.

Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

Standard Voltage

MG ECU - MOTOR RESOLVER (VOLTAGE)

Tester Connection	Specified Condition
MRF (I22-13) - Body ground	Below 1 V
MRFG (I22-23) - Body ground	Below 1 V
MSN (I22-21) - Body ground	Below 1 V
MSNG (I22-20) - Body ground	Below 1 V
MCS (I22-19) - Body ground	Below 1 V
MCSG (I22-18) - Body ground	Below 1 V

Fig 8: Checking Harness And Connector (MG ECU - Motor Resolver)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Turning the ignition switch to the ON position with the MG ECU connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing the inspection.

Turn the ignition switch off.

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

Standard Resistance

MG ECU - MOTOR RESOLVER (IGNITION SWITCH OFF - 1 OF 2)

Tester Connection	Specified Condition
MRF (I22-13) - MRFG (I22-23)	7.65 to 10.2 Ω
MSN (I22-21) - MSNG (I22-20)	12.6 to 16.8 Ω
MCS (I22-19) - MCSG (I22-18)	12.6 to 16.8 Ω

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

Standard Resistance

MG ECU - MOTOR RESOLVER (IGNITION SWITCH OFF - 2 OF 2)

Tester Connection	Specified Condition
MRF (I22-13) or MRFG (I22-23) - Body ground	10 kΩ or higher
MSN (I22-21) or MSNG (I22-20) - Body ground	10 kΩ or higher
MCS (I22-19) or MCSG (I22-18) - Body ground	10 kΩ or higher

NG: Go to step 13

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - GENERATOR RESOLVER)

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the I22 connector from the MG ECU.

Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

Standard Resistance

MG ECU - GENERATOR RESOLVER (IGNITION SWITCH ON)

Tester Connection	Specified Condition
GRF (I22-12) - Body ground	Below 1 V
GRFG (I22-22) - Body ground	Below 1 V
GSN (I22-11) - Body ground	Below 1 V
GSNG (I22-10) - Body ground	Below 1 V
GCS (I22-9) - Body ground	Below 1 V
GCSG (I22-8) - Body ground	Below 1 V

Fig 9: Checking Harness And Connector (MG ECU - Generator Resolver)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Turning the ignition switch to the ON position with the MG ECU connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing the inspection.

Turn the ignition switch off.

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

Standard Resistance

MG ECU - GENERATOR RESOLVER (IGNITION SWITCH OFF - 1 OF 2)

Tester Connection	Specified Condition
GRF (I22-12) - GRFG (I22-22)	7.65 to 10.2 Ω
GSN (I22-11) - GSNG (I22-10)	12.6 to 16.8 Ω
GCS (I22-9) - GCSG (I22-8)	12.6 to 16.8 Ω

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

Standard Resistance

MG ECU - GENERATOR RESOLVER (IGNITION SWITCH OFF - 2 OF 2)

Tester Connection	Specified Condition
GRF (I22-12) or GRFG (I22-22) - Body ground	10 kΩ or higher
GSN (I22-11) or GSNG (I22-10) - Body ground	10 kΩ or higher
GCS (I22-9) or GCSG (I22-8) - Body ground	10 kΩ or higher

NG: Go to step 14

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - REAR MOTOR RESOLVER)

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the I21 connector from the MG ECU.

Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

Standard Voltage

MG ECU - REAR MOTOR RESOLVER VOLTAGE

Tester Connection	Specified Condition
RRF (I21-21) - Body ground	Below 1 V
RRFG (I21-22) - Body ground	Below 1 V
RSN (I21-29) - Body ground	Below 1 V
RSNG (I21-30) - Body ground	Below 1 V
RCS (I21-11) - Body ground	Below 1 V
RCSG (I21-23) - Body ground	Below 1 V

Fig 10: Checking Harness And Connector (MG ECU - Rear Motor Resolver)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Turning the ignition switch to the ON position with the MG ECU connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing the inspection.

Turn the ignition switch off.

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

Standard Resistance

MG ECU - REAR MOTOR RESOLVER (IGNITION SWITCH OFF - 1 OF 2)

Tester Connection	Specified Condition
RRF (I21-21) - RRFG (I21-22)	7.65 to 10.2 Ω
RSN (I21-29) - RSNG (I21-30)	12.6 to 16.8 Ω
RCS (I21-11) - RCSG (I21-23)	12.6 to 16.8 Ω

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

Standard Resistance

MG ECU - REAR MOTOR RESOLVER (IGNITION SWITCH OFF - 2 OF 2)

Tester Connection	Specified Condition
RRF (I21-21) or RRFG (I21-22) - Body ground	10 kΩ or higher
RSN (I21-29) or RSNG (I21-30) - Body ground	10 kΩ or higher
RCS (I21-11) or RCSG (I21-23) - Body ground	10 kΩ or higher

NG: Go to step 15

OK: GO TO NEXT STEP

CHECK AMOUNT OF GASOLINE
1. Turn the ignition switch to the ON position. Check the amount of fuel with the fuel gauge in the meter.
  OK:
  
  Proper amount of fuel is in the tank.
NG: REFUEL GASOLINE AND GO TO STEP 10

OK: GO TO NEXT STEP
CHECK ENGINE START
1. Put the vehicle into the READY-on state.
2. Depress the accelerator pedal with the shift lever in the P position.
  OK:
  
  The engine starts.
NG: Go to step 12

OK: GO TO NEXT STEP
CHECK ENGINE IDLING
1. Turn the ignition switch off.
2. Connect the intelligent tester to the DLC3.
3. Put the vehicle into the READY-on state.
4. Leave the vehicle as it is until the engine automatically starts.
  HINT:
  
  Leaving the vehicle with the A/C switch in the MAX COOL position makes it easier for the engine to start.
5. Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES.
6. Read output DTC. (See DTC CHECK / CLEAR ).
  OK:
  
  No DTCs are output 1 minute after the engine is started.
NG: GO TO DIAGNOSTIC TROUBLE CODE CHART

OK: LEAVE VEHICLE IN P POSITION, AND CHARGE HV BATTERY IN IDLE STATUS UNTIL IDLING STOPS
READ OUTPUT DTC (HV)
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch to the ON position.
3. Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES.
4. Read output DTC. (See DTC CHECK / CLEAR )
  Result:
  
  DTC other than P0494 is not output.
NO: GO TO DIAGNOSTIC TROUBLE CODE CHART

YES: REPLACE W/ CONVERTER INVERTER ASSEMBLY

INSPECT MOTOR RESOLVER

Disconnect the M14 motor resolver connector.

Fig 11: Identifying Motor Resolver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

MOTOR RESOLVER

Tester Connection	Specified Condition
MRF (M14-1) - MRFG (M14-4)	7.65 to 10.2 Ω
MSN (M14-2) - MSNG (M14-5)	12.6 to 16.8 Ω
MCS (M14-3) - MCSG (M14-6)	12.6 to 16.8 Ω

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

Standard Resistance

MOTOR RESOLVER (USING MEGOHMMETER)

Tester Connection	Specified Condition
MRF (M14-1) - MSN (M14-2)	10 MΩor higher
MRF (M14-1) - MCS (M14-3)	10 MΩor higher
MSN (M14-2) - MCS (M14-3)	10 MΩor higher
MRFG (M14-4) - MSNG (M14-5)	10 MΩor higher
MRFG (M14-4) - MCSG(M14-6)	10 MΩor higher
MSNG (M14-5) - MCSG (M14-6)	10 MΩor higher
Each terminal listed above - Transaxle housing	10 MΩor higher

Fig 12: Inspecting Motor Resolver

NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

INSPECT GENERATOR RESOLVER

Remove the w/ converter inverter assembly.
Disconnect the M13 generator resolver connector.

Fig 13: Identifying Generator Resolver Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

GENERATOR RESOLVER

Tester Connection	Specified Condition
GRF (M13-1) - GRFG (M13-6)	7.65 to 10.2 Ω
GSN (M13-2) - GSNG (M13-7)	12.6 to 16.8 Ω
GCS (M13-3) - GCSG (M13-8)	12.6 to 16.8 Ω

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

Standard Resistance

GENERATOR RESOLVER (USING MEGOHMMETER)

Tester Connection	Specified Condition
GRF (M13-1) - GSN (M13-2)	10 MΩ or higher
GRF (M13-1) - GCS (M13-3)	10 MΩ or higher
GSN (G13-2) - GCS (M13-3)	10 MΩ or higher
GRFG (M13-6) - GSNG (M13-7)	10 MΩ or higher
GRFG (M13-6) - GCSG (M13-8)	10 MΩ or higher
GSNG (M13-7) - GCSG (M13-8)	10 MΩ or higher
Each terminal listed above - Transaxle housing	10 MΩ or higher

Fig 14: Inspecting Generator Resolver

NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

INSPECT REAR MOTOR RESOLVER

Disconnect the M18 rear motor resolver connector.

Fig 15: Identifying Rear Motor Resolver Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

REAR MOTOR RESOLVER

Tester Connection	Specified Condition
RRF (M18-1) - RRFG (M18-4)	7.65 to 10.2 Ω
RSN (M18-2) - RSNG (M18-5)	12.6 to 16.8 Ω
RCS (M18-3) - RCSG (M18-6)	12.6 to 16.8 Ω

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

Standard Resistance

REAR MOTOR RESOLVER (USING MEGOHMMETER)

Tester Connection	Specified Condition
RRF (M18-1) - RSN (M18-2)	10 MΩ or higher
RRF (M18-1) - RCS (M18-3)	10 MΩ or higher
RSN (M18-2) - RCS (M18-3)	10 MΩ or higher
RRFG (M18-4) - RSNG (M18-5)	10 MΩ or higher
RRFG (M18-4) - RCSG (M18-6)	10 MΩ or higher
RSNG (M18-5) - RCSG (M18-6)	10 MΩ or higher
Each terminal listed above - Transaxle housing	10 MΩ or higher

Fig 16: Inspecting Rear Motor Resolver

NG: REPLACE REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

INSPECT FRAME WIRE NO. 3

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the frame wire No. 3 from the rear traction motor w/ transaxle assembly.

Fig 17: Identifying Frame Wire No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

FRAME WIRE NO. 3 (USING MEGOHMMETER)

Tester Connection	Specified Condition
U - Body ground and shielded wire ground	10 MΩ or higher
V - Body ground and shielded wire ground	10 MΩ or higher
W - Body ground and shielded wire ground	10 MΩ or higher

NOTE: Wrap the terminals U, V and W of the w/ converter inverter assembly side No. 3 wire frame (three-phase AC cable of the rear traction motor w/ transaxle assembly) with the insulating tape to prevent them from shorting to ground.

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

Standard Resistance

FRAME WIRE NO. 3

Tester Connection	Specified Condition
U - V	10 kΩ or higher
U - W	10 kΩ or higher
V - W	10 kΩ or higher

Fig 18: Identifying Three-Phase AC Cable For Rear Motor (W/ Converter Inverter Assembly Side And Rear Traction W/Transaxle Assembly Side)

NG: REPLACE FRAME WIRE NO. 3

OK: GO TO NEXT STEP

INSPECT EXTENSION WIRE ASSEMBLY

Remove the rear traction motor w/ transaxle assembly. (See OIL PUMP ASSEMBLY )
Remove the extension wire assembly from the rear traction motor w/ transaxle assembly. (See OIL PUMP ASSEMBLY )

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

Standard Resistance

EXTENSION WIRE ASSEMBLY (USING MEGOHMMETER)

Tester Connection	Specified Condition
U - Shield shell	10 MΩ or higher
V - Shield shell	10 MΩ or higher
W - Shield shell	10 MΩ or higher

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

Standard Resistance

EXTENSION WIRE ASSEMBLY

Tester Connection	Specified Condition
U - U	Below 1 Ω
V - V	Below 1 Ω
W - W	Below 1 Ω

Fig 19: Inspecting Extension Wire Assembly

NG: REPLACE EXTENSION WIRE ASSEMBLY

OK: REPLACE REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY