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 control ECU 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 556)	Boost converter function malfunction
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 malfunction

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.
P0A78-284 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.
Fig 1: Checking Connection Condition Of MG ECU Connector (Looseness And Poor Contact)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

OK: GO TO NEXT STEP

CONFIRM INFORMATION (EXCLUSIVE INFO 4)

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.
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.
Display freeze frame data corresponding to DTC P0A94 and select the information.

Select INF code 556 and read "EXCLUSIVE INFO 4".

Result

INFORMATION (EXCLUSIVE INFO 4)

Displayed item in exclusive information 4	Proceed to
-63 to 64	A
65 to 128	B

B: Go to step 6

A: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - MOTOR RESOLVER)

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 1V
MCSG (I22-18) - Body ground	Below 1 V

Fig 2: Checking Harness And Connector (MG ECU - Motor Resolver)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn the ignition switch off.

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

Standard Resistance

MG ECU - MOTOR RESOLVER (RESISTANCE - 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 (RESISTANCE - 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 7

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - GENERATOR RESOLVER)

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 - GENERATOR RESOLVER (VOLTAGE)

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn the ignition switch off.

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

Standard Resistance

MG ECU - GENERATOR RESOLVER (RESISTANCE - 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 (RESISTANCE - 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 9

OK: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

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

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 4: Disconnecting I21 Connector From MG ECU

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn the ignition switch off.

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

Standard Resistance

MG ECU - REAR MOTOR RESOLVER (RESISTANCE - 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 (RESISTANCE - 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 11

OK: REPLACE REAR TRACTION MOTOR W/TRANSAXLE ASSEMBLY

CHECK CONNECTION CONDITION OF MOTOR RESOLVER CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connections of the motor resolver connector.
  OK:
  
  Connectors are connected securely and there is no poor connection.
Fig 5: Identifying Motor Resolver Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

OK: GO TO NEXT STEP

INSPECT MOTOR RESOLVER

Disconnect the M14 motor resolver connector.

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 MΩ or higher
MRF (M14-1) - MCS (M14-3)	10 MΩ or higher
MSN (M14-2) - MCS (M14-3)	10 MΩ or higher
MRFG (M14-4) - MSNG (M14-5)	10 MΩ or higher
MRFG (M14-4) - MCSG(M14-6)	10 MΩ or higher
MSNG (M14-5) - MCSG (M14-6)	10 MΩ or higher
Each terminal listed above - Transaxle housing	10 MΩ or higher

Fig 6: Inspecting Motor Resolver

NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK CONNECTION CONDITION OF GENERATOR RESOLVER CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Remove the w/ converter inverter assembly.
2. Check the connections of the generator resolver connector.
  OK:
  
  Connectors are connected securely and there is no poor connection.
Fig 7: Identifying Generator Resolver Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

OK: GO TO NEXT STEP

INSPECT GENERATOR RESOLVER

Disconnect the M13 generator resolver connector.

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 (M13-2) - 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 8: Inspecting Generator Resolver

NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK CONNECTION CONDITION OF REAR MOTOR RESOLVER CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connections of the rear motor resolver connector.
  OK:
  
  Connectors are connected securely and there is no poor connection.
Fig 9: Identifying Rear Motor Resolver Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

OK: GO TO NEXT STEP

INSPECT REAR MOTOR RESOLVER

Remove the w/ converter inverter assembly.
Disconnect the M18 rear motor resolver connector.

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 10: Inspecting Rear Motor Resolver

NG: REPLACE REAR TRACTION MOTOR W/TRANSAXLE ASSEMBLY

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR