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 (SFI SYSTEM)
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch to the ON position.
3. Select the following menu items: DIAGNOSIS / ENHANCED OBDII / ENGINE / DTC INFO / CURRENT CODES.
4. Read output DTC. (See DTC CHECK / CLEAR )
  Result: DTC is output.
YES: GO TO DTC CHART

NO: Go to next step

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: Any two or more of the following DTCs are output simultaneously

OUTPUT DTC REFERENCE

DTC No.	Relevant Diagnosis
P0A3F-243, P0A40-500, P0A4D-255, P0A1A-791, P0A1A-793, P0A1B-795, P0A41-245, P0A4B-253, P0A4C-513, P0A1A-792, P0A1B-794, P0A1B-796	Motor resolver circuit, Generator resolver circuit

YES: GO TO DTC CHART

NO: Go to next step

CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connections of all HV control ECU connectors.
  OK: Connectors are connected securely and there is no poor connection.
NG: CONNECT SECURELY

Fig 1: Identifying HV Control ECU Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: 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 HYBRID CONTROL SYSTEM )
  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.
  - Be sure to 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

Fig 2: Identifying MG ECU Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - MG ECU)

CAUTION: Be sure to wear insulated gloves.

Disconnect the H38 HV control ECU connector.
Disconnect the I21 MG ECU connector.

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

Standard Resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
GO (H34-15) - GI (I21-24)	Below 1 Ω

Standard Resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
GO (H34-15) or GI (I21-24) - Body ground	10 kΩ or more

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

Fig 3: Identifying MG ECU And HV Control ECU

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 M14 motor resolver connector.
Disconnect the I22 MG ECU connector.

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

Standard Voltage

TESTER CONNECTION AND SPECIFIED CONDITION

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

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.

Fig 4: Disconnecting I22 MG ECU Connector

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 (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
MRF (I22-13) - MRF (M14-1)	Below 1 Ω
MRFG (I22-23) - MRFG (M14-4)	Below 1 Ω
MSN (I22-21) - MSN (M14-2)	Below 1 Ω
MSNG (I22-20) - MSNG (M14-5)	Below 1 Ω
MCS (I22-19) - MCS (M14-3)	Below 1 Ω
MCSG (I22-18) - MCSG (M14-6)	Below 1 Ω

Standard (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
MRF (I22-13) or MRF (M14-1) - Body ground	10 kΩ or more
MRFG (I22-23) or MRFG (M14-4) - Body ground	10 kΩ or more
MSN (I22-21) or MSN (M14-2) - Body ground	10 kΩ or more
MSNG (I22-20) or MSNG (M14-5) - Body ground	10 kΩ or more
MCS (I22-19) or MCS (M14-3) - Body ground	10 kΩ or more
MCSG (I22-18) or MCSG (M14-6) - Body ground	10 kΩ or more

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HARNESS AND CONNECTOR (MG ECU - GENERATOR RESOLVER)

Disconnect the M13 generator resolver connector.

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

Standard Voltage

TESTER CONNECTION AND SPECIFIED CONDITION

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

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.

Fig 5: 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 (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
GRF (I22-12) - GRF (M13-1)	Below 1 Ω
GRFG (I22-22) - GRFG (M13-6)	Below 1 Ω
GSN (I22-11) - GSN (M13-2)	Below 1 Ω
GSNG (I22-10) - GSNG (M13-7)	Below 1 Ω
GCS (I22-9) - GCS (M13-3)	Below 1 Ω
GCSG (I22-8) - GCSG (M13-8)	Below 1 Ω

Standard Resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
GRF (I22-12) or GRF (M13-1) - Body ground	10 kΩ or more
GRFG (I22-22) or GRFG (M13-6) - Body ground	10 kΩ or more
GSN (I22-11) or GSN (M13-2) - Body ground	10 kΩ or more
GSNG (I22-10) or GSNG (M13-7) - Body ground	10 kΩ or more
GCS (I22-9) or GCS (M13-3) - Body ground	10 kΩ or more
GCSG (I22-8) or GCSG (M13-8) - Body ground	10 kΩ or more

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

INSPECT HYBRID VEHICLE CONTROL ECU

Using an oscilloscope, measure the waveform according to the value (s) in the table below.

Fig 6: Identifying Hybrid Vehicle Control ECU Waveform Signal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WAVEFORM VALUE

Item	Condition
Terminal	CH1: W1 +- NE- CH2: W2+ - NE- CH3: NE+ - NE-
Equipment Setting	2 V / DIV, 20 ms / DIV
Condition	After engine warmed up and idling

HINT:

Each amplitude becomes larger with an increase in engine speed.
Each pulse cycle becomes shorter with an increase in engine speed.
DTCs may be detected by noise.

OK: REPLACE HYBRID VEHICLE CONTROL ECU

NG: Go to next step

INSPECT CRANKSHAFT POSITION SENSOR

Disconnect the C3 connector from the crankshaft position sensor.

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

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Condition	Specified Condition
1-2	Cold	1,630 to 2,740 Ω
1-2	Hot	2,065 to 3,225 Ω

HINT:

Terms cold and hot refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (I22 to 212°F).

NG: REPLACE CRANKSHAFT POSITION SENSOR

Fig 7: Identifying Crankshaft Position Sensor Connector Terminals

OK: Go to next step

CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - CRANKSHAFT POSITION SENSOR)

Disconnect the H31 connector from the HV control ECU.

Disconnect the C3 connector from the crankshaft position sensor.

Standard Resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
C3-1 - NE+ (H31-25)	Below 1 Ω
C3-2 - NE- (H31-24)	Below 1 Ω

Standard Resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
C3-1 or NE+ (H31-25) - Body ground	10 kΩ or more
C3-2 or NE- (H31-24) - Body ground	10 kΩ or more

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

Fig 8: Identifying Connectors (HV Control ECU - Crankshaft Position Sensor)

OK: Go to next step

CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)
1. Check the crankshaft position sensor installation.
  OK: Sensor is installed correctly.
NG: TIGHTEN SENSOR

Fig 9: Identifying Installation Position Of Camshaft Position Sensor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step
CHECK CRANKSHAFT POSITION SENSOR PLATE (TEETH OF SENSOR PLATE)
1. Check the teeth of the sensor plate.
  OK: Sensor plate does not have any crack or deformation.
NG: REPLACE CRANKSHAFT POSITION SENSOR PLATE

OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY