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 DTCs. (See DTC CHECK / CLEAR )

Result: The DTCs shown in the table below are output

DTCS RESULT DESCRIPTION

DTC No.	Relevant Diagnosis
P0A94-547, 548, 549	Boost converter circuit
P0AA6-526, 613, 655	High-voltage insulation problem detection circuit
POADB-227, P0ADF-229	SMR circuit
P3004-131, 803	High-voltage system
P0A93-346, 347, P0A05-776	Inverter cooling system

YES: GO TO DTC CHART

NO: Go to next step

CHECK RELAY BLOCK ASSEMBLY
1. Check the installation of the fusible links (DC/DC and MAIN) and fuse (DC/DC-S) in the relay block. Check if the circuits are open.
  OK: They are connected securely. There are no open circuits in the fuse or fusible links.
NG: REPLACE FUSIBLE LINK OR FUSE, OR REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: 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.
  - 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.
  Standard: 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 INSULATION RESISTANCE OF HIGH-VOLTAGE SYSTEM

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.

Using a megohmmeter, measure the insulation 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 AND SPECIFIED CONDITION

Tester Connection	Specified Condition
Three-phase AC Cable for Motor U - Body ground and shielded wire ground	1 MΩ or higher
Three-phase AC Cable for Motor V - Body ground and shielded wire ground	1 MΩ or higher
Three-phase AC Cable for Motor W - Body ground and shielded wire ground	1 MΩ or higher

HINT:

Perform this inspection with the three-phase AC cable of the Motor connected.

NG: GO TO step 11

Fig 3: Identifying Three Phase AC Cable For Motor

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK CONNECTION OF AMD TERMINAL
CAUTION: Be sure to wear insulated gloves.
1. Check that the service plug grip is removed.
  
  Fig 4: Identifying Three-Phase AC Cable For Rear Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the three-phase AC cable for the Rear Motor from the w/ converter inverter assembly.
3. Check the connection of the AMD terminal.
  OK: Terminal is connected securely and there is no poor connection.
NG: GO TO step 13

Fig 5: Identifying Converter Inverter Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK AMD TERMINAL VOLTAGE (W/ CONVERTER INVERTER ASSEMBLY SIDE)

CAUTION: Be sure to wear insulated gloves.

Turn the ignition switch off.
Check that the service plug grip is removed.

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

Standard Voltage

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
AMD terminal (w/ converter inverter assembly side) -Body ground	10 to 14 V

NG: GO TO step 19

Fig 6: Identifying AMD Terminal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

INSPECT MG ECU

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Turn the ignition switch to the ON position.
NOTE: Do not put the vehicle into the READY-on state with the service plug grip removed as this may cause a malfunction.

HINT:

Turning the ignition switch to the ON position with the service grip and inverter cover removed causes interlock switch system DTC P0A0D-350 to be output.

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

Standard Voltage

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
+B (I21-7) - Body ground	10 to 14 V
+B2 (I21-4) - Body ground	10 to 14 V
SI (I21-35) - Body ground	10 to 14 V

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

Fig 7: Identifying MG ECU Connectors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE HV CONTROL ECU)

Turn the ignition switch off.
(b)Disconnect the I21 connector from the MG ECU.

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

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
NODD (I21-33) - Body ground	120 to 140 kΩ

NG: GO TO step 20

Fig 8: Disconnecting I21 Connector From MG ECU

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK OPERATION DC/DC CONVERTER

HINT:

The current at the AMD terminal cannot be measured directly because of space limitations. Measure the current flowing from the auxiliary battery instead.

Connect the AC/DC 400 A probe to the positive auxiliary battery line.
Install the inverter cover. (See INVERTER WITH CONVERTER )
Install the service plug grip.
Put the vehicle into the READY-on state and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.

Fig 9: Checking Operation DC/DC Converter (1 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the current flowing from the auxiliary battery with the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on. (*1)

Measure the auxiliary battery voltage according to the previous conditions (*1).

Standard Current and Voltage

MEASUREMENT ITEM AND SPECIFIED CONDITION

Measurement Item	Specified Condition
Current flowing from auxiliary battery	0 A or less (no current from auxiliary battery)
Auxiliary battery voltage	13 to 15 V

Fig 10: Checking Operation DC/DC Converter (2 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: GO TO step 14

NG: REPLACE W/ CONVERTER INVERTER ASSEMBLY

INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR AND GENERATOR)

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the three-phase AC cables of the HV transaxle assembly (Motor and Generator) from the w/ converter inverter assembly.

Fig 11: Locating Three-Phase AC Cable For Motor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a megohmmeter, measure the insulation 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.

Fig 12: Identifying Three-Phase AC Cables For Motor And Generator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
Three-phase AC cable for Motor U terminal - Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Motor V terminal - Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Motor W terminal - Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Generator U terminal -Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Generator V terminal -Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Generator W terminal -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 the Rear Motor from the w/ converter inverter assembly.

Fig 13: Locating Three-Phase AC Cable For Rear Motor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a megohmmeter, measure the insulation 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.

Fig 14: Identifying Shielded Wire Ground

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
Three-phase AC cable for Rear Motor U terminal -Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Rear Motor V terminal -Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Rear Motor W terminal -Body ground and shielded wire ground	10 MΩ or higher

NG: GO TO step 21

OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY

CHECK AMD TERMINAL
CAUTION: Be sure to wear insulated gloves.
1. Check for ark marks on the AMD terminals (w/ converter inverter assembly side and wire harness side).
  OK: There are no ark marks.
  
  HINT:
  
  The wire harness between the AMD terminal on the w/ converter inverter assembly side and the AMD terminal on the vehicle side is supplied with the w/ converter inverter assembly as a unit. If the wire harness is faulty, replace the w/ converter inverter assembly.
NG: REPLACE W/ CONVERTER INVERTER ASSEMBLY

Fig 15: Identifying AMD Terminal On W/ Converter Inverter Assembly Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: CONNECT SECURELY
CHECK QUANTITY OF COOLANT (FOR INVERTER)
1. Check the coolant level.
  OK: There is a sufficient amount of coolant.
NG: CHECK FOR COOLANT LEAKS AND ADD COOLANT (FOR INVERTER)

OK: Go to next step
CHECK COOLANT HOSE
1. Check if the hoses of the cooling system are not bent or clogged.
  OK: The hoses of the cooling system are not bent or clogged.
NG: CORRECT TO NORMAL CONDITION

Fig 16: Identifying Water Pump And Bracket Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step
CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connection of the water pump w/ motor & bracket assembly connector.
  OK: Connector is connected securely and there is no poor connection.
NG: CONNECT SECURELY

Fig 17: Identifying Water Pump W/ Motor & Bracket Assembly Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step
PERFORM ACTIVE TEST BY INTELLIGENT TESTER (WATER PUMP)
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 / ACTIVE TEST / WATER PUMP.
4. During the WATER PUMP active test, check operation of the water pump.
  OK: There are ripples in the reservoir tank coolant.
  
  HINT:
  
  The water pump is also activated in the READY-on state.
NG: INSPECT WATER PUMP W/ MOTOR & BRACKET ASSEMBLY CIRCUIT

OK: Go to next step
PERFORM ACTIVE TEST BY INTELLIGENT TESTER (COOLING FAN)
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 OBD II / ENGINE / ACTIVE TEST / COOLING FAN.
4. Perform the COOLING FAN active test.
  OK: Electrical cooling fan operate.
NG: CHECK COOLING FAN CIRCUIT

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK AMD TERMINAL (VEHICLE SIDE)

Turn the ignition switch off.

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

Standard Voltage

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
AMD terminal - Body ground	10 to 14 V

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

Fig 18: Locating AMD Terminal (Vehicle Side)

OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY

INSPECT HYBRID VEHICLE CONTROL ECU

Turn the ignition switch off and disconnect all HV control ECU connectors.

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

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
NODD (H34-11) - E1 (H31-5)	120 to 140 kΩ

NG: REPLACE HYBRID VEHICLE CONTROL ECU

Fig 19: Disconnecting HV Control ECU Connectors

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

INSPECT REAR TRACTION MOTOR W/TRANSAXLE ASSEMBLY

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the frame wire No.3 (three-phase AC cable for Rear Motor) from the rear traction motor w/ transaxle assembly.

Fig 20: Locating Frame Wire No.3 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a megohmmeter, measure the insulation 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.

Fig 21: Identifying Shielded Wire Ground

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
Three-phase AC cable for Rear Motor U terminal -Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Rear Motor V terminal -Body ground and shielded wire ground	10 MΩ or higher
Three-phase AC cable for Rear Motor W terminal -Body ground and shielded wire ground	10 MΩ or higher

NOTE: Wrap terminals U, V, and W of the frame wire No.3 (three-phase AC cable for Rear Motor) on the w/ converter inverter assembly side with insulation tape to prevent the terminals from contacting the ground.

NG: REPLACE FRAME WIRE NO.3

OK: REPLACE REAR TRACTION MOTOR W/TRANSAXLE ASSEMBLY