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.	INF Code	Detection Item
P0A7A	321, 323	Generator inverter function malfunction
P0A3F	243	Motor resolver circuit
P0A40	500	Motor resolver output is out of normal range
P0A41	245	Motor resolver circuit (Low)
P0A45	669	Interphase short in rear motor resolver circuit
P0A46	671	Rear motor resolver output is out of normal range
P0A47	670	Rear motor resolver circuit (Low)
P0A4B	253	Generator resolver circuit
P0A4C	513	Generator resolver output is out of normal range
P0A4D	255	Generator resolver circuit (Low)
P0A93	346	Inverter cooling system
P0A93	347	Inverter cooling system
P0A05	776	Inverter water pump malfunction

NOTE: If a DTC indicating a malfunction in the above systems is output, repair the malfunctioning area indicated by the DTC and check for DTC outputs. If P0A7A-324 is output, replace the w/ converter inverter assembly.

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.
P0A7A-324 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 DTC 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 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.
  OK: Connectors are connected securely and there is no poor connection.
NG: CONNECT SECURELY

Fig 1: Identifying MG ECU Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY