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
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 (Except for 325 and 517)	Generator inverter function malfunction
P0A90	Motor function malfunction
P0A92	Generator function malfunction
P0A94 (Except for 554 and 555)	Boost converter circuit
POADB, P0ADC, P0ADF, P0AE0, P0AE6, P0AE7	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
P0A1A, P0A1B, P0A1C	MG ECU 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.
P0A7A-325 and P0A78-517 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 HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connections of the HV control ECU connectors.
  OK: Connectors are connected securely and there is no poor connection.
NG: CONNECT SECURELY

Fig 1: Identifying HV Control ECU Connectors
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.
  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 W/ CONVERTER INVERTER ASSEMBLY
CAUTION: Be sure to wear insulated gloves.
1. Check that the service plug grip and the inverter cover are removed.
2. Check that the bolts for the HV Generator three-phase AC cable for Generator are tightened to the specified torque.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NG: TIGHTEN THEM TO SPECIFIED TORQUE

Fig 3: Identifying Bolts For HV Generator Three-Phase AC Cable
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step

CHECK 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 cables for Motor and Generator from the w/ converter inverter assembly.

Fig 4: Locating Three-Phase AC Cables Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Specified Condition
U - V	36 to 43 mΩ (20°C)
V - W	36 to 43 mΩ (20°C)
W - U	36 to 43 mΩ (20°C)

Fig 5: Identifying Three-Phase AC Cables Terminals For Generator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: If the Generator 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 3 mΩ or less

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
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

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 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

Fig 6: Disconnecting I22 Connector From MG ECU

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

TESTER CONNECTION AND SPECIFIED CONDITION

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

TESTER CONNECTION AND SPECIFIED CONDITION

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

OK: GO TO step 9

NG: Go to next step

CHECK CONNECTION CONDITION OF GENERATOR RESOLVER CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Remove the w/ converter inverter. (See INVERTER WITH CONVERTER )
2. Check the connection of the generator resolver connector.
  OK: Connector is connected securely and there is no poor connection.
NG: CONNECT SECURELY

Fig 7: Locating Generator Resolver Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

TESTER CONNECTION AND SPECIFIED CONDITION

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.

Fig 8: Identifying M13 Generator Resolver Connector Terminals

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
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

NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK: REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK ENGINE START
1. Put the vehicle into the READY-on state. Check if the engine starts.
  OK: The engine starts.
OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY

NG: Go to next step
CRANKSHAFT PULLEY REVOLUTION (P POSITION)
1. Turn the ignition switch off, move the shift lever to the P position, and lift up the vehicle.
  CAUTION: Do not put the vehicle into the READY-on state while performing this inspection. Be sure to turn the ignition switch off because the engine may start.
  
  OK: The crankshaft rotates.
OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY

NG: Go to next step
CRANKSHAFT PULLEY REVOLUTION (N POSITION)
1. Turn the ignition switch off, move the shift lever to the N position, and lift up the vehicle.
  CAUTION: Do not put the vehicle into the READY-on state while performing this inspection. Be sure to turn the ignition switch off because the engine may start.
  
  OK: The crankshaft rotates.
NG: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

NG: REPAIR OR REPLACE ENGINE