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Home >> Lexus >> 2007 >> RX 400h AWD >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Vehicle Control (P310) - RX400H - DTC P0A7A-309 Through P0A94-589 >> DTC P0A7A-518 Generator Inverter Performance >> Inspection Procedure

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.

  1. READ OUTPUT DTC (HV) 
    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 / DTC INFO / CURRENT CODES.
    4. 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 32S, 517, and 518) Generator inverter function malfunction
      P0A90 Motor function malfunction
      P0A92 Generator function malfunction
      P0A94 (Except for 554 and 555) Boost converter circuit
      P0ADB, 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-518 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 

  2. 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 Connector
    G05201226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  3. 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
    G05201350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  4. CHECK W/ CONVERTER INVERTER ASSEMBLY (GENERATOR) 
    CAUTION: Be sure to wear insulated gloves.
    1. Check that the service plug grip is removed.
    2. Check that the bolts for the 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
    G05201453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  5. CHECK CONNECTION CONDITION OF GENERATOR RESOLVER CONNECTOR (LOOSENESS AND POOR CONTACT) 
    NOTE: Be sure to wear insulated gloves.
    1. Remove the w/ converter inverter assembly. (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 4: Locating Generator Resolver Connector
    G05201556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (MG ECU - GENERATOR RESOLVER) 
    CAUTION: Be sure to wear insulated gloves.
    1. Check that the service plug grip is removed.
    2. Disconnect the I22 connector from the MG ECU.
    3. 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 w/ converter inverter connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing the inspection.
      Fig 5: Disconnecting I22 Connector From MG ECU
      G05278589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the ignition switch off.
    5. 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) - 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
    6. 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: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

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