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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 P0A91-705 Drive Motor "B" 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
      P0A1A (all details), P0A1B (all details), P0A1C (all details) MG ECU circuit malfunction
      P0A1D (all details) HV ECU circuit malfunction
      P0A3F-243, P0A40-500, P0A41-245 Motor resolver circuit malfunction
      P0A45-669, P0A46-671, P0A47-670 Rear motor resolver circuit malfunction
      P0A4B-253, P0A4C-513, P0A4D-255 Generator resolver circuit malfunction
      P0A51-174, P0A55-687 MG ECU circuit malfunction
      P0A60 (all details), P0A63 (all details) Motor current sensor circuit
      P0A69 (all details), P0A6C (all details) Rear motor current sensor circuit
      P0A72 (all details), P0A75 (all details) Generator current sensor circuit
      P0A78-306, 510, 508, 586, 266, 272, 280, 304, 267, 278, 283, 285, 305, 523 Motor inverter function malfunction
      P0A79-703, 704, 701, 672, 690, 691, 697, 698 Rear motor inverter function malfunction
      P0A7A-344, 522, 520, 309, 321, 323, 342, 343 Generator inverter function malfunction
      P0A90-509 Motor function malfunction
      P0A91-702 Rear motor function malfunction
      P0A92-521 Generator function malfunction
      P0A94-585, 587, 561, 551, 588, 589, 545, 546, 552, 558, 559, 590 Boost converter circuit
      P0AA6 (all details), P3004-132 High-voltage system
      P3232-749, P3233-750 HV gate shutdown wiring malfunction

      HINT:

      • Turning the ignition switch to the ON position with the service plug grip and inverter cover removed causes interlock switch system DTC P0AOD-350 to be output.
      • P0A91-705 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. REPRODUCTION TEST 
    1. Connect the intelligent tester to the DLC3.
    2. Test-drive the vehicle at a speed of 40 km/h for approximately 1 minute.
    3. Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES.
    4. Read output DTCs. (See DTC CHECK / CLEAR )

      Result 

      DTC RESULT DESCRIPTION

      DTC output. Proceed to
      P0A79-704 or P0A91-702 is output A
      P0A91-705 is output or no DTC is output B

    A: GO TO  DTC CHART 

    B: Go to next step 

  3. CHECK REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY 
    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. Check that the bolts for the three-phase AC cable of the rear traction motor w/ transaxle assembly are tightened to the specified torque.

    Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

    NG: TIGHTEN THEM TO SPECIFIED TORQUE 

    Fig 1: Identifying Rear Traction Motor W/ Transaxle Assembly Bolts
    G05201481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  4. CHECK CONNECTION CONDITION OF MG ECU CONNECTOR (LOOSENESS AND POOR CONTACT) 
    CAUTION: Be sure to wear insulated gloves.
    1. Check that the service plug grip is removed.
    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 Connector Terminals
    G05201350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CHECK W/ CONVERTER INVERTER ASSEMBLY (REAR MOTOR) 
    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 of the rear traction motor w/ transaxle assembly 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 Three-Phase AC Cable Of Rear Traction Motor W/ Transaxle Assembly
    G05278615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  6. CHECK FRAME WIRE NO.3 
    CAUTION: Be sure to wear insulated gloves.
    1. Turn the ignition switch off and remove the service plug grip.
      NOTE: Do not put the vehicle into the READY-on state with the service plug grip removed as this may cause a malfunction.
    2. Disconnect the three-phase AC cable for Rear Motor from the rear traction motor w/ transaxle assembly.
      Fig 4: Identifying Three-Phase AC Cable Of Rear Motor
      G05201256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the three-phase AC cable for Rear Motor from the w/ converter inverter assembly.
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      U - U Below 1 Ω
      V - V Below 1 Ω
      W - W Below 1 Ω

    NG: REPLACE FRAME WIRE NO.3 

    Fig 5: Identifying Shielded Wire Ground
    G05201437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  7. INSPECT EXTENSION WIRE ASSEMBLY 
    1. Remove the rear traction motor w/ transaxle assembly. (See REMOVAL )
    2. Remove the extension wire assembly from the rear traction motor w/transaxle assembly. (See REMOVAL )
    3. 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 - Shield shell 10 MΩ or higher
      V - Shield shell 10 MΩ or higher
      W - Shield shell 10 MΩ or higher
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      U - U Below 1 Ω
      V - V Below 1 Ω
      W - W Below 1 Ω

    NG: REPLACE EXTENSION WIRE ASSEMBLY 

    Fig 6: Identifying Extension Wire Assembly Terminals
    G05201410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY 

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