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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 P0A94-549 DC / DC Converter 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. INF Code Detection Item
      P0A3F 243 Motor resolver circuit
      P0A40 500 Motor resolver output is out of normal range
      P0A41 245 Motor resolver malfunction (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 malfunction (Low)
      P0A4B 253 Generator resolver circuit
      P0A4C 513 Generator resolver output is out of normal range
      P0A4D 255 Generator resolver malfunction (Low)
      P0A78 266, 280 Motor inverter function malfunction
      P0A94 558, 559, 588, 589 Boost converter circuit malfunction
      P0A95 123 High voltage fuse blown out
      P0ADC 226 SMR+ stuck closed
      P0ADB 227 SMR+ stuck open
      P0AE0 228 SMR- stuck closed
      P0ADF 229 SMR- stuck open
      P3004 803 High-current 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.
      • P0A94-549 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 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.
    3. Check the connections of all MG ECU connectors.

      OK: Connectors are connected securely and there is no poor connection. 

    OK: CONNECT SECURELY 

    Fig 1: Identifying MG ECU Connector Terminals
    G05201350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: Go to next step 

  3. INSPECT HV RELAY ASSEMBLY (SMR2) 
    CAUTION: Be sure to wear insulated gloves.
    1. Check that the service plug grip is removed.
    2. Remove the HV relay assembly from the vehicle.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      S47-1 - S44-1 Below 1 Ω (Apply auxiliary battery voltage between terminals CON2 (S48-1) and GND (S48-4))
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      CON2 (S48-1) - GND (S48-4) 20 to 60 Ω at -35 to 80°C (-31 to 176°F)

    NG: REPLACE HV RELAY ASSEMBLY 

    Fig 2: Identifying HV Relay Assembly
    G05278472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  4. INSPECT HV RELAY ASSEMBLY (SMR3) 
    CAUTION: Be sure to wear insulated gloves.
    1. Check that the service plug grip is removed.
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      S49-1 - S45-1 Below 1 Ω (Apply auxiliary battery voltage between terminals CON3 (S48-2) and GND (S48-4))
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      CON3 (S48-2) - GND (S48-4) 20 to 60 Ω at -35 to 80°C (-31 to 176°F)

    NG: REPLACE HV RELAY ASSEMBLY 

    Fig 3: Identifying S45 And S49 HV Relay Assembly (SMR2)
    G05278637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  5. CONFIRM INFORMATION (EXCLUSIVE INFO 4) 
    1. Connect the intelligent tester to the DLC3.
    2. Turn the ignition switch to the ON position.

      HINT:

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

    3. Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES.
    4. Read output DTCs.
    5. Display freeze frame data corresponding to DTC P0A94 and select the information.
    6. Select INF code 556 and read "EXCLUSIVE INFO 4".

      Result 

      DTC RESULT DESCRIPTION

      Displayed item in exclusive information 4 Proceed to
      -63 to 64 A
      65 to 128 B

    B: GO TO step   8 

    A: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (MG ECU - MOTOR RESOLVER) 
    1. Disconnect the I22 connector from the MG ECU.
    2. 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
      MRF (I22-13) - Body ground Below 1 V
      MRFG (I22-23) - Body ground Below 1 V
      MSN (I22-21) - Body ground Below 1V
      MSNG (I22-20) - Body ground Below 1 V
      MCS (I22-19) - Body ground Below 1V
      MCSG (I22-18) - Body ground Below 1 V
      Fig 4: Checking Harness And Connector (MG ECU - Motor Resolver)
      G05278641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the ignition switch off.
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      MRF (I22-13) - MRFG (I22-23) 7.65 to 10.2 Ω
      MSN (I22-21) - MSNG (I22-20) 12.6 to 16.8 Ω
      MCS (I22-19) - MCSG (I22-18) 12.6 to 16.8 Ω
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      MRF (I22-13) or MRFG (I22-23) - Body ground 10 kΩ or higher
      MSN (I22-21) or MSNG (I22-20) - Body ground 10 kΩ or higher
      MCS (I22-19) or MCSG (I22-18) - Body ground 10 kΩ or higher

    NG: GO TO step   9 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (MG ECU - GENERATOR RESOLVER) 
    1. Disconnect the I22 connector from the MG ECU.
    2. 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 1V
      GCS (I22-9) - Body ground Below 1 V
      GCSG (I22-8) - Body ground Below 1 V
      Fig 5: Checking Harness And Connector (MG ECU - Generator Resolver)
      G05278413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the ignition switch off.
    4. 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
    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) 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

    NG: GO TO step   10 

    OK: REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

  8. CHECK HARNESS AND CONNECTOR (MG ECU - REAR MOTOR RESOLVER) 
    1. Disconnect the I21 connector from the MG ECU.
    2. 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
      RRF (I21-21) - Body ground Below 1 V
      RRFG (I21-22) - Body ground Below 1 V
      RSN (I21-29) - Body ground Below 1 V
      RSNG (I21-30) - Body ground Below 1 V
      RCS (I21-11) - Body ground Below 1 V
      RCSG (I21-23) - Body ground Below 1 V
      Fig 6: Disconnecting I21 Connector From MG ECU
      G05278504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the ignition switch off.
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      RRF (I21-21) - RRFG (I21-22) 7.65 to 10.2 Ω
      RSN (I21-29) - RSNG (I21-30) 12.6 to 16.8 Ω
      RCS (I21-11) - RCSG (I21-23) 12.6 to 16.8 Ω
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      RRF (I21-21) or RRFG (I21 -22) - Body ground 10 kΩ or higher
      RSN (I21-29) or RSNG (I21-30) - Body ground 10 kΩ or higher
      RCS (I21-11) or RCSG (I21-23) - Body ground 10 kΩ or higher

    NG: GO TO step   11 

    OK: REPLACE REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY 

  9. INSPECT MOTOR RESOLVER 
    1. Disconnect the M14 motor resolver connector.
      Fig 7: Locating Motor Resolver Connector
      G05201331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      MRF (M14-1) - MRFG (M14-4) 7.65 to 10.2 Ω
      MSN (M14-2) - MSNG (M14-5) 12.6 to 16.8 Ω
      MCS (M14-3) - MCSG (M14-6) 12.6 to 16.8 Ω
    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.
      Fig 8: Identifying M14 Motor Resolver Connector
      G05278484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      MRF (M14-1) - MSN (M14-2) 10 MΩ or higher
      MRF (M14-1) - MCS (M14-3) 10 MΩ or higher
      MSN (M14-2) - MCS (M14-3) 10 MΩ or higher
      MRFG (M14-4) - MSNG (M14-5) 10 MΩ or higher
      MRFG (M14-4) - MCSG (M14-6) 10 MΩ or higher
      MSNG (M14-5) - MCSG (M14-6) 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 

  10. INSPECT GENERATOR RESOLVER 
    1. Remove the w/ converter inverter assembly.
      Fig 9: Locating Converter Inverter Assembly
      G05278646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the M13 generator resolver connector.
    3. 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
      Fig 10: Identifying M13 Generator Resolver Connector
      G05278414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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
      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 

  11. INSPECT REAR MOTOR RESOLVER 
    1. Disconnect the M18 rear motor resolver connector.
      Fig 11: Locating M18 Rear Motor Resolver Connector
      G05278648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      RRF (M18-1) - RRFG (M18-4) 7.65 to 10.2 Ω
      RSN (M18-2) - RSNG (M18-5) 12.6 to 16.8 Ω
      RCS (M18-3) - RCSG (M18-6) 12.6 to 16.8 Ω
      Fig 12: Identifying M18 Rear Motor Resolver Connector
      G05278458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      RRF (M18-1) - RSN (M18-2) 10 MΩ or higher
      RRF (M18-1) - RCS (M18-3) 10 MΩ or higher
      RSN (M18-2) - RCS (M18-3 10 MΩ or higher
      RRFG (M18-4) - RSNG (M18-5) 10 MΩ or higher
      RRFG (M18-4) - RCSG (M18-6) 10 MΩ or higher
      RSNG (M18-5) - RCSG (M18-6) 10 MΩ or higher
      Each terminal listed above - Transaxle housing 10 MΩ or higher

    NG: REPLACE REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY 

    OK: REPAIR OR REPLACE HARNESS OR CONNECTOR 

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