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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 P0A94-553 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. 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 Generator inverter function malfunction
      P0A90 Motor function malfunction
      P0A92 Generator function malfunction
      P0A93 Inverter cooling system
      P0A94 (Except for 553), P3227, P3228 Boost converter function malfunction
      P0ADB, P0ADC, P0ADF, P0AE0, P0AE6, P0AE7 System main relay circuit
      P0AA6, P3004 High-voltage system
      P3211 Motor inverter temperature sensor circuit
      P0AEE, P0AEF, P0AF0 Generator inverter temperature sensor circuit
      P3226 Boost converter temperature sensor circuit
      P0A05 Water pump w/ motor malfunction
      P0A79 Rear motor inverter function malfunction
      P0AF3, P0AF4, P0AF5 Rear motor temperature sensor malfunction
      P0A45, P0A46, P0A47 Rear motor resolver malfunction
      P0A69, P0A6C, P0A55 Rear motor current sensor 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.
      • P0A94-553 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 QUANTITY OF COOLANT (FOR INVERTER) 
    1. Check the coolant level.

      OK: There is a sufficient amount of coolant. 

    NG: CHECK FOR COOLANT LEAKS AND ADD COOLANT (FOR INVERTER) 

    OK: Go to next step 

  3. CHECK COOLANT HOSE 
    1. Check if the hoses of the cooling system are not bent or clogged.

      OK: The hoses of the cooling system are not bent or clogged. 

    NG: CORRECT TO NORMAL CONDITION 

    Fig 1: Identifying Water Pump W/ Motor And Bracket Assembly
    G05201355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  4. CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) 
    1. Check the connection of the water pump w/ motor connector.

      OK: Connector is connected securely and there is no poor connection. 

    NG: CONNECT SECURELY 

    Fig 2: Identifying Water Pump W/ Motor And Bracket Assembly
    G05278653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  5. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (WATER PUMP) 
    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 / ACTIVE TEST / WATER PUMP.
    4. During the WATER PUMP active test, check operation of the water pump.

      OK: There are ripples in the reservoir tank coolant. 

      HINT:

      The water pump is also activated in the READY-on state.

    NG: CHECK WATER PUMP W/ MOTOR & BRACKET ASSEMBLY 

    OK: Go to next step 

  6. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (COOLING FAN) 
    1. Connect the intelligent tester to the DLC3.
    2. Turn the ignition switch to the ON position.
    3. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ENGINE /ACTIVE TEST / COOLING FAN.
    4. Perform the COOLING FAN active test.

      Standard: 

      The electric cooling fan rotates. 

    NG: CHECK COOLING FAN CIRCUIT 

    OK: Go to next step 

  7. CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) 
    1. Check the connections of all HV control ECU connectors.

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

    NG: CONNECT SECURELY 

    Fig 3: Identifying HV Control ECU Connector
    G05201226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  8. 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.
      • Be sure to 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 4: Identifying MG ECU Connector Terminals
    G05201350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  9. CHECK HARNESS AND CONNECTOR (MG ECU - MOTOR 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
      MRF (I22-13) - Body ground Below 1 V
      MRFG (I22-23) - Body ground Below 1 V
      MSN (I22-21) - Body ground Below 1 V
      MSNG (I22-20) - Body ground Below 1V
      MCS (I22-19) - Body ground Below 1 V
      MCSG (I22-18) - Body ground Below 1 V
      Fig 5: Disconnecting I22 Connector From MG ECU
      G05278641Courtesy 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.
    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
      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
    6. 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   12 

    OK: Go to next step 

  10. 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
      Fig 6: Disconnecting I22 Connector From MG ECU
      G05278657Courtesy 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.
    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) - 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
    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

    NG: GO TO step   13 

    OK: Go to next step 

  11. CHECK HARNESS AND CONNECTOR (MG ECU - REAR MOTOR RESOLVER) 
    CAUTION: Be sure to wear insulated gloves.
    1. Check that the service plug grip is removed.
    2. Disconnect the I21 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
      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 7: Disconnecting I21 Connector From MG ECU
      G05278504Courtesy 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.
    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
      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
    6. 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   14 

    OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY 

  12. INSPECT MOTOR RESOLVER 
    1. Disconnect the M14 motor resolver connector.
      Fig 8: 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.
      Fig 9: Identifying M14 Motor Resolver Connector
      G05278484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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
      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 

  13. INSPECT GENERATOR RESOLVER 
    1. Remove the w/ converter inverter assembly. (See INVERTER WITH CONVERTER )
    2. Disconnect the M13 generator resolver connector.
      Fig 10: Locating M6 Generator Temperature Sensor Connector
      G05201323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
    4. Using a megohmmeter, measure the insulation resistance according to the value(s) in the table below.
      Fig 11: Identifying M13 Generator Resolver Connector
      G05278414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 

  14. INSPECT REAR MOTOR RESOLVER 
    1. Disconnect the M18 rear motor resolver connector.
      Fig 12: Locating Rear Motor Resolver Connector
      G05201336Courtesy 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
    3. Using a megohmmeter, measure the insulation resistance according to the value(s) in the table below.
      Fig 13: Identifying M18 Rear Motor Resolver Connector
      G05278458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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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