Inspection Procedure

WARNING: This page is about a different car, the 2006 Lexus RX 400h. However, it is still accessible from the selected car via links, so may be relevant.

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 (SFI SYSTEM)
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 OBDII / ENGINE / DTC INFO / CURRENT CODES.
4. Read output DTC. (See DTC CHECK / CLEAR )
  Result:
  
  DTC is output.
  
  YES: GO TO DIAGNOSTIC TROUBLE CODE CHART
  
  NO: GO TO NEXT STEP

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 DTC. (See DTC CHECK / CLEAR )

Result:

Any two or more of the following DTCs are output simultaneously

DTC DETECTION TROUBLE CONDITION

DTC No.	Relevant Diagnosis
P0A3F-243, P0A40-500, P0A4D-255, P0A1A-791, P0A1A-793, P0A1B-795, P0A41-245, P0A4B-253, P0A4C-513, P0A1A-792, P0A1B-794, P0A1B-796	Motor resolver circuit, Generator resolver circuit

YES: GO TO DIAGNOSTIC TROUBLE CODE CHART

NO: GO TO NEXT STEP

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.
Fig 1: Checking Connection Condition Of Hybrid Vehicle Control ECU Connector (Looseness And Poor Contact)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

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 PRECAUTION )
  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.
Fig 2: Checking Connection Condition Of MG ECU Connector (Looseness And Poor Contact)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - MG ECU)

CAUTION: Be sure to wear insulated gloves.

Disconnect the H38 HV control ECU connector.
Disconnect the I21 MG ECU connector.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for open)

HV CONTROL ECU - MG ECU (CHECK FOR OPEN)

Tester Connection	Specified Condition
GO (H38-15) - GI (I21-24)	Below 1 Ω

Standard Resistance (Check for short)

HV CONTROL ECU - MG ECU (CHECK FOR SHORT)

Tester Connection	Specified Condition
GO (H38-15) or GI (I21-24) - Body ground	10 kΩ or more

Fig 3: Checking Harness And Connector (HV Control ECU - MG ECU)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - MOTOR RESOLVER)

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the M14 motor resolver connector.
Disconnect the I22 MG ECU connector.

Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

Standard Voltage

MG ECU - MOTOR RESOLVER VOLTAGE

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 1 V
MCS (I22-19) - Body ground	Below 1 V
MCSG (I22-18) - Body ground	Below 1 V

Fig 4: Checking Harness And Connector (MG ECU - Motor Resolver)

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 (Check for open)

MG ECU - MOTOR RESOLVER (CHECK FOR OPEN)

Tester Connection	Specified Condition
MRF (I22-13) - MRF (M14-1)	Below 1 Ω
MRFG (I22-23) - MRFG (M14-4)	Below 1 Ω
MSN (I22-21) - MSN (M14-2)	Below 1 Ω
MSNG (I22-20) - MSNG (M14-5)	Below 1 Ω
MCS (I22-19) - MCS (M14-3)	Below 1 Ω
MCSG (I22-18) - MCSG (M14-6)	Below 1 Ω

Standard (Check for short)

MG ECU - MOTOR RESOLVER (CHECK FOR SHORT)

Tester Connection	Specified Condition
MRF (I22-13) or MRF (M14-1) - Body ground	10 kΩ or more
MRFG (I22-23) or MRFG (M14-4) - Body ground	10 kΩ or more
MSN (I22-21) or MSN (M14-2) - Body ground	10 kΩ or more
MSNG (I22-20) or MSNG (M14-5) - Body ground	10 kΩ or more
MCS (I22-19) or MCS (M14-3) - Body ground	10 kΩ or more
MCSG (I22-18) or MCSG (M14-6) - Body ground	10 kΩ or more

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - GENERATOR RESOLVER)

Disconnect the M13 generator resolver connector.

Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

Standard Voltage

MG ECU - GENERATOR RESOLVER VOLTAG

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 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.

Fig 5: Checking Harness And Connector (MG ECU - Generator Resolver)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Resistance (Check for open)

MG ECU - GENERATOR RESOLVER (CHECK FOR OPEN)

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

Standard Resistance (Check for short)

MG ECU - GENERATOR RESOLVER (CHECK FOR SHORT)

Tester Connection	Specified Condition
GRF (I22-12) or GRF (M13-1) - Body ground	10 kΩ or more
GRFG (I22-22) or GRFG (M13-6) - Body ground	10 kΩ or more
GSN (I22-11) or GSN (M13-2) - Body ground	10 kΩ or more
GSNG (I22-10) or GSNG (M13-7) - Body ground	10 kΩ or more
GCS (I22-9) or GCS (M13-3) - Body ground	10 kΩ or more
GCSG (I22-8) or GCSG (M13-8) - Body ground	10 kΩ or more

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: GO TO NEXT STEP

INSPECT HYBRID VEHICLE CONTROL ECU

Using an oscilloscope, measure the waveform according to the value(s) in the table below.

Fig 6: Inspecting Hybrid Vehicle Control ECU

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ITEM CONDITIONS

Item	Condition
Terminal	CH1: VV1+ - NE- CH2: VV2+ - NE- CH3: NE+ - NE-
Equipment Setting	2 V / DIV, 20 ms / DIV
Condition	After engine warmed up and idling

HINT:

Each amplitude becomes larger with an increase in engine speed.
Each pulse cycle becomes shorter with an increase in engine speed.
DTCs may be detected by noise.

OK: REPLACE HYBRID VEHICLE CONTROL ECU

NG: GO TO NEXT STEP

INSPECT CRANKSHAFT POSITION SENSOR

Disconnect the C3 connector from the crankshaft position sensor.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

CRANKSHAFT POSITION SENSOR

Tester Connection	Condition	Specified Condition
1 - 2	Cold	1,630 to 2,740 Ω
1 - 2	Hot	2,065 to 3,225 Ω

Fig 7: Inspecting Crankshaft Position Sensor

HINT:

Terms cold and hot refer to the temperature of the coils. "Cold" means approximately - 10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F).

NG: REPLACE CRANKSHAFT POSITION SENSOR

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - CRANKSHAFT POSITION SENSOR)

Disconnect the H31 connector from the HV control ECU.

Disconnect the C3 connector from the crankshaft position sensor.

Standard Resistance (Check for open)

HV CONTROL ECU - CRANKSHAFT POSITION SENSOR (CHECK FOR OPEN)

Tester Connection	Specified Condition
C3-1 - NE+ (H31-25)	Below 1 Ω
C3-2 - NE- (H31-24)	Below 1 Ω

Standard Resistance (Check for short)

HV CONTROL ECU - CRANKSHAFT POSITION SENSOR (CHECK FOR SHORT)

Tester Connection	Specified Condition
C3-1 or NE+ (H31-25) - Body ground	10 kΩ or more
C3-2 or NE- (H31-24) - Body ground	10 kΩ or more

Fig 8: Checking Harness And Connector (HV Control ECU - Crankshaft Position Sensor)

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: GO TO NEXT STEP

CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)
1. Check the crankshaft position sensor installation.
  OK:
  
  Sensor is installed correctly.
  
  Fig 9: Checking Sensor Installation (Crankshaft Position Sensor)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NG: TIGHTEN SENSOR

OK: GO TO NEXT STEP
CHECK CRANKSHAFT POSITION SENSOR PLATE (TEETH OF SENSOR PLATE)
1. Check the teeth of the sensor plate.
  OK:
  
  Sensor plate does not have any crack or deformation.
NG: REPLACE CRANKSHAFT POSITION SENSOR PLATE

OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY