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Home >> Lexus >> 2010 >> LS 600hL >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Vehicle Control (Diagnostic Codes (P0A1A-200 - P0A7A-344) >> Hybrid Control System >> DTC P0A78-121: Drive Motor "A" Inverter Performance >> Procedure

DTC P0A78-121: Drive Motor "A" Inverter Performance: Procedure

  1. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      P0A78-121 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A (all INF codes) *1 Generator Control Module
      P0A1B (all INF codes) *1 Drive Motor "A" Control Module
      P0A1D (all INF codes) *1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes) *1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes) *1 Drive Motor "A" Phase W Current
      P0A72 (all INF codes) *1 Generator Phase V Current
      P0A75 (all INF codes) *1 Generator Phase W Current
      P0A78-113, 128, 266, 267, 279, 284, 286, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-122, 130, 322, 324, 325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-172, 442, 547, 548, 549, 553, 554, 555, 556, 557, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 Power Cable Malfunction

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic flowchart.
      • P0A78-121 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    B → See step   27 

    A: Go to next step 

  2. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) See step   3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  3. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) See step   4 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  4. CHECK GENERATOR RESOLVER See step   5 

    NG → See step   19 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) See step   6 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  6. CHECK MOTOR RESOLVER See step   7 

    NG → See step   21 

    OK: Go to next step 

  7. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) See step   8 

    C → CONNECT SECURELY 

    B → REPLACE MALFUNCTIONING PARTS 

    A: Go to next step 

  8. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) See step   9 

    C → CONNECT SECURELY 

    B → REPLACE MALFUNCTIONING PARTS 

    A: Go to next step 

  9. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1) See step   10 

    NG → See step   23 

    OK: Go to next step 

  10. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG2) See step   11 

    NG → See step   25 

    OK: Go to next step 

  11. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) See step   12 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  12. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) See step   13 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  13. CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH-VOLTAGE CONNECTOR CONNECTION CONDITION) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Remove the connector cover from the inverter with converter assembly.
      Fig 1: Locating Connector Cover Bolts
      GTY147639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the connection of the high-voltage DC connector of the inverter with converter assembly.
      Fig 2: Locating DC Connector Of Inverter
      GTY129344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

      The connector is connected securely and there are no contact problems.

    4. Check for arc marks on the terminals of the high-voltage DC connector of the inverter with converter assembly.

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    C → CONNECT SECURELY 

    B → REPLACE MALFUNCTIONING PARTS 

    A: Go to next step 

  14. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK

      Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

    NG → See step   31 

    OK: Go to next step 

  15. CHECK SERVICE PLUG GRIP 
    1. Measure the resistance according to the value(s) in the table below.
      Fig 3: Identifying Service Plug Grip
      GTY267795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω

    NG → See step   32 

    OK: Go to next step 

  16. CHECK FRAME WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Disconnect the frame wire from the HV battery junction block.
      Fig 4: Identifying Frame Wire (HV Battery Junction Block)
      GTY270679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the frame wire (high-voltage DC connector) from the inverter with converter assembly.
      Fig 5: Locating DC Connector Of Inverter
      GTY129344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      Fig 6: Identifying Frame Wire HV Battery Junction Block And Inverter With Converter Assembly
      GTY142330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Switch Condition Specified Condition
      g2-1 - g1-1 (CBI) (Positive terminal) Power switch off Below 1 Ω
      g3-1 - g1-2 (CEI) (Negative terminal) Power switch off Below 1 Ω
    5. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      Fig 7: Identifying Frame Wire HV Battery Junction Block
      GTY148490Courtesy 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 Switch Condition Specified Condition
      g2-1 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      g3-1 - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      g2-1 - g3-1 Power switch off 10 MΩ or higher

    NG → See step   33 

    OK: Go to next step 

  17. INSPECT HV BATTERY JUNCTION BLOCK (SMRB) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Remove the HV battery junction block from the vehicle. Refer to COMPONENTS .
    3. Measure the resistance according to the value(s) in the table below.

      Standard resistance

      Tester Connection Switch Condition Specified Condition
      g2-1 - z30-1 Auxiliary battery voltage is not applied between terminals z38-3 (SNRB) and z38-2 (GND) 10 MΩ or higher
      g2-1 - z30-1 Auxiliary battery voltage is applied between terminals z38-3 (SMRB) and z38-2 (GND) Below 1 Ω
      Fig 8: HV Battery Junction Block G2, Z30 And Z38 Terminal Connectors
      GTY277460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.

      Standard resistance

      Tester Connection Condition Specified Condition
      z38-3 (SMRB) - z38-2 (GND) -31 to 176°F (-35 to 80°C) 18.8 to 32.1 Ω

    NG → See step   28 

    OK: Go to next step 

  18. INSPECT HV BATTERY JUNCTION BLOCK (SMRG) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Measure the resistance according to the value(s) in the table below.

      Standard resistance

      Tester Connection Switch Condition Specified Condition
      g3-1 - z34-1 Auxiliary battery voltage is not applied between terminals z38-1 (SMRG) and z38-2 (GND) 10 MΩ or higher
      g3-1 - z34-1 Auxiliary battery voltage is applied between terminals z38-1 (SMRG) and z38-2 (GND) Below 1 Ω
      Fig 9: HV Battery Junction Block G3, Z34 And Z38 Terminal Connectors
      GTY277256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance according to the value(s) in the table below.

      Standard resistance

      Tester Connection Condition Specified Condition
      z38-1 (SMRG) - z38-2 (GND) -31 to 176°F (-35 to 80°C) 18.8 to 32.1 Ω

    NG → See step   28 

    OK → See step   29 

  19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) See step   14 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY (MG ECU) - GENERATOR RESOLVER) See step   15 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   30 

  21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) See step   16 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  22. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY (MG ECU) - MOTOR RESOLVER) See step   17 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   30 

  23. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) See step   18 

    C → CONNECT SECURELY 

    B → REPLACE MALFUNCTIONING PARTS 

    A: Go to next step 

  24. CHECK GENERATOR CABLE See step   19 

    NG → See step   34 

    OK → See step   30 

  25. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) See step   20 

    C → CONNECT SECURELY 

    B → REPLACE MALFUNCTIONING PARTS 

    A: Go to next step 

  26. CHECK MOTOR CABLE See step   21 

    NG → See step   35 

    OK → See step   30 

  27. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  28. REPLACE HV BATTERY JUNCTION BLOCK. Refer to  COMPONENTS 
  29. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS 
  30. REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY. Refer to  COMPONENTS 
  31. REPLACE SERVICE PLUG GRIP. Refer to  REMOVAL 
  32. REPLACE SERVICE PLUG GRIP. Refer to  REMOVAL 
  33. REPLACE FRAME WIRE. Refer to  COMPONENTS 
  34. REPLACE GENERATOR CABLE. Refer to  COMPONENTS 
  35. REPLACE MOTOR CABLE. Refer to  COMPONENTS 
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