Cooling System [06/2018 - 08/2021]: Procedure

1. Make sure that the front side of the radiator grille is not blocked with anything.
2. Ask the customer if the front side of the radiator grille was blocked with anything.

   Result

   Result	Proceed to
   Not blocked.	A
   Is/was blocked.	B

   HINT: 

   If the radiator grille is blocked, the inverter coolant temperature will increase and this DTC may be stored.

Result: 

B 

IF EQUIPPED, EXPLAIN TO CUSTOMER THAT OPTIONAL COMPONENTS WILL BE REMOVED 

Result: 

A 

See step  2

1. Check the HV coolant level in the inverter reserve tank.
2. Check for HV coolant leaks.

   Result

   Result	Proceed to
   No leaks are found and the HV coolant level in the inverter reserve tank assembly is above the low line	A
   No leaks are found and the HV coolant level in the inverter reserve tank assembly is below the low line	B
   HV coolant leaks are evident	C

   HINT: 

   • After repairing the HV coolant leaks and adding coolant, perform the Active Tests "Activate the Inverter Water Pump" (Hybrid Control System) and "Control the Cooling Fan Duty Ratio" (Engine Control System) and make sure that there are no malfunctions.
   • If there are signs of coolant leakage around the connecting parts of a hose and the inverter with converter assembly, replace the hose with a new one.

Result: 

B 

ADD HV COOLANT 

Result: 

C 

INSPECT FOR COOLANT LEAK AND ADD COOLANT 

Result: 

A 

See step  3

1. Check that the cooling system hoses are not kinked or clogged.

   OK

   The cooling system hoses are not kinked or clogged.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE COOLANT HOSE 

Result: 

OK 

See step  4

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Engine / Active Test / Control the Engine Cooling Fan Duty Ratio.

   Powertrain > Engine > Active Test 

   Tester Display
   Control the Engine Cooling Fan Duty Ratio

4. Perform the "Control the Engine Cooling Fan Duty Ratio" Active Test.

   OK

   Techstream Operation	Fan Operation
   30 - 100%	Cooling fan operates
   0%	Cooling fan stops

   Result

   Result	Proceed to
   Cooling fan operate	A
   Cooling fan does not operate	B
   Cooling fan do not stop

5. Turn the power switch off.

Result: 

B 

CHECK COOLING FAN SYSTEM. Refer to  ON-VEHICLE INSPECTION [06/2018 - ] 

Result: 

A 

See step  5

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Body Electrical / Grill Shutter / Utility / Grill Shutter Control Mode Switching.
4. According to the display on the Techstream, change the grille shutter control mode from normal mode to maintenance mode.

   Body Electrical > Grill Shutter > Utility 

   Tester Display
   Grill Shutter Control Mode Switching

5. Enter the following menus: Body Electrical / Grill Shutter / Active Test / Shutter Closing Operation Lock Detection / Data List / Shutter Operation Lock Detection Result for Active Test.
6. According to the display on the Techstream, perform the Active Test and read the value of Data List item Shutter Operation Lock Detection Result for Active Test.

   Body Electrical > Grill Shutter > Active Test 

   Active Test Display
   Shutter Closing Operation Lock Detection

   Data List Display
   Shutter Operation Lock Detection Result for Active Test

   OK

   "Normal" is displayed.

7. Enter the following menus: Body Electrical / Grill Shutter / Active Test / Shutter Opening Operation Lock Detection / Data List / Shutter Operation Lock Detection Result for Active Test.
8. According to the display on the Techstream, perform the Active Test and read the value of Data List item Shutter Operation Lock Detection Result for Active Test.

   Body Electrical > Grill Shutter > Active Test 

   Active Test Display
   Shutter Opening Operation Lock Detection

   Data List Display
   Shutter Operation Lock Detection Result for Active Test

   OK

   "Normal" is displayed.

   HINT: 

   When the value of Data List item Shutter Operation Lock Detection Result for Active Test is "Normal", it can be determined that the grille shutter system is normal.

9. Enter the following menus: Body Electrical / Grill Shutter / Utility / Grill Shutter Control Mode Switching.
10. According to the display on the Techstream, change the grille shutter control mode from maintenance mode to normal mode.

    Body Electrical > Grill Shutter > Utility 

    Tester Display
    Grill Shutter Control Mode Switching

11. Turn the power switch off.

    Result

    Proceed to
    OK
    NG

Result: 

NG 

CHECK GRILLE SHUTTER SYSTEM. Refer to  HOW TO PROCEED WITH TROUBLESHOOTING [06/2018 - 08/2021] 

Result: 

OK 

See step  6

HINT: 

When the auxiliary battery voltage is low, the inverter water pump assembly may not operate.

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Inverter Water Pump.

   Powertrain > Hybrid Control > Active Test 

   Active Test Display
   Activate the Inverter Water Pump

   Data List Display
   Inverter Water Pump Revolution

4. Select the Data List item "Inverter Water Pump Revolution".
5. According to the display on the Techstream, perform the Active Test "Activate the Inverter Water Pump" and check the value of the Data List item "Inverter Water Pump Revolution".

   OK

   Tester Display	Condition	Specified Condition
   Inverter Water Pump Revolution	Power switch on (IG) During Active Test	3176 to 8617 rpm

   HINT: 

   • Perform the Active Test with the inverter coolant temperature between -15 and 65°C (5 to 149°F).
   • When the inverter water pump assembly is not operating, the Data List item "Inverter Water Pump Revolution" displays a value lower than 200 rpm.
6. Turn the power switch off.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  9

Result: 

OK 

See step  7

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (READY) and wait for 1 minute with the engine stopped.
3. Enter the following menus: Powertrain / Hybrid Control / Data List / Generator Inverter Calculated Temperature, Motor Inverter Temperature, Boosting Converter Temperature (Upper), Boosting Converter Temperature (Lower) and Inverter Coolant Water Temperature.

   Powertrain > Hybrid Control > Data List 

   Tester Display
   Generator Inverter Calculated Temperature
   Motor Inverter Temperature
   Boosting Converter Temperature (Upper)
   Boosting Converter Temperature (Lower)
   Inverter Coolant Water Temperature

4. Read the Data List with the engine stopped.

   Result

   Result	Proceed to
   Other than below.	A
   "Inverter Coolant Water Temperature" value is higher than the displayed temperature of any other Data List item by 20°C (68°F) or more.	B

   HINT: 

   The lower limit temperature that can be displayed for "Generator Inverter Calculated Temperature", "Motor Inverter Temperature", "Boosting Converter Temperature (Upper)" and "Boosting Converter Temperature (Lower)" is 15°C (59°F). The lower limit temperature for "Inverter Coolant Water Temperature" is -40°C (-40°F). The "Inverter Coolant Water Temperature" value displayed on the Techstream may be lower than the others, but this is not a malfunction.

5. Turn the power switch off.

Result: 

B 

REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL [06/2018 - 08/2020]  , or refer to  REMOVAL [08/2020 - 08/2021] 

Result: 

A 

See step  8

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

   Powertrain > Hybrid Control > Trouble Codes 

4. Read the freeze frame data item "Ambient Temperature" using the Techstream.
5. Check if the freeze frame data item "Ambient Temperature" is below the freezing temperature of the HV coolant.

   Result

   Result	Proceed to
   Ambient Temperature value is above freezing temperature of the HV coolant	A
   Ambient Temperature value is below freezing temperature of the HV coolant	B

   HINT: 

   • HV coolant (SLLC) with a 30% concentration freezes at -15°C (5°F) and HV coolant (SLLC) with a 50% concentration freezes at -35°C (-31°F).
   • If the HV coolant freezes in the HV radiator or inverter water pump, the coolant temperature in the inverter with converter assembly rises because the HV coolant cannot circulate. As a result, a DTC may be stored.
   • A DTC is stored when the inverter water pump impeller cannot rotate due to freezing of the HV coolant.
   • If DTCs are output due to freezing of the LLC, the problem symptom cannot be reproduced. Check the LLC replacement history and whether the LLC was frozen based on the ambient temperature when the DTCs were stored.
6. Turn the power switch off.

Result: 

A 

COOLING SYSTEM NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC) 

Result: 

B 

REPLACE HV COOLANT. Refer to  REPLACEMENT [06/2018 - ] 

Refer to PROCEDURE - Step 1

Result

Result: 

NG 

CONNECT SECURELY 

Result: 

OK 

See step  10

1. Check the connector connections and contact pressure of the relevant terminals for the inverter water pump assembly connector.

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [06/2018 - ]

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The connector is connected securely, the terminals are not deformed or corroded and there are no contact problems.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

CONNECT SECURELY 

Result: 

OK 

See step  11

1. Disconnect the A32 hybrid vehicle control ECU connector.
2. Disconnect the Z1 inverter water pump assembly connector.
3. Measure the resistance according to the value(s) in the table below.

   Standard Resistance (Check for Open)

   Tester Connection	Condition	Specified Condition
   A32-13 (IWP) - Z1-3 (SWP)	Power switch off	Below 1 Ω

   Standard Resistance (Check for Short)

   Tester Connection	Condition	Specified Condition
   A32-13 (IWP) or Z1-3 (SWP) - Body ground and other terminals	Power switch off	10 kΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Rear view of wire harness connector (to Hybrid Vehicle Control ECU)
   *b	Front view of wire harness connector (to Inverter Water Pump Assembly)

   HINT: 

   Check the condition (looseness, deterioration, etc.) of the wire to body ground for the inverter water pump assembly.

4. Reconnect the Z1 inverter water pump assembly connector.
5. Reconnect the A32 hybrid vehicle control ECU connector.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

OK 

See step  12

HINT: 

When the auxiliary battery voltage is low, the inverter water pump assembly may not operate.

1. Connect the Techstream to the DLC3.
2. Remove the INV W/PMP fuse from the No. 4 relay block.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 4 Relay Block
   *2	INV W/PMP Fuse

3. Turn the power switch on (IG).
4. Enter the following menus: Powertrain / Hybrid Control / Data List / Inverter Water Pump Revolution.

   Powertrain > Hybrid Control > Data List 

   Tester Display
   Inverter Water Pump Revolution

5. According to the display on the Techstream, read the Data List.

   Standard

   Techstream Display	Condition	Specified Condition
   Inverter Water Pump Revolution	Power switch on (IG)	200 rpm or less

6. Turn the power switch off.
7. Install the INV W/PMP fuse.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL [06/2018 - 08/2021] 

Result: 

OK 

See step  13

1. Disconnect the A32 hybrid vehicle control ECU connector.
2. Turn the power switch on (IG).
3. Measure the voltage according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Component with harness connected (Hybrid Vehicle Control ECU)
   *b	Rear view of wire harness connector (to Hybrid Vehicle Control ECU)

   Standard Voltage

   Tester Connection	Condition	Specified Condition
   A32-13 (IWP) - G59-6 (E1)	Power switch on (IG)	11 to 14 V

   NOTE:

   Turning the power switch on (IG) with the hybrid vehicle control ECU connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

4. Turn the power switch off.
5. Reconnect the A32 hybrid vehicle control ECU connector.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  15

Result: 

OK 

See step  14

1. Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the table below.
2. Turn the power switch on (IG).
3. While turning the power switch on (IG), check the waveform between the hybrid vehicle control ECU terminals.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Component with harness connected (Hybrid Vehicle Control ECU)

   Item	Content
   Terminal	A32-13 (IWP) - G59-6 (E1)
   Equipment Setting	5 V/DIV., 50 ms./DIV.
   Condition	Power switch on (IG)

   OK

   Waveform duty ratio is between 3% and 9%.

4. Turn the power switch off.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL [06/2018 - 08/2021] 

Result: 

OK 

See step  15

Refer to REMOVAL [06/2018 - ]

Result

Result: 

NEXT 

See step  16

1. After replacing the inverter water pump assembly, add HV coolant and perform air bleeding.

   Refer to REPLACEMENT [06/2018 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END