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Motor Resolver Circuit [10/2018 - ]: Procedure

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  1. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Disconnect the C42 inverter with converter assembly connector.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the power switch on (IG).
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      C42-5 (MRF) - Body ground Power switch on (IG) Below 1 V
      C42-6 (MRFG) - Body ground Power switch on (IG) Below 1 V
      C42-1 (MSN) - Body ground Power switch on (IG) Below 1 V
      C42-2 (MSNG) - Body ground Power switch on (IG) Below 1 V
      C42-4 (MCS) - Body ground Power switch on (IG) Below 1 V
      C42-3 (MCSG) - Body ground Power switch on (IG) Below 1 V
      GTY806393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
      NOTE:

      Turning the power switch on (IG) with the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    6. Turn the power switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.
    8. Reconnect the C42 inverter with converter assembly connector.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  2

  2. CHECK MOTOR RESOLVER 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the service information because this may cause a malfunction.

    2. Disconnect the C42 inverter with converter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      C42-5 (MRF) - C42-6 (MRFG) Power switch off 8.9 to 14.9 Ω
      C42-1 (MSN) - C42-2 (MSNG) Power switch off 16.2 to 28.1 Ω
      C42-4 (MCS) - C42-3 (MCSG) Power switch off 18.2 to 30.1 Ω

      HINT: 

      To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).

      R20 = Rt / {1 + 0.00393 X (T - 20)}

      The calculation is based on the following:

      R20: Resistance at 20°C (68°F) (mΩ)

      Rt: Measured resistance (mΩ)

      T: Temperature when the resistance is measured (°C (°F).)

      Standard Resistance (Check for Short)

      Tester Connection Condition Specified Condition
      C42-5 (MRF) or C42-6 (MRFG) - C42-4 (MCS) or C42-3 (MCSG) Power switch off 1 MΩ or higher
      C42-5 (MRF) or C42-6 (MRFG) - C42-1 (MSN) or C42-2 (MSNG) Power switch off 1 MΩ or higher
      C42-5 (MRF) or C42-6 (MRFG) - C42-8 (GRF) or C42-9 (GRFG) Power switch off 1 MΩ or higher
      C42-5 (MRF) or C42-6 (MRFG) - C42-13 (GCS) or C42-12 (GCSG) Power switch off 1 MΩ or higher
      C42-5 (MRF) or C42-6 (MRFG) - C42-10 (GSN) or C42-11 (GSNG) Power switch off 1 MΩ or higher
      C42-5 (MRF) or C42-6 (MRFG) - C42-7 (DRN3) Power switch off 1 MΩ or higher
      C42-5 (MRF) or C42-6 (MRFG) - Body ground Power switch off 1 MΩ or higher
      C42-4 (MCS) or C42-3 (MCSG) - C42-1 (MSN) or C42-2 (MSNG) Power switch off 1 MΩ or higher
      C42-4 (MCS) or C42-3 (MCSG) - C42-8 (GRF) or C42-9 (GRFG) Power switch off 1 MΩ or higher
      C42-4 (MCS) or C42-3 (MCSG) - C42-13 (GCS) or C42-12 (GCSG) Power switch off 1 MΩ or higher
      C42-4 (MCS) or C42-3 (MCSG) - C42-10 (GSN) or C42-11 (GSNG) Power switch off 1 MΩ or higher
      C42-4 (MCS) or C42-3 (MCSG) - C42-7 (DRN3) Power switch off 1 MΩ or higher
      C42-4 (MCS) or C42-3 (MCSG) - Body ground Power switch off 1 MΩ or higher
      C42-1 (MSN) or C42-2 (MSNG) - C42-8 (GRF) or C42-9 (GRFG) Power switch off 1 MΩ or higher
      C42-1 (MSN) or C42-2 (MSNG) - C42-13 (GCS) or C42-12 (GCSG) Power switch off 1 MΩ or higher
      C42-1 (MSN) or C42-2 (MSNG) - C42-10 (GSN) or C42-11 (GSNG) Power switch off 1 MΩ or higher
      C42-1 (MSN) or C42-2 (MSNG) - C42-7 (DRN3) Power switch off 1 MΩ or higher
      C42-1 (MSN) or C42-2 (MSNG) - Body ground Power switch off 1 MΩ or higher
      GTY965505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Reconnect the C42 inverter with converter assembly connector.

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    MOTOR RESOLVER CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC) 

    Result: 

    NG 

    See step  3

  3. CHECK CONNECTOR CONNECTION CONDITION (RESOLVER CONNECTOR) 
    1. Check the connection condition of the resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [10/2018 - ]

      GTY779591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

      - The connector is connected securely.

      - The terminals are not deformed and are connected securely.

      - No water or foreign matter in the connector.

      Result

      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  4

  4. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER) 
    1. Disconnect the C44 resolver connector.
      GTY779591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.
      GTY793040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Motor Resolver (Hybrid Vehicle Transaxle Assembly))

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      C44-6 (MRF) - C44-9 (MRFG) Power switch off 8.8 to 14.8 Ω
      C44-4 (MSN) - C44-5 (MSNG) Power switch off 16.2 to 28.0 Ω
      C44-10 (MCS) - C44-14 (MCSG) Power switch off 18.1 to 30.0 Ω

      HINT: 

      To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).

      R20 = Rt / {1 + 0.00393 X (T - 20)}

      The calculation is based on the following:

      R20: Resistance at 20°C (68°F) (mΩ)

      Rt: Measured resistance (mΩ)

      T: Temperature when the resistance is measured (°C (°F).)

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      C44-6 (MRF) - Body ground and other terminals (except C44-9 (MRFG)) Power switch off 1 MΩ or higher
      C44-9 (MRFG) - Body ground and other terminals (except C44-6 (MRF)) Power switch off 1 MΩ or higher
      C44-4 (MSN) - Body ground and other terminals (except C44-5 (MSNG)) Power switch off 1 MΩ or higher
      C44-5 (MSNG) - Body ground and other terminals (except C44-4 (MSN)) Power switch off 1 MΩ or higher
      C44-10 (MCS) - Body ground and other terminals (except C44-14 (MCSG)) Power switch off 1 MΩ or higher
      C44-14 (MCSG) - Body ground and other terminals (except C44-10 (MCS)) Power switch off 1 MΩ or higher
    3. Reconnect the C44 resolver connector.

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  REMOVAL [10/2018 - 07/2022]  Refer to  REMOVAL [07/2022 - ] 

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