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 servicing 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 are required to discharge the high-voltage condenser inside the inverter.

CONFIRM INFORMATION (EXCLUSIVE INFO 3)
1. Connect the intelligent tester to the DLC3.
2. Turn the power switch ON (IG).
3. Turn the intelligent tester ON.
4. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
5. Select DTC P0A94 to display its freeze frame data.
6. Select the item that has INF code 547, 548, or 549 from among INFORMATION 1 to 5, and press ENTER.
7. Read EXCLUSIVE INFO 3.
  Result: -32 to 32 (during driving without battery power)
  
  HINT:
  
  If the value is inside the range shown above, DTCs other than P0A78 (INF 547, 548 and 549) have been detected as well. Perform troubleshooting for those DTCs first.
YES : GO TO RELEVANT 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 connection condition of all the connectors at the HV control ECU.
  OK : Connectors have been connected securely and there is no poor connection.
NG : CONNECT SECURELY

Fig 1: Identifying HV Control ECU Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK : GO TO NEXT STEP
CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT)
CAUTION: Wear insulated gloves before performing the following operation.
1. Turn the power switch OFF.
2. Remove the service plug grip (See REMOVAL ).
  NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
3. Remove the inverter cover (see REMOVAL ).
4. Check the connection condition of the I9 and I10 inverter connectors.
5. Reinstall the inverter cover (see INSTALLATION ).
6. Reinstall the service plug grip (See INSTALLATION ).
NG : CONNECT SECURELY

Fig 2: Identifying I9 And I10 Inverter Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK : GO TO NEXT STEP

CONFIRM INFORMATION (EXCLUSIVE INFO 4)

Connect the intelligent tester to the DLC3.
Turn the power switch ON (IG).
HINT:

DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.
Turn the intelligent tester ON.
Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
Select DTC P0A94 to display its freeze frame data.
Select the item that has INF code 547, 548, or 549 from among INFORMATION 1 to 5, and press ENTER.

Read EXCLUSIVE INFO 4.

Result:

RESULT REFERENCE

Displayed in Exclusive Information 4	Proceed to
-127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104	A
-119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112	B
-111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120	C
-103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127	B

B : REPLACE HYBRID VEHICLE CONTROL ECU

C : REPLACE INVERTER WITH CONVERTER ASSEMBLY

D : REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

A : GO TO NEXT STEP

READ OUTPUT DTC (HV ECU)

Connect the intelligent tester to the DLC3.
Turn the power switch ON (IG).
HINT:

DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.
Turn the intelligent tester ON.
Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.

Read DTCs.

DTC CHART

DTC No.	INF Code	Detection Item
P0A78	266	Drive Motor "A" Inverter Performance
P0A94	558 or 560	DC / DC Converter Performance
P0A94	588	DC / DC Converter Performance
P0A94	589	DC / DC Converter Performance
P0ADB	227	Hybrid Battery Positive Contractor Control Circuit Low
P0ADF	229	Hybrid Battery Negative Contractor Control Circuit Low
P3000	125	HV Battery Malfunction
P3004	131	Power Cable Malfunction

YES : GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE

NO : GO TO NEXT STEP

INSPECT HYBRID VEHICLE MOTOR ASSEMBLY

CAUTION: Wear insulated gloves before performing the following operation.

Turn the power switch OFF.
Remove the service plug grip (See REMOVAL ).
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
Remove the inverter cover (see REMOVAL ).
Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter.

Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor.

NOTE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped.

Fig 3: Identifying Hybrid Vehicle Motor Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

TERMINALS RESISTANCE SPECIFICATION

Tester Connection

Specified Condition⁽¹⁾

U (I14-1) - V (I14-2)

Below 135 mΩ at 20°C

V (I14-2) - W (I14-3)

Below 135 mΩ at 20°C

W (I14-3) - U (I14-1)

Below 135 mΩ at 20°C

⁽¹⁾	Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C)

Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U.
Standard resistance: Below 2 mΩ

Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground.

Standard resistance

TERMINALS RESISTANCE SPECIFICATION

Tester Connection	Specified Condition
U (I14-1) - Body ground	10 MΩ or higher
V (I14-2) - Body ground	10 MΩ or higher
W (I14-3) - Body ground	10 MΩ or higher

Reconnect the three-phase alternating current cable for the hybrid vehicle motor.

NG : REPLACE HYBRID VEHICLE MOTOR ASSEMBLY

OK : GO TO NEXT STEP

INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY

CAUTION: Wear insulated gloves before performing the following operation.

Check that the service plug grip and inverter cover have been removed.
Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter.

Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator.

NOTE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped.

Fig 4: Identifying Hybrid Vehicle Generator Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

TERMINALS RESISTANCE SPECIFICATION

Tester Connection

Specified Condition⁽¹⁾

U (I15-1) - V (I15-2)

Below 109 mΩ at 20°C

V (I15-2) - W (I15-3)

Below 109 mΩ at 20°C

W (I15-3) - U (I15-1)

Below 109 mΩ at 20°C

⁽¹⁾	Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C )

Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U.
Standard resistance: Below 2 mΩ

Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground.

Standard resistance

TERMINALS RESISTANCE SPECIFICATION

Tester Connection	Specified Condition
U (I15-1) - Body ground	10 MΩ or higher
V (I15-2) - Body ground	10 MΩ or higher
W (I15-3) - Body ground	10 MΩ or higher

Reconnect the three-phase alternating current cable for the hybrid vehicle generator.

NG : REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY

OK : GO TO NEXT STEP

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP)

CAUTION: Wear insulated gloves before performing the following operation.

Check that the service plug grip and inverter cover have been removed.
Connect the intelligent tester to the DLC3.
Turn the power switch ON (IG).
HINT:

DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.
Turn the intelligent tester ON.
Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST.

Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP.

Standard voltage

TERMINALS VOLTAGE SPECIFICATION

Tester Connection	Specified Condition
MUU (I10-9) - GINV (I10-16)	12 to 16 V
MVU (I10-10) - GINV (I10-16)	12 to 16 V
MWU (I10-11) - GINV (I10-16)	12 to 16 V
GUU (I10-4) - GINV (I10-16)	12 to 16 V
GVU (I10-5) - GINV (I10-16)	12 to 16 V
GWU (I10-6) - GINV (I10-16)	12 to 16 V

Turn the power switch OFF.

OK : REPLACE HYBRID VEHICLE CONTROL ECU AND INVERTER WITH CONVERTER ASSEMBLY

Fig 5: Identifying Inverter Connector

NG : GO TO NEXT STEP

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP)

CAUTION: Wear insulated gloves before performing the following operation.

Check that the service plug grip and inverter cover have been removed.
Disconnect the I10 inverter connector.
Connect the intelligent tester to the DLC3.
Turn the power switch ON (IG).
HINT:

DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.
Turn the intelligent tester ON.
Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST.

Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP.

Standard voltage

TERMINALS VOLTAGE SPECIFICATION

Tester Connection	Specified Condition
MUU (I10-9) - GINV (I10-16)	14 to 16 V
MVU (I10-10) - GINV (I10-16)	14 to 16 V
MWU (I10-11) - GINV (I10-16)	14 to 16 V
GUU (I10-4) - GINV (I10-16)	14 to 16 V
GVU (I10-5) - GINV (I10-16)	14 to 16 V
GWU (I10-6) - GINV (I10-16)	14 to 16 V

Fig 6: Disconnecting I10 Inverter Connector

Turn the power switch OFF.
Reconnect the inverter connector.
Reinstall the inverter cover (see INSTALLATION ).
Reinstall the service plug grip (See INSTALLATION ).

NG : REPLACE INVERTER WITH CONVERTER ASSEMBLY

OK : REPLACE HYBRID VEHICLE CONTROL ECU