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.

READ OUTPUT DTC (HV ECU)

Connect the intelligent tester to the DLC3.
Turn the power switch ON (IG).
Turn the intelligent tester ON.
Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.

Read DTCs.

Result: DTCs listed in the table below are output

DTC CHART

DTC No.	Relevant Diagnosis
P0A1D	Hybrid Powertrain Control Module
P0A2B, P0A2C or P0A2D	Drive Motor "A" Temperature Sensor Circuit System
P0A37, P0A38 or P0A39	Generator Temperature Sensor Circuit System
P0A3F, P0A40 or P0A4	Drive Motor "A" Position Sensor Circuit System
P0A4B, P0A4C or P0A4D	Generator Position Sensor Circuit System
P0A60 or P0A63	Drive Motor "A" Current Sensor Circuit System
P0A72 or P0A75	Generator Current Sensor Circuit System
P0A78	Drive Motor "A" Inverter Performance
P0A7A	Generator Inverter Performance
P0A90	Drive Motor "A" Performance
P0A92	Hybrid Generator Performance
P0A93	Inverter Cooling System Malfunction
P0A94	DC / DC Converter Malfunction
P0AA1, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF	System Main Relay Circuit System
P0AA6, P3004	High Voltage System
P0AEE	Motor Inverter Temperature Sensor Malfunction
P3000	HV Battery System Malfunction
P3110	Integration Relay Malfunction
P3221	Generator Inverter Temperature Sensor Circuit System
P3226	DC / DC Boost Converter Temperature Sensor Circuit System

YES : GO TO DIAGNOSTIC TROUBLE CODE CHART

NO : GO TO NEXT STEP

CHECK QUANTITY OF HV COOLANT
1. Check that there is a sufficient amount of coolant for the inverter.
  OK : There is a sufficient amount of coolant for the inverter
NG : ADD HV COOLANT

OK : GO TO NEXT STEP
CHECK COOLANT HOSE
1. Check that the hoses of the cooling system are not bent or clogged (refer to the COOLING SYSTEM ).
  OK : The hoses of the cooling system are not bent or clogged
NG : CORRECT TO NORMAL CONDITION

OK : GO TO NEXT STEP
CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connection condition of the water pump connector.
  OK : Connector has been connected securely and there is no poor connection.
NG : CONNECT SECURELY

Fig 1: Identifying Water Pump Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK : GO TO NEXT STEP
CHECK WATER PUMP WITH MOTOR ASSEMBLY
1. Turn the power switch ON (IG).
2. Check the operation of the water pump.
  OK : Coolant is sloshing in the reservoir tank
NG : REPLACE WATER PUMP WITH MOTOR ASSEMBLY

OK : GO TO NEXT STEP
CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connection condition of the cooling fan motor connectors.
  OK : Connectors have been connected securely and there is no poor connection.
NG : CONNECT SECURELY

Fig 2: Identifying Cooling Fan Motor Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK : GO TO NEXT STEP
INSPECT COOLING FAN MOTOR
1. Inspect the cooling fan motor (see ON-VEHICLE INSPECTION ).
NG : REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT

OK : GO TO NEXT STEP
INSPECT NO. 2 COOLING FAN MOTOR
1. Inspect the No. 2 cooling fan motor (see ON-VEHICLE INSPECTION ).
NG : REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT

OK : 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 3: 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.
  OK : Connectors have been connected securely and there is no poor connection.
5. Reinstall the inverter cover (see INSTALLATION ).
6. Reinstall the service plug grip (See INSTALLATION ).
NG : CONNECT SECURELY

Fig 4: 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 553 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	D

B : REPLACE HYBRID VEHICLE CONTROL ECU

C : REPLACE INVERTER WITH CONVERTER ASSEMBLY

D : REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

A : 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 5: 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 6: 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 Ω

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 INVERTER WITH CONVERTER 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 INVERTER WITH CONVERTER ASSEMBLY

Fig 7: 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 8: 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