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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.

  1. READ VALUE OF INTELLIGENT TESTER (CONVERTER TEMP) 
    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 / DATA LIST.
    5. Read the CONVERTER TEMP value.

      Result: 

      TEMPERATURE SPECIFICATION

      Temperature Displayed Proceed to
      -50°C (-58°F) A
      205°C (401°F) B
      -49°C to 204°C (-57°F to 400°F) C

      HINT:

      • If there is a +B short circuit, the intelligent tester indicates -50°C (-58°F).
      • If there is an open or GND short circuit, the intelligent tester indicates 205°C (401°F).

    B : Go to step   4 

    C : CHECK FOR INTERMITTENT PROBLEMS 

    A : GO TO NEXT STEP 

  2. READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) 
    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. Disconnect the I10 inverter connector.
      Fig 1: Disconnecting I10 Inverter Connector
      G04473570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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.

    6. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST.
    7. Read the CONVERTER TEMP value.

      OK : 205°C (401°F) 

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

    OK : REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    Fig 2: Identifying HV Control ECU Connector
    G04473571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG : GO TO NEXT STEP 

  3. READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) 
    1. Disconnect the H16 HV control ECU connector.
      Fig 3: Disconnecting H16 HV Control ECU Connector
      G04473572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.

    3. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST.
    4. Read the CONVERTER TEMP value on the intelligent tester.

      OK : 205°C (401°F) 

    5. Reconnect the HV control ECU connector.

    NG : REPLACE HYBRID VEHICLE CONTROL ECU 

    Fig 4: Identifying HV Control ECU Connector
    G04473573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : REPAIR OR REPLACE HARNESS OR CONNECTOR 

  4. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) 
    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. Disconnect the H16 HV control ECU connector.
      Fig 5: Disconnecting H16 HV Control ECU Connector
      G04473574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the I10 inverter connector.
    6. Measure the resistance between the wire harness side connectors.

      Standard resistance (Check for open) 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      CT (H16-21) - CT (I10-14) Below 1 Ω
      GCNV (H16-8) - GCNV (I10-32) Below 1 Ω

      Standard resistance (Check for short) 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      CT (H16-21) or CT (I10-14) - Body ground 10 kΩ or higher
      GCNV (H16-8) or GCNV (I10-32) - Body ground 10 kΩ or higher
      Fig 6: Disconnecting I10 Inverter Connector
      G04473575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Reconnect the inverter connector.
    8. Reconnect the HV control ECU connector.
    9. Reinstall the inverter cover (see INSTALLATION ).
    10. Reinstall the service plug grip (See INSTALLATION ).

    NG : REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK : GO TO NEXT STEP 

  5. INSPECT HYBRID VEHICLE CONTROL ECU (CT VOLTAGE) 
    1. 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.

    2. Measure the voltage between the terminals of the H16 HV control ECU connector.

      Standard voltage 

      TERMINALS VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      CT (H16-21) - GCNV (H16-8) 2.0 to 4.5 V

    NG REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    Fig 7: Identifying HV Control ECU Connector
    G04473576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : REPLACE HYBRID VEHICLE CONTROL ECU 

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