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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. 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 

  2. 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 

  3. 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
    G04473702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  4. 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 

  5. 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
    G04473703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  6. 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 

  7. 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 

  8. 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
    G04473505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  9. 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. 

    NG : CONNECT SECURELY 

    Fig 4: Identifying Inverter Connector
    G04473705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  10. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Check that the service plug grip and inverter cover have been removed.
    2. Disconnect the H16 HV control ECU connector.
      Fig 5: Disconnecting H16 HV Control ECU Connector
      G04473706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the I9 and I10 inverter connectors.
    4. 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.

    5. Measure the voltage between the terminals of the HV control ECU connector and body ground.

      Standard voltage 

      TERMINALS VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      CT (H16-21) - Body ground Below 1 V
      GCNV (H16-8) - Body ground Below 1 V
    6. Turn the power switch OFF.
    7. Measure the resistance between the wire harness side connectors.
      Fig 6: Disconnecting I9 And I10 Inverter Connectors
      G04473707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 (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
    8. Reconnect the inverter connectors.
    9. Reconnect the HV control ECU connector.
    10. Reinstall the inverter cover (see INSTALLATION ).
    11. Reinstall the service plug grip (See INSTALLATION ).

    NG : REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK : REPLACE INVERTER WITH CONVERTER ASSEMBLY 

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