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Home >> Toyota >> 2012 >> Highlander Hybrid >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Vehicle Control System (Diagnostic Codes (P0A69-677 - P0A79-716)) (Hybrid) >> Hybrid Control System >> DTC P0A78-113: Drive Motor "A" Inverter Performance >> Procedure

DTC P0A78-113: Drive Motor "A" Inverter Performance: Procedure

  1. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      P0A78-113 is set before any of the DTCs in the table below are set. A
      Any of the DTCs in the table below are set before P0A78-113 is set. B
      DTC No. Relevant Diagnosis
      P3011-123, P3012-123, P3013-123, P0314-123, P3015-123, P3016-123, P0317-123, P3018-123, P3019-123, P3020-123, P3021-123, P3022-123, P3023-123, P3024-123, P3025-123 Battery Block # Becomes Weak
      P0AFC-123 Hybrid Battery Pack Sensor Module
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low
      P0AC0-123 Hybrid Battery Pack Current Sensor Circuit Range/Performance
      P0AC1-123 Hybrid Battery Pack Current Sensor Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor Circuit High
      P0A9C-123 Hybrid Battery Temperature Sensor "A"
      P0A9D-123 Hybrid Battery Temperature Sensor "A" Circuit Low
      P0A9E-123 Hybrid Battery Temperature Sensor "A" Circuit High
      P0C6E-123 Hybrid Battery Temperature Sensor "A" / "B" Correlation
      P0AC6-123 Hybrid Battery Temperature Sensor "B" Range/Performance
      P0AC7-123 Hybrid Battery Temperature Sensor "B" Circuit Low
      P0AC8-123 Hybrid Battery Temperature Sensor "B" Circuit High
      P0ACB-123 Hybrid Battery Pack Cooling Fan 3 Performance or Stuck OFF
      P0ACC-123 Hybrid Battery Pack Cooling Fan 3 Stuck ON
      P0ACD-123 Hybrid Battery Pack Cooling Fan 3 Control Circuit Low
      P0C70-123 Hybrid Battery Temperature Sensor "C" / "D" Correlation
      P0AE9-123 Hybrid Battery Temperature Sensor "D" Range/Performance
      P0AEA-123 Hybrid Battery Temperature Sensor "D" Circuit Low
      P0AEB-123 Hybrid Battery Temperature Sensor "D" Circuit High
      P0BC3-123 Hybrid Battery Temperature Sensor "E" Range/Performance
      P0BC4-123 Hybrid Battery Temperature Sensor "E" Circuit Low
      P0BC5-123 Hybrid Battery Temperature Sensor "E" Circuit High
      P0C72-123 Hybrid Battery Temperature Sensor "E" / "F" Correlation
      P0C34-123 Hybrid Battery Temperature Sensor "F" Range/Performance
      P0C35-123 Hybrid Battery Temperature Sensor "F" Circuit Low
      P0C36-123 Hybrid Battery Temperature Sensor "F" Circuit High

      HINT: 

      P0A78-113 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the ignition switch off.

    B → See step   31 

    A: Go to next step 

  2. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      P0A78-202 is not output. A
      P0A78-202 is also output. B
      NOTE:
      • If P0A78-202 is output, troubleshoot it first. After completing the troubleshooting for P0A78-202, return to perform troubleshooting for this DTC.
      • Parts repaired or replaced during troubleshooting for P0A78-202 do not need to be re-inspected in this diagnosis procedure.
    5. Turn the ignition switch off.

    B → See step   26 

    A: Go to next step 

  3. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      HINT: 

      • If P0A78-202 was not output in step 2 of this diagnosis procedure, check Table 1 below.
      • If P0A78-202 was output in step 2 of this diagnosis procedure, repair that DTC first, and then check Table 2 below.

      Result

      Result Proceed to
      P0A78-113 only is output. A
      Any of the following DTCs are also output. B
      TABLE 1

      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1C (all INF codes)*1 Drive Motor "B" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-671 Drive Motor "B" Position Sensor Circuit Range/Performance
      P0A47-670 Drive Motor "B" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A69 (all INF codes)*1 Drive Motor "B" Phase V Current
      P0A6C (all INF codes)*1 Drive Motor "B" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-118, 119, 120, 266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-693, 694, 695, 704, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A91-702 Drive Motor "B" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-124, 125, 126, 169, 170, 171, 442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC/DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource
      TABLE 2

      DTC No. Relevant Diagnosis
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1C (all INF codes)*1 Drive Motor "B" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-671 Drive Motor "B" Position Sensor Circuit Range/Performance
      P0A47-670 Drive Motor "B" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60-294 Drive Motor "A" Phase V Current
      P0A63-302 Drive Motor "A" Phase W Current
      P0A69 (all INF codes)*1 Drive Motor "B" Phase V Current
      P0A6C (all INF codes)*1 Drive Motor "B" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-118, 119, 120, 266, 267, 279, 287, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-693, 694, 695, 704, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A91-702 Drive Motor "B" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-124, 125, 126, 169, 170, 171, 442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC/DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A78-113 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.
    5. Turn the ignition switch off.

    B → See step   27 

    A: Go to next step 

  4. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR). Refer to  PROCEDURE - Step 4 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER). Refer to  PROCEDURE - Step 3 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  6. CHECK GENERATOR RESOLVER. Refer to  PROCEDURE - Step 4 

    NG → See step   19 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER). Refer to  PROCEDURE - Step 5 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  8. CHECK MOTOR RESOLVER. Refer to  PROCEDURE - Step 6 

    NG → See step   21 

    OK: Go to next step 

  9. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter terminal cover from the inverter with converter assembly.
      Fig 1: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.
      Fig 2: Identifying Generator Cables & Fasteners
      GTY299673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified Condition

      T=8.0 N*m {82 kgf*cm, 71 in.*lbf}

      NOTE:

      Make sure that the tightening torque of the bolts is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Check for arc marks at the bolts for the generator cable.

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    5. Install the inverter terminal cover.

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  10. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter terminal cover from the inverter with converter assembly.
      Fig 3: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.
      Fig 4: Identifying Motor Cable & Fasteners
      GTY299672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified Condition

      T=8.0 N*m {82 kgf*cm, 71 in.*lbf}

      NOTE:

      Make sure that the tightening torque of the bolts is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Check for arc marks at the bolts for the motor cable.

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    5. Install the inverter terminal cover.

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  11. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter terminal cover from the inverter with converter assembly.
      Fig 5: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the generator cable and motor cable from the inverter with converter assembly.
    4. Check MG1 for an interphase short using a milliohmmeter.
      Fig 6: Identifying Three-Phase AC Cables for MG1
      GTY303934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

        HINT: 

        If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance

        Tester Connection Switch Condition Specified Condition
        z28-3 (U) - z28-2 (V) Ignition switch off 37 to 43 mΩ
        z28-2 (V) - z28-1 (W) Ignition switch off 36 to 42 mΩ
        z28-1 (W) - z28-3 (U) Ignition switch off 36 to 42 mΩ
        TEXT IN ILLUSTRATION

        *1 Three-phase AC Cable for MG1
        *a Shield Ground

        HINT: 

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

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

        The calculation is based on the following:

        • R20: Resistance at 68° F (20°C) (mΩ)
        • Rt: Measured resistance (mΩ)
        • T: Temperature when the resistance is measured (° C)
    5. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      NOTE:

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      z28-3 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      z28-2 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      z28-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
    6. Connect the generator cable and motor cable.
    7. Install the inverter terminal cover.

    NG → See step   28 

    OK: Go to next step 

  12. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter terminal cover from the inverter with converter assembly.
      Fig 7: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the generator cable and motor cable from the inverter with converter assembly.
    4. Check MG2 for an interphase short using a milliohmmeter.
      Fig 8: Identifying Three-Phase AC Cables For MG1
      GTY305744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

        HINT: 

        If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance

        Tester Connection Switch Condition Specified Condition
        z26-3 (U) - z26-2 (V) Ignition switch off 52 to 60 mΩ
        z26-2 (V) - z26-1 (W) Ignition switch off 50 to 58 mΩ
        z26-1 (W) - z26-3 (U) Ignition switch off 50 to 58 mΩ
        TEXT IN ILLUSTRATION

        *1 Three-phase AC Cable for MG2
        *a Shield Ground

        HINT: 

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

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

        The calculation is based on the following:

        • R20: Resistance at 68° F (20°C) (mΩ)
        • Rt: Measured resistance (mΩ)
        • T: Temperature when the resistance is measured (° C)
    5. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      NOTE:

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      z26-3 (U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      z26-2 (V) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      z26-1 (W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
    6. Connect the generator cable and motor cable.
    7. Install the inverter terminal cover.

    NG → See step   28 

    OK: Go to next step 

  13. CHECK FUSE (PCU) 
    1. Remove the PCU fuse from the engine room relay block No. 2.
      Fig 9: Identifying PCU Fuse
      GTY302280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      PCU fuse Always Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block No. 2
      *2 PCU fuse
    3. Install the PCU fuse.

    NG → See step   23 

    OK: Go to next step 

  14. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT) 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect connector A64 from the inverter with converter assembly.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 10: Checking Harness And Connector (Inverter With Converter Assembly Power Source Circuit)
      GTY300955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A64-10 (GND1) - Body ground Ignition switch off Below 1 Ω
      A64-11 (GND2) - Body ground Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A64-30 (+B) - Body ground Ignition switch ON 11 to 14 V
      A64-31 (+B2) - Body ground Ignition switch ON 11 to 14 V
    6. Turn the ignition switch off.
    7. Connect the inverter with converter assembly connector.

    NG → REPAIR OR REPLACE POWER SOURCE CIRCUIT 

    OK: Go to next step 

  15. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER) 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Turn the ignition switch off.
    3. Disconnect connector A64 from the inverter with converter assembly.
    4. Disconnect connector A66 from the hybrid vehicle control ECU.
    5. Measure the resistance according to the value(s) in the table below.
      Fig 11: Checking Harness And Connector (Hybrid Vehicle Control ECU - Inverter With Converter)
      GTY300202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      A66-24 (HTM+) - A64-9 (HTM+) Ignition switch off Below 1 Ω
      A66-25 (HTM-) - A64-20 (HTM-) Ignition switch off Below 1 Ω
      A66-30 (MTH+) - A64-8 (MTH+) Ignition switch off Below 1 Ω
      A66-29 (MTH-) - A64-19 (MTH-) Ignition switch off Below 1 Ω
      A66-33 (REQ+) - A64-26 (REQ+) Ignition switch off Below 1 Ω
      A66-32 (REQ-) - A64-37 (REQ-) Ignition switch off Below 1 Ω
      A66-21 (CLK+) - A64-7 (CLK+) Ignition switch off Below 1 Ω
      A66-20 (CLK-) - A64-18 (CLK-) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A66-24 (HTM+) or A64-9 (HTM+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-25 (HTM-) or A64-20 (HTM-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-30 (MTH+) or A64-8 (MTH+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-29 (MTH-) or A64-19 (MTH-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-33 (REQ+) or A64-26 (REQ+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-32 (REQ-) or A64-37 (REQ-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-21 (CLK+) or A64-7 (CLK+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-20 (CLK-) or A64-18 (CLK-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
      *b Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
    6. Turn the ignition switch to ON.
    7. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A66-24 (HTM+) or A64-9 (HTM+) - Body ground Ignition switch ON Below 1 V
      A66-25 (HTM-) or A64-20 (HTM-) - Body ground Ignition switch ON Below 1 V
      A66-30 (MTH+) or A64-8 (MTH+) - Body ground Ignition switch ON Below 1 V
      A66-29 (MTH-) or A64-19 (MTH-) - Body ground Ignition switch ON Below 1 V
      A66-33 (REQ+) or A64-26 (REQ+) - Body ground Ignition switch ON Below 1 V
      A66-32 (REQ-) or A64-37 (REQ-) - Body ground Ignition switch ON Below 1 V
      A66-21 (CLK+) or A64-7 (CLK+) - Body ground Ignition switch ON Below 1 V
      A66-20 (CLK-) or A64-18 (CLK-) - Body ground Ignition switch ON Below 1 V
      NOTE:

      Turning the ignition switch to ON with the hybrid vehicle control ECU and inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    8. Turn the ignition switch off.
    9. Connect the hybrid vehicle control ECU connector.
    10. Connect the inverter with converter assembly connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  16. CHECK HYBRID VEHICLE CONTROL ECU 
    1. Disconnect connector A66 from the hybrid vehicle control ECU.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 12: Checking Hybrid Vehicle Control ECU
      GTY302582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A66-24 (HTM+) - A66-25 (HTM-) Ignition switch off 109 to 131 Ω
      A66-30 (MTH+) - A66-29 (MTH-) Ignition switch off 109 to 131 Ω
      A66-33 (REQ+) - A66-32 (REQ-) Ignition switch off 109 to 131 Ω
      A66-21 (CLK+) - A66-20 (CLK-) Ignition switch off 109 to 131 Ω
      TEXT IN ILLUSTRATION

      *a Component without harness connected
      (Hybrid Vehicle Control ECU)
    3. Connect the hybrid vehicle control ECU connector.

    NG → See step   29 

    OK: Go to next step 

  17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 9 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 10 

    NG → CONNECT SECURELY 

    OK → See step   30 

  19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 12 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER). Refer to  PROCEDURE - Step 13 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   28 

  21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 14 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  22. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER). Refer to  PROCEDURE - Step 15 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   28 

  23. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect connector A64 from the inverter with converter assembly.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 13: Checking Harness And Connector (Inverter With Converter Assembly - PCU Fuse)
      GTY298207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A64-30 (+B) - Body ground Ignition switch off 10 kΩ or higher
      A64-31 (+B2) - Body ground Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Connect the inverter with converter assembly connector.

    NG → See step   25 

    OK: Go to next step 

  24. REPLACE INVERTER WITH CONVERTER ASSEMBLY 
    1. Replace the inverter with converter assembly. Refer to REMOVAL .

    NEXT → REPLACE FUSE (PCU) 

  25. REPAIR OR REPLACE HARNESS OR CONNECTOR 
    1. Repair or replace the wire harness or connector.

    NEXT → REPLACE FUSE (PCU) 

  26. GO TO DTC CHART. Refer to  DTC P0A78-202: Drive Motor "A" Inverter Performance  
  27. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  28. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  29. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
  30. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL 
  31. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART