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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 P0A78-121: Drive Motor "A" Inverter Performance >> Procedure

DTC P0A78-121: 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
      P0A78-121 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 P0A78-121 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
      P0A78-282 Drive Motor "A" Inverter Performance
      P0A94-127, 550, 564 DC/DC Converter Performance
      P0C30-390 Hybrid Battery Pack State of Charge High

      HINT: 

      • Refer to the Freeze Frame Data to determine the order in which the DTCs were set.
      • P0A78-121 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   47 

    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
      P0A78-121 only is output. A
      Any of the following DTCs are also output. B
      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
      P0A78-113, 118, 119, 120, 128, 266, 267, 279, 284, 286, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-136, 692, 693, 694, 695, 696, 704, 712, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-122, 130, 322, 324, 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
      P0A93-346 Inverter Cooling System Performance
      P0A94-124, 125, 126, 169, 170, 171, 172, 442, 547, 548, 549, 553, 554, 555, 556, 557, 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
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource
      P314A-828 Inverter Coolant Pump Speed Signal

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A78-121 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   48 

    A: Go to next step 

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  4. 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 

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

    NG → See step   31 

    OK: Go to next step 

  6. 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 

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

    NG → See step   34 

    OK: Go to next step 

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

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  9. CHECK REAR MOTOR RESOLVER. Refer to  PROCEDURE - Step 8 

    NG → See step   37 

    OK: Go to next step 

  10. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) See step   9 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  11. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) See step   10 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  12. CHECK INVERTER WITH CONVERTER ASSEMBLY (REAR 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 1: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the bolts for the rear motor cable are tightened to the specified torque, the rear motor cable is connected securely, and there are no contact problems.
      Fig 2: Identifying Rear Motor Cable & Fasteners
      GTY306441Courtesy 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 rear 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 

  13. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) See step   11 

    NG → See step   49 

    OK: Go to next step 

  14. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) See step   12 

    NG → See step   50 

    OK: Go to next step 

  15. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (MGR) 
    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. Disconnect the rear motor cable from the inverter with converter assembly.
      Fig 4: Identifying Rear Motor Cable & Fasteners
      GTY306441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check MGR for an interphase short using a milliohmmeter.
      Fig 5: Identifying Three-Phase AC Cables for MGR
      GTY297554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

        HINT: 

        If the MGR 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
        j9-3 (R-U) - j9-2 (R-V) Ignition switch off 163 to 176 mΩ
        j9-2 (R-V) - j9-1 (R-W) Ignition switch off 163 to 176 mΩ
        j9-1 (R-W) - j9-3 (R-U) Ignition switch off 163 to 176 mΩ
        TEXT IN ILLUSTRATION

        *1 Three-phase AC Cable for MGR
        *a Shielded 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
      j9-3 (R-U) - Body ground and shielded ground Ignition switch off 100 MΩ or higher
      j9-2 (R-V) - Body ground and shielded ground Ignition switch off 100 MΩ or higher
      j9-1 (R-W) - Body ground and shielded ground Ignition switch off 100 MΩ or higher
    6. Connect the rear motor cable.
    7. Install the inverter terminal cover.

    NG → See step   40 

    OK: Go to next step 

  16. CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH VOLTAGE CONNECTOR 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 6: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the bolts for the No. 3 wire frame are tightened to the specified torque, the No. 3 wire frame is connected securely, and there are no contact problems.
      Fig 7: Identifying No. 3 Wire Frame & Fasteners
      GTY299670Courtesy 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 No. 3 wire frame.

      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 

  17. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK

      Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

    NG → See step   51 

    OK: Go to next step 

  18. CHECK SERVICE PLUG GRIP 
    1. Measure the resistance according to the value(s) in the table below.
      Fig 8: Identifying Service Plug Grip
      GTY305124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Service plug grip

    NG → See step   52 

    OK: Go to next step 

  19. CHECK ELECTRIC VEHICLE FUSE 
    1. Remove the electric vehicle fuse. Refer to REMOVAL .
    2. Measure the resistance according to the value(s) in the table below.
      Fig 9: Identifying Electric Vehicle Fuse
      GTY300687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

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

      *1 Electric Vehicle Fuse
    3. Install the electric vehicle fuse.

    NG → See step   53 

    OK: Go to next step 

  20. CHECK NO. 3 WIRE FRAME 
    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 the No. 3 wire frame from the hybrid battery junction block assembly.
      Fig 10: Identifying No. 3 Wire Frame & The Hybrid Battery Junction Block Assembly
      GTY303562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the inverter terminal cover from the inverter with converter assembly.
      Fig 11: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the No. 3 wire frame from the inverter with converter assembly.
      Fig 12: Identifying No. 3 Wire Frame & Fasteners
      GTY299670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the resistance according to the value(s) in the table below.
      Fig 13: Measuring Resistance Of Three-Phase AC Cable For MGR
      GTY300004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      j2-1 - j8-2 (CBI) (Positive terminal) Ignition switch off Below 1 Ω
      j3-1 - j8-1 (CEI) (Negative terminal) Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 No. 3 Wire Frame (Inverter with Converter Assembly Side)
      *2 No. 3 Wire Frame (Hybrid Battery Junction Block Assembly Side)
      *a Red Mark
    6. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      Fig 14: Identifying J2 & J3 Body Ground & Shielded Ground
      GTY304875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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
      j2-1 - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      j3-1 - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      j2-1 - j3-1 Ignition switch off 10 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 No. 3 Wire Frame (Hybrid Battery Junction Block Assembly Side)
      *a Red Mark
    7. Connect the No. 3 wire frame to the hybrid battery junction block assembly.
    8. Connect the No. 3 wire frame to the inverter with converter assembly.
    9. Install the inverter terminal cover.

    NG → See step   54 

    OK: Go to next step 

  21. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB) 
    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 hybrid battery junction block assembly.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 15: Inspecting Hybrid Battery Junction Block Assembly (SMRB)
      GTY301111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      z30 - j2 Auxiliary battery voltage is not applied between terminals z20-4 (SMRB) and z20-2 (GND) 10 kΩ or higher
      z30 - j2 Auxiliary battery voltage is applied between terminals z20-4 (SMRB) and z20-2 (GND) Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Hybrid Battery Junction Block Assembly
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      z20-4 (SMRB) - z20-2 (GND) -40 to 176°F (-40 to 80°C) 19.0 to 35.5 Ω
    5. Install the hybrid battery junction block assembly.

    NG → See step   55 

    OK: Go to next step 

  22. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG) 
    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 hybrid battery junction block assembly.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 16: Checking Hybrid Battery Junction Block Assembly (SMRG)
      GTY307585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      z31 - j3 Auxiliary battery voltage is not applied between terminals z20-1 (SMRG) and z20-2 (GND) 10 kΩ or higher
      z31 - j3 Auxiliary battery voltage is applied between terminals z20-1 (SMRG) and z20-2 (GND) Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Hybrid Battery Junction Block Assembly
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      z20-1 (SMRG) - z20-2 (GND) -40 to 176°F (-40 to 80°C) 19.0 to 35.5 Ω
    5. Install the hybrid battery junction block assembly.

    NG → See step   56 

    OK: Go to next step 

  23. CHECK FUSE (PCU) See step   13 

    NG → See step   44 

    OK: Go to next step 

  24. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT) See step   14 

    NG → REPAIR OR REPLACE POWER SOURCE CIRCUIT 

    OK: Go to next step 

  25. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER) See step   15 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  26. CHECK HYBRID VEHICLE CONTROL ECU See step   16 

    NG → See step   57 

    OK: Go to next step 

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  29. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 11 

    NG → CONNECT SECURELY 

    OK → See step   30 

  30. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL 
  31. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 12 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  32. 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   33 

  33. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  34. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 14 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  35. 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   36 

  36. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  37. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR). Refer to  PROCEDURE - Step 16 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  38. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - REAR MOTOR RESOLVER). Refer to  PROCEDURE - Step 17 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   39 

  39. REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  40. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (REAR 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. Check that the bolts for the rear motor cable are tightened to the specified torque, the rear motor cable is connected securely, and there are no contact problems.
      Fig 17: Identifying Rear Motor Cable & Fasteners
      GTY307515Courtesy 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).

    3. Disconnect the rear motor cable from the rear traction motor with transaxle assembly.
    4. Check for arc marks at the bolts for the rear 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. Connect the rear motor cable.

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  41. CHECK NO. 3 WIRE FRAME (REAR MOTOR CABLE) 
    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 18: Identifying Inverter Terminal Cover, The Inverter With Converter Assembly & Bolts
      GTY273338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the rear motor cable from the inverter with converter assembly.
      Fig 19: Identifying Rear Motor Cable & Fasteners
      GTY306441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the rear motor cable from the rear traction motor with transaxle assembly.
      Fig 20: Identifying Rear Motor Cable & Fasteners
      GTY307515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      Fig 21: Identifying Three-Phase AC Cables for MGR
      GTY306812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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
      j9-3 (R-U) - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      j9-2 (R-V) - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      j9-1 (R-W) - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 Three-phase AC Cable for MGR
      *a Shielded Ground
      NOTE:

      Wrap the terminals of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground.

    6. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      j9-3 (R-U) - j10-3 (R-U) Ignition switch off Below 1 Ω
      j9-2 (R-V) - j10-2 (R-V) Ignition switch off Below 1 Ω
      j9-1 (R-W) - j10-1 (R-W) Ignition switch off Below 1 Ω
      j9-3 (R-U) - j10-2 (R-V) Ignition switch off 10 kΩ or higher
      j9-2 (R-V) - j10-1 (R-W) Ignition switch off 10 kΩ or higher
      j9-1 (R-W) - j10-3 (R-U) Ignition switch off 10 kΩ or higher
    7. Connect the rear motor cable to the rear traction motor with transaxle assembly.
    8. Connect the rear motor cable to the inverter with converter assembly.
    9. Install the inverter terminal cover.

    NG → See step   58 

    OK: Go to next step 

  42. CHECK EXTENSION WIRE ASSEMBLY 
    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 rear traction motor with transaxle assembly.
    3. Remove the extension wire assembly from the rear traction motor with transaxle assembly.
    4. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      Fig 22: Identifying Extension Wire Assembly
      GTY307201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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
      R-U - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      R-V - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      R-W - Body ground and shielded ground Ignition switch off 10 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 Extension Wire Assembly
      *a Shielded Ground
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      R-U - R-U Ignition switch off Below 1 Ω
      R-V - R-V Ignition switch off Below 1 Ω
      R-W - R-W Ignition switch off Below 1 Ω
      R-U - R-V Ignition switch off 10 kΩ or higher
      R-V - R-W Ignition switch off 10 kΩ or higher
      R-W - R-U Ignition switch off 10 kΩ or higher
    6. Install the extension wire.
    7. Install the rear traction motor with transaxle assembly.

    NG → See step   59 

    OK → See step   43 

  43. REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  44. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) See step   23 

    NG → See step   46 

    OK: Go to next step 

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

    NEXT → REPLACE FUSE (PCU) 

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

    NEXT → REPLACE FUSE (PCU) 

  47. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  48. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  49. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  50. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  REMOVAL 
  51. REPLACE SERVICE PLUG GRIP. Refer to  REMOVAL 
  52. REPLACE SERVICE PLUG GRIP. Refer to  REMOVAL 
  53. REPLACE ELECTRIC VEHICLE FUSE. Refer to  REMOVAL 
  54. REPLACE NO. 3 WIRE FRAME. Refer to  REMOVAL 
  55. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  REMOVAL 
  56. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  REMOVAL 
  57. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
  58. REPLACE NO. 3 WIRE FRAME. Refer to  REMOVAL 
  59. REPLACE EXTENSION WIRE ASSEMBLY. Refer to  REMOVAL