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Home >> Toyota >> 2012 >> Prius V >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control System [Diagnostic Codes (P0069-273 - P0A78-113)] >> 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 (HYBRID CONTROL) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    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 1 below are set before P0A78-113 is set. B
      Any of the DTCs in the table 2 below are set before P0A78-113 is set. C
      TABLE 1

      DTC No. Relevant Diagnosis
      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
      P3004-803 High Voltage Power Resource
      TABLE 2

      DTC No. Relevant Diagnosis
      P0A9C-123 Hybrid Battery Temperature Sensor "A" Range / Performance
      P0A9D-123 Hybrid Battery Temperature Sensor "A" Circuit Low
      P0A9E-123 Hybrid Battery Temperature Sensor "A" Circuit High
      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
      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 Temperature Sensor "C" Range / Performance
      P0ACC-123 Hybrid Battery Temperature Sensor "C" Circuit Low
      P0ACD-123 Hybrid Battery Temperature Sensor "C" Circuit High
      P0AFC-123 Hybrid Battery Pack Sensor Module
      P3011-123, P3012-123, P3013-123, P3014-123, P3015-123, P3016-123, P3017-123, P3018-123, P3019-123, P3020-123, P3021-123, P3022-123, P3023-123, P3024-123 Battery Block # Becomes Weak
      P3065-123 Hybrid Battery Temperature Sensor Range/Performance Stuck "A"
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low

      HINT: 

      • Refer to the Freeze Frame data to determine the order in which the DTCs were set.
      • 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 power switch off.

    B → See step   31 

    C → See step   35 

    A: Go to next step 

  2. CHECK DTC OUTPUT (HYBRID CONTROL) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    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 power switch off.

    B → See step   30 

    A: Go to next step 

  3. CHECK DTC OUTPUT (HYBRID CONTROL) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    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, 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
      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
      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
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 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
      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
      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
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-266, 267, 279, 287, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-442, 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 power switch off.

    B → See step   31 

    A: Go to next step 

  4. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) See step   4 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) See step   3 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  6. CHECK GENERATOR RESOLVER See step   4 

    NG → See step   19 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) See step   5 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  8. CHECK MOTOR RESOLVER See 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter cover from the inverter with converter assembly.
      Fig 1: Identifying Bolts And Inverter Cover
      GTY231954Courtesy 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 Cable & Fasteners
      GTY221975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified Condition

      Bolt A 

      8.0 N*m (82 kgf*cm, 71 in.*lbf)

      Bolt B 

      9.2 N*m (94 kgf*cm, 81 ft.*lbf)

      NOTE:
      • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).
      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).
    4. Disconnect the generator cable from the inverter with converter assembly.
    5. Check for arc marks at the bolts and terminals 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
    6. Connect the generator cable to the inverter with converter assembly.
    7. Install the inverter 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter cover from the inverter with converter assembly.
      Fig 3: Identifying Bolts And Inverter Cover
      GTY231954Courtesy 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
      GTY330431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified Condition

      Bolt A 

      8.0 N*m (82 kgf*cm, 71 in.*lbf)

      Bolt B 

      9.2 N*m (94 kgf*cm, 81 ft.*lbf)

      NOTE:
      • Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).
      • Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).
    4. Disconnect the motor cable from the inverter with converter assembly.
    5. Check for arc marks at the bolts and terminals 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
    6. Connect the motor cable to the inverter with converter assembly.
    7. Install the inverter 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter cover from the inverter with converter assembly.
      Fig 5: Identifying Bolts And Inverter Cover
      GTY231954Courtesy 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: Checking MG1 For An Interphase Short
      GTY341385Courtesy 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
        f1-1 (W) - f1-2 (U) Power switch off 89.5 to 98.9 mΩ
        f1-2 (U) - f1-3 (V) Power switch off 89.5 to 98.9 mΩ
        f1-3 (V) - f1-1 (W) Power switch off 89.5 to 98.9 mΩ
        TEXT IN ILLUSTRATION

        *1 Generator Cable
        (Inverter with Converter Assembly Side)
        *2 Shield Ground

        HINT: 

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

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

        The calculation is based on the following:

        • R20: Resistance at 20°C (68° F) (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
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
    6. Connect the generator cable and motor cable.
    7. Install the inverter cover.

    NG → See step   26 

    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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter cover from the inverter with converter assembly.
      Fig 7: Identifying Bolts And Inverter Cover
      GTY231954Courtesy 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: Checking MG2 For An Interphase Short
      GTY327129Courtesy 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
        e1-1 (W) - e1-2 (U) Power switch off 152.6 to 169.0 mΩ
        e1-2 (U) - e1-3 (V) Power switch off 157.6 to 174.0 mΩ
        e1-3 (V) - e1-1 (W) Power switch off 151.6 to 168.0 mΩ
        TEXT IN ILLUSTRATION

        *1 Motor Cable
        (Inverter with Converter Assembly Side)
        *2 Shield Ground

        HINT: 

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

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

        The calculation is based on the following:

        • R20: Resistance at 20°C (68° F) (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
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
    6. Connect the generator cable and motor cable.
    7. Install the inverter 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 and junction block assembly.
      Fig 9: Checking Fuse (PCU)
      GTY336379Courtesy 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 terminal Always Below 1Ω
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block and Junction Block Assembly
      *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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect connector A59 from 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)
      GTY325269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A59-28 (GND1) - Body ground Power switch off Below 1 Ω
      A59-27 (GND2) - Body ground Power switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Connect the cable to the negative (-) auxiliary battery terminal.
    5. Turn the power switch on (IG).
    6. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A59-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A59-9 (+B2) - Body ground Power switch on (IG) 11 to 14 V
      NOTE:

      Turning the power switch on (IG) with the inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.
    8. Disconnect the cable from the negative (-) auxiliary battery terminal.
    9. Connect the inverter with converter assembly connector.

    NG → REPAIR OR REPLACE POWER SOURCE CIRCUIT 

    OK: Go to next step 

  15. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect connector A59 from the inverter with converter assembly.
    3. Disconnect connector A22 from the power management control ECU.
    4. Measure the resistance according to the value(s) in the table below.
      Fig 11: Checking Harness And Connector (Power Management Control ECU - Inverter With Converter)
      GTY329384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      A22-24 (HTM+) - A59-8 (HTM+) Power switch off Below 1 Ω
      A22-25 (HTM-) - A59-18 (HTM-) Power switch off Below 1 Ω
      A22-30 (MTH+) - A59-7 (MTH+) Power switch off Below 1 Ω
      A22-29 (MTH-) - A59-17 (MTH-) Power switch off Below 1 Ω
      A22-33 (REQ+) - A59-6 (REQ+) Power switch off Below 1 Ω
      A22-32 (REQ-) - A59-16 (REQ-) Power switch off Below 1 Ω
      A22-21 (CLK+) - A59-5 (CLK+) Power switch off Below 1 Ω
      A22-20 (CLK-) - A59-15 (CLK-) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A22-24 (HTM+) or A59-8 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-25 (HTM-) or A59-18 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-30 (MTH+) or A59-7 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-29 (MTH-) or A59-17 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-33 (REQ+) or A59-6 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-32 (REQ-) or A59-16 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-21 (CLK+) or A59-5 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-20 (CLK-) or A59-15 (CLK-) - Body ground and other terminals Power 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 Power Management Control ECU)
    5. Connect the cable to the negative (-) auxiliary battery terminal.
    6. Turn the power switch on (IG).
    7. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A22-24 (HTM+) or A59-8 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A22-25 (HTM-) or A59-18 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A22-30 (MTH+) or A59-7 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A22-29 (MTH-) or A59-17 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A22-33 (REQ+) or A59-6 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A22-32 (REQ-) or A59-16 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A22-21 (CLK+) or A59-5 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A22-20 (CLK-) or A59-15 (CLK-) - Body ground Power switch on (IG) Below 1 V
      NOTE:

      Turning the power switch on (IG) with the power management 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 power switch off.
    9. Disconnect the cable from the negative (-) auxiliary battery terminal.
    10. Connect the power management control ECU connector.
    11. Connect the inverter with converter assembly connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  16. CHECK POWER MANAGEMENT CONTROL ECU 
    1. Disconnect connector A22 from the power management control ECU.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 12: Checking Power Management Control ECU
      GTY333594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A22-24 (HTM+) - A22-25 (HTM-) Power switch off 80 to 170 Ω
      A22-30 (MTH+) - A22-29 (MTH-) Power switch off 80 to 170 Ω
      A22-33 (REQ+) - A22-32 (REQ-) Power switch off 80 to 170 Ω
      A22-21 (CLK+) - A22-20 (CLK-) Power switch off 80 to 170 Ω
      TEXT IN ILLUSTRATION

      *a Component without harness connected
      (Power Management Control ECU)
    3. Connect the power management control ECU connector.

    NG → See step   33 

    OK: Go to next step 

  17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) See step   7 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) See step   8 

    NG → CONNECT SECURELY 

    OK → See step   34 

  19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) See step   9 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) See step   10 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   32 

  21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) See step   11 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  22. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) See step   12 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   32 

  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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect connector A59 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)
      GTY328925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A59-10 (+B) - Body ground Power switch off 10 kΩ or higher
      A59-9 (+B2) - Body ground Power 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 

    Refer to COMPONENTS

    NEXT → REPLACE FUSE (PCU) 

  25. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT → REPLACE FUSE (PCU) 

  26. CHECK HYBRID VEHICLE TRANSAXLE 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter with converter assembly.
    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 14: Identifying Generator Cable & Fasteners
      GTY224152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified Condition

      Bolt A 

      T=20 N*m {204 kgf*cm, 15 ft.*lbf}

      Bolt B 

      T=10 N*m {102 kgf*cm, 7 ft.*lbf}

      NOTE:
      • Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 and 245 kgf*cm, 12 and 18 ft.*lbf).
      • Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).
    4. Disconnect the generator cable from the hybrid vehicle transaxle assembly.
    5. Check for arc marks at the bolts and terminals 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
    6. Connect the generator cable to the hybrid vehicle transaxle assembly.
    7. Install the inverter with converter assembly.

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  27. CHECK GENERATOR 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the generator cable.
    3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      Fig 15: Measuring Resistance Of Generator Cable
      GTY329932Courtesy 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
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 Shielded ground
      *a Generator Cable
      (Inverter with Converter Assembly Side)
      *b Generator Cable
      (Hybrid Vehicle Transaxle Assembly Side)
      NOTE:

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

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

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      f1-1 (W) - f2-3 (W) Power switch off Below 1 Ω
      f1-2 (U) - f2-2 (U) Power switch off Below 1 Ω
      f1-3 (V) - f2-1 (V) Power switch off Below 1 Ω
      f1-1 (W) - f2-2 (U) Power switch off 100 MΩ or higher
      f1-2 (U) - f2-1 (V) Power switch off 100 MΩ or higher
      f1-3 (V) - f2-3 (W) Power switch off 100 MΩ or higher
    5. Install the generator cable.

    NG → See step   36 

    OK → See step   32 

  28. CHECK HYBRID VEHICLE TRANSAXLE 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. 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 16: Identifying Motor Cable & Fasteners
      GTY221072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified Condition

      T=10 N*m {102 kgf*cm, 7 ft.*lbf}

      NOTE:

      Make sure that the tightening torque of the bolts is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

    3. Disconnect the motor cable from the hybrid vehicle transaxle assembly.
    4. Check for arc marks at the bolts and terminals 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. Connect the motor cable to the hybrid vehicle transaxle assembly.

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  29. CHECK 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the motor cable.
    3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      Fig 17: Measuring Resistance Of Motor Cable
      GTY343415Courtesy 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
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      TEXT IN ILLUSTRATION

      *1 Shielded ground
      *a Motor Cable
      (Inverter with Converter Assembly Side)
      *b Motor Cable
      (Hybrid Vehicle Transaxle Assembly Side)
      NOTE:

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

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

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      e1-1 (W) - e2-1 (W) Power switch off Below 1 Ω
      e1-2 (U) - e2-3 (U) Power switch off Below 1 Ω
      e1-3 (V) - e2-2 (V) Power switch off Below 1 Ω
      e1-1 (W) - e2-3 (U) Power switch off 100 MΩ or higher
      e1-2 (U) - e2-2 (V) Power switch off 100 MΩ or higher
      e1-3 (V) - e2-1 (W) Power switch off 100 MΩ or higher
    5. Install the motor cable.

    NG → See step   37 

    OK → See step   32 

  30. GO TO DTC CHART (P0A78-202). Refer to  DTC P0A78-202: Drive Motor "A" Inverter Performance 
  31. GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  32. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS 
  33. REPLACE POWER MANAGEMENT CONTROL ECU. Refer to  COMPONENTS 
  34. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS 
  35. GO TO DTC CHART (HYBRID BATTERY SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  36. REPLACE GENERATOR CABLE. Refer to  COMPONENTS 
  37. REPLACE MOTOR CABLE. Refer to  COMPONENTS 
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