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DTC P0A78-113: Drive Motor "A" Inverter Performance [10/2015 - ]: 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 for DTCs.

      Result

      Result Proceed to
      P0A78-113 is stored before any of the DTCs in the tables below are stored. A
      Any of the DTCs including pending DTCs in table 1 below are stored before P0A78-113 is stored. B
      Any of the DTCs in table 2 below are stored before P0A78-113 is stored. 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, P3025-123, P3026-123, P3027-123 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 stored.
      • P0A78-113 may be stored due to a malfunction which also causes DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.
    5. Turn the power switch off.

    Result: 

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) 

    (Refer to DIAGNOSTIC TROUBLE CODE CHART [10/2015 - ] )

    Result: 

    C 

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) 

    (Refer to DIAGNOSTIC TROUBLE CODE CHART [10/2015 - ] )

    Result: 

    A 

    See step  2

  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 for DTCs.

      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, 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.

    Result: 

    B 

    GO TO DTC CHART (P0A78-202) 

    (Refer to DTC P0A78-202: Drive Motor "A" Inverter Performance [10/2015 - ] )

    Result: 

    A 

    See step  3

  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 for DTCs.

      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, diagnose that DTC first, then check Table 2 below.

      Result

      Result Proceed to
      P0A78-113 only is output, or DTCs except the ones in the tables below are also output. A
      Any of the following DTCs including pending DTCs are also output. B
      TABLE 1

      DTC No. Relevant Diagnosis
      P06B0-163 Sensor Power Supply "A" Circuit / Open
      P06D6-511 Sensor Reference Voltage "F" Circuit / Open
      P06E6-164 Sensor Power Supply "C" Circuit / Open
      P0A1A-151, 166, 517, 658, 791, 809 Generator Control Module
      P0A1B-198, 503, 505, 547, 554, 786, 794, 806 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500, 504, 506, 549, 556, 808 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, 518, 811 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A78-279, 287, 548, 555, 807 Drive Motor "A" Inverter Performance
      P0A7A-325, 810 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A92-521 Hybrid Generator 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
      P0BEA-290 Drive Motor "A" Phase V Current Sensor Circuit Range / Performance
      P0BEE-298 Drive Motor "A" Phase W Current Sensor Circuit Range / Performance
      P0C19-306 Drive Motor "A" Torque Delivered Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-586 Drive Motor "A" Inverter Voltage Sensor Circuit Range / Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Voltage Sensor Circuit High
      P0E05-328 Generator Phase V Current Sensor Circuit Range / Performance
      P0E09-336 Generator Phase W Current Sensor Circuit Range / Performance
      P0E32-585 DC/DC Converter Voltage Sensor "A" Range / Performance
      P0E33-589 DC/DC Converter Voltage Sensor "A" Low
      P0E34-590 DC/DC Converter Voltage Sensor "A" High
      P0E71-344 Generator Torque Delivered Performance
      P1C2A-155 Generator A/D Converter Circuit
      P1C2B-192 Drive Motor "A" A/D Converter Circuit
      P1C2D-587 Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294 Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302 Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333 Generator Phase V Current Sensor Correlation
      P1C3F-341 Generator Phase W Current Sensor Correlation
      P1C4A-288 Drive Motor "A" Phase V Current Sensor Sub Circuit Range / Performance
      P1C4F-296 Drive Motor "A" Phase W Current Sensor Sub Circuit Range / Performance
      P1C54-326 Generator Phase V Current Sensor Sub Circuit Range / Performance
      P1C59-334 Generator Phase W Current Sensor Sub Circuit Range / Performance
      P1C6D-501 Drive Motor "A" Phase V Current Sensor Offset Range / Performance
      P1C6E-502 Drive Motor "A" Phase W Current Sensor Offset Range / Performance
      P1C71-515 Generator Phase V Current Sensor Offset Range / Performance
      P1C72-516 Generator Phase W Current Sensor Offset Range / Performance
      P1C73-512 Sensor Standard Voltage "F" Circuit / Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3004-803 High Voltage Power Resource
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      TABLE 2

      DTC No. Relevant Diagnosis
      P06B0-163 Sensor Power Supply "A" Circuit / Open
      P06D6-511 Sensor Reference Voltage "F" Circuit / Open
      P06E6-164 Sensor Power Supply "C" Circuit / Open
      P0A1A-151, 166, 517, 658, 791, 809 Generator Control Module
      P0A1B-198, 503, 505, 547, 554, 786, 794, 806 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500, 504, 506, 549, 556, 808 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, 518, 811 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A78-279, 287, 548, 555, 807 Drive Motor "A" Inverter Performance
      P0A7A-325, 810 Generator Inverter Performance
      P0A92-521 Hybrid Generator 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
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-586 Drive Motor "A" Inverter Voltage Sensor Circuit Range / Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Voltage Sensor Circuit High
      P0E05-328 Generator Phase V Current Sensor Circuit Range / Performance
      P0E09-336 Generator Phase W Current Sensor Circuit Range / Performance
      P0E32-585 DC/DC Converter Voltage Sensor "A" Range / Performance
      P0E33-589 DC/DC Converter Voltage Sensor "A" Low
      P0E34-590 DC/DC Converter Voltage Sensor "A" High
      P0E71-344 Generator Torque Delivered Performance
      P1C2A-155 Generator A/D Converter Circuit
      P1C2B-192 Drive Motor "A" A/D Converter Circuit
      P1C2D-587 Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294 Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302 Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333 Generator Phase V Current Sensor Correlation
      P1C3F-341 Generator Phase W Current Sensor Correlation
      P1C54-326 Generator Phase V Current Sensor Sub Circuit Range / Performance
      P1C59-334 Generator Phase W Current Sensor Sub Circuit Range / Performance
      P1C71-515 Generator Phase V Current Sensor Offset Range / Performance
      P1C72-516 Generator Phase W Current Sensor Offset Range / Performance
      P1C73-512 Sensor Standard Voltage "F" Circuit / Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3004-803 High Voltage Power Resource
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator

      HINT: 

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

    Result: 

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) 

    (Refer to DIAGNOSTIC TROUBLE CODE CHART [10/2015 - ] )

    Result: 

    A 

    See step  4

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

    Refer to PROCEDURE - Step 4

    Result: 

    NG 

    CONNECT SECURELY 

    Result: 

    OK 

    See step  5

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

    Refer to PROCEDURE - Step 3

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  6

  6. CHECK GENERATOR RESOLVER 

    Refer to PROCEDURE - Step 4

    Result: 

    NG 

    See step  19

    Result: 

    OK 

    See step  7

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

    Refer to PROCEDURE - Step 5

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  8

  8. CHECK MOTOR RESOLVER 

    Refer to PROCEDURE - Step 6

    Result: 

    NG 

    See step  21

    Result: 

    OK 

    See step  9

  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 otherwise instructed because this may cause a malfunction.

    2. Remove the upper inverter cover (generator cable side) from the inverter with converter assembly.
      GTY561773Courtesy 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.
      GTY317703Courtesy 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 bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Disconnect the generator cable from the inverter with converter assembly.
    5. Check for arc marks at the 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 upper inverter cover (generator cable side).

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  10

  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 otherwise instructed because this may cause a malfunction.

    2. Remove the upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY561768Courtesy 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.
      GTY317701Courtesy 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 bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Disconnect the motor cable from the inverter with converter assembly.
    5. Check for arc marks at the 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 upper inverter cover (motor cable side).

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  11

  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 otherwise instructed because this may cause a malfunction.

    2. Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY561774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the generator cable and motor cable from the inverter with converter assembly.
      GTY568840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Cable
      *2 Motor Cable
    4. Check MG1 for an interphase short using a milliohmmeter.
      GTY604537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a Generator Cable
      (Inverter with Converter Assembly Side)
      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 Condition Specified Condition
        e1-1 (W) - e1-3 (U) Power switch off 59.1 to 67.5 mΩ
        e1-2 (V) - e1-1 (W) Power switch off 59.1 to 67.5 mΩ
        e1-3 (U) - e1-2 (V) Power switch off 62.1 to 70.5 mΩ
        • 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)

        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).

    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 Condition Specified Condition
      e1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      e1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
    6. Connect the generator cable and motor cable.
    7. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    When Not Using the Engine Support Bridge: Refer to COMPONENTS [10/2014 - ]

    When Using the Engine Support Bridge: Refer to COMPONENTS [10/2015 - ]

    Result: 

    OK 

    See step  12

  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 otherwise instructed because this may cause a malfunction.

    2. Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY561774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the generator cable and motor cable from the inverter with converter assembly.
      GTY568840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Cable
      *2 Motor Cable
    4. Check MG2 for an interphase short using a milliohmmeter.
      GTY595217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a Motor Cable
      (Inverter with Converter Assembly Side)
      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 Condition Specified Condition
        d1-1 (W) - d1-3 (U) Power switch off 71.4 to 81.0 mΩ
        d1-2 (V) - d1-1 (W) Power switch off 71.4 to 81.0 mΩ
        d1-3 (U) - d1-2 (V) Power switch off 74.4 to 84.1 mΩ

        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 Condition Specified Condition
      d1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      d1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
    6. Connect the generator cable and motor cable.
    7. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    When Not Using the Engine Support Bridge: Refer to COMPONENTS [10/2014 - ]

    When Using the Engine Support Bridge: Refer to COMPONENTS [10/2015 - ]

    Result: 

    OK 

    See step  13

  13. CHECK FUSE (INV) 
    1. Remove the INV fuse from the No. 2 engine room relay block.
      GTY599916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Engine Room Relay Block
      *2 INV fuse
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      INV fuse terminal Always Below 1 Ω
    3. Install the INV fuse.

    Result: 

    NG 

    See step  23

    Result: 

    OK 

    See step  14

  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 otherwise instructed because this may cause a malfunction.

    2. Disconnect the A50 inverter with converter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.
      GTY562957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)

      Standard Resistance

      Tester Connection Condition Specified Condition
      A50-10 (GND1) - Body ground Power switch off Below 1 Ω
      A50-11 (GND2) - Body ground Power switch off Below 1 Ω
    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 Condition Specified Condition
      A50-30 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A50-31 (+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. Reconnect the A50 inverter with converter assembly connector.

    Result: 

    NG 

    REPAIR OR REPLACE POWER SOURCE CIRCUIT 

    Result: 

    OK 

    See step  15

  15. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - INVERTER WITH CONVERTER 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 power switch on (READY), unless otherwise instructed because this may cause a malfunction.

    2. Disconnect the A68 hybrid vehicle control ECU assembly connector.
    3. Disconnect the A50 inverter with converter assembly connector.
    4. Measure the resistance according to the value(s) in the table below.
      GTY569545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU Assembly)
      *b Front view of wire harness connector
      (to Inverter with Converter Assembly)

      Standard Resistance (Check for Open)

      Tester Connection Condition Specified Condition
      A68-24 (HTM+) - A50-9 (HTM+) Power switch off Below 1 Ω
      A68-25 (HTM-) - A50-20 (HTM-) Power switch off Below 1 Ω
      A68-23 (MTH+) - A50-8 (MTH+) Power switch off Below 1 Ω
      A68-22 (MTH-) - A50-19 (MTH-) Power switch off Below 1 Ω
      A68-31 (REQ+) - A50-26 (REQ+) Power switch off Below 1 Ω
      A68-30 (REQ-) - A50-37 (REQ-) Power switch off Below 1 Ω
      A68-33 (CLK+) - A50-7 (CLK+) Power switch off Below 1 Ω
      A68-32 (CLK-) - A50-18 (CLK-) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Condition Specified Condition
      A68-24 (HTM+) or A50-9 (HTM+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A68-25 (HTM-) or A50-20 (HTM-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A68-23 (MTH+) or A50-8 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A68-22 (MTH-) or A50-19 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A68-31 (REQ+) or A50-26 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A68-30 (REQ-) or A50-37 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
      A68-33 (CLK+) or A50-7 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A68-32 (CLK-) or A50-18 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
    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 Condition Specified Condition
      A68-24 (HTM+) or A50-9 (HTM+) - Body ground Power switch on (IG) Below 1 V
      A68-25 (HTM-) or A50-20 (HTM-) - Body ground Power switch on (IG) Below 1 V
      A68-23 (MTH+) or A50-8 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A68-22 (MTH-) or A50-19 (MTH-) - Body ground Power switch on (IG) Below 1 V
      A68-31 (REQ+) or A50-26 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A68-30 (REQ-) or A50-37 (REQ-) - Body ground Power switch on (IG) Below 1 V
      A68-33 (CLK+) or A50-7 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A68-32 (CLK-) or A50-18 (CLK-) - Body ground Power switch on (IG) Below 1 V
      NOTE:

      Turning the power switch on (IG) with the hybrid vehicle control ECU assembly and inverter with converter assembly connectors 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. Reconnect the A50 inverter with converter assembly connector.
    11. Reconnect the A68 hybrid vehicle control ECU assembly connector.

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  16

  16. CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY 
    1. Disconnect the A68 hybrid vehicle control ECU assembly connector.
    2. Measure the resistance according to the value(s) in the table below.
      GTY569279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Hybrid Vehicle Control ECU Assembly)

      Standard Resistance

      Tester Connection Condition Specified Condition
      A68-24 (HTM+) - A68-25 (HTM-) Power switch off 80 to 170 Ω
      A68-23 (MTH+) - A68-22 (MTH-) Power switch off 80 to 170 Ω
      A68-31 (REQ+) - A68-30 (REQ-) Power switch off 80 to 170 Ω
      A68-33 (CLK+) - A68-32 (CLK-) Power switch off 80 to 170 Ω
    3. Reconnect the A68 hybrid vehicle control ECU assembly connector.

    Result: 

    NG 

    REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY 

    (Refer to COMPONENTS [10/2015 - ] )

    Result: 

    OK 

    See step  17

  17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 7

    Result: 

    NG 

    CONNECT SECURELY 

    Result: 

    OK 

    See step  18

  18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 8

    Result: 

    OK 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    Result: 

    NG 

    CONNECT SECURELY 

  19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 9

    Result: 

    NG 

    CONNECT SECURELY 

    Result: 

    OK 

    See step  20

  20. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER) 

    Refer to PROCEDURE - Step 10

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    When Not Using the Engine Support Bridge: Refer to COMPONENTS [10/2014 - ]

    When Using the Engine Support Bridge: Refer to COMPONENTS [10/2015 - ]

  21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 11

    Result: 

    NG 

    CONNECT SECURELY 

    Result: 

    OK 

    See step  22

  22. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER) 

    Refer to PROCEDURE - Step 12

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    When Not Using the Engine Support Bridge: Refer to COMPONENTS [10/2014 - ]

    When Using the Engine Support Bridge: Refer to COMPONENTS [10/2015 - ]

  23. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - INV 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 otherwise instructed because this may cause a malfunction.

    2. Disconnect the A50 inverter with converter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.
      GTY592612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)

      Standard Resistance

      Tester Connection Condition Specified Condition
      A50-30 (+B) - Body ground Power switch off 10 kΩ or higher
      A50-31 (+B2) - Body ground Power switch off 10 kΩ or higher
    4. Reconnect the A50 inverter with converter assembly connector.

    Result: 

    NG 

    See step  25

    Result: 

    OK 

    See step  24

  24. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    NEXT 

    REPLACE FUSE (INV) 

  25. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT 

    REPLACE FUSE (INV) 

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