DTC P0A78-113: Drive Motor "A" Inverter Performance [12/2014 - ]: Procedure

1. Connect the Techstream to the DLC3.
2. Turn the ignition switch to 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 including pending DTCs in the table 1 below are set before P0A78-113 is set.	B
   Any of the DTCs including pending 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	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 ignition switch off.

B → See step   32 

C → See step   35 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the ignition switch to 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 ignition switch off.

B → See step   30 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the ignition switch to 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
   Only P0A78-113 is output, or DTCs other than the ones in the table 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 Performance
   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 Performance
   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 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   32 

A: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

NG → See step   19 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

NG → See step   21 

OK: Go to next step 

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.

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3. Remove the inverter cover from the inverter with converter assembly.

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4. Check that the bolts for the motor cable (for MG1) are tightened to the specified torque, the motor cable (for MG1) is connected securely, and there are no contact problems.

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   Specified Condition

   Bolt A 

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

   Bolt B 

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

   NOTE: 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).
5. Disconnect the motor cable (for MG1) from the inverter with converter assembly.
6. Check for arc marks at the terminals for the motor cable (for MG1).

   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

7. Connect the motor cable (for MG1) to the inverter with converter assembly.
8. Install the inverter cover.
9. Install the inverter terminal cover.

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

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.

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3. Check that the bolts for the motor cable (for MG2) are tightened to the specified torque, the motor cable (for MG2) is connected securely, and there are no contact problems.

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   Specified Condition

   Bolt A 

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

   Bolt B 

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

   NOTE: 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 (for MG2) from the inverter with converter assembly.
5. Check for arc marks at the terminals for the motor cable (for MG2).

   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 (for MG2) to the inverter with converter assembly.
7. Install the inverter terminal cover.

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

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.

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3. Remove the inverter cover from the inverter with converter assembly.

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4. Disconnect the motor cable from the inverter with converter assembly.

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5. Check MG1 for an interphase short using a milliohmmeter.

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   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
      a2-1 (W) - a2-2 (U)	Ignition switch off	139.1 to 153.7 mΩ
      a2-2 (U) - a2-3 (V)	Ignition switch off	139.1 to 153.7 mΩ
      a2-3 (V) - a2-1 (W)	Ignition switch off	139.1 to 153.7 mΩ

      TEXT IN ILLUSTRATION
      
      

      *1	Shield Ground
      *a	Motor Cable (for MG1) (Inverter with Converter Assembly Side)

      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)
6. 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
   a2-1 (W) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a2-2 (U) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a2-3 (V) - Body ground and shield ground	Ignition switch off	100 MΩ or higher

7. Connect the motor cable.
8. Install the inverter cover.
9. Install the inverter terminal cover.

NG → See step   26 

OK: Go to next step 

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.

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3. Remove the inverter cover from the inverter with converter assembly.

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4. Disconnect the motor cable from the inverter with converter assembly.

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5. Check MG2 for an interphase short using a milliohmmeter.

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   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
      a4-1 (W) - a4-2 (U)	Ignition switch off	172.5 to 190.7 mΩ
      a4-2 (U) - a4-3 (V)	Ignition switch off	172.5 to 190.7 mΩ
      a4-3 (V) - a4-1 (W)	Ignition switch off	172.5 to 190.7 mΩ

      TEXT IN ILLUSTRATION
      
      

      *1	Shield Ground
      *a	Motor Cable (for MG2) (Inverter with Converter Assembly Side)

      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)
6. 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
   a4-1 (W) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a4-2 (U) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a4-3 (V) - Body ground and shield ground	Ignition switch off	100 MΩ or higher

7. Connect the motor cable.
8. Install the inverter cover.
9. Install the inverter terminal cover.

NG → See step   28 

OK: Go to next step 

1. Remove the PCU fuse from the No. 2 engine room relay block and No. 2 junction block assembly.

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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	No. 2 Engine Room Relay Block and No. 2 Junction Block Assembly
   *2	PCU fuse

3. Install the PCU fuse.

NG → See step   23 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   NOTE: After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.
2. Disconnect connector A47 from inverter with converter assembly.
3. Measure the resistance according to the value(s) in the table below.

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   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A47-28 (GND1) - Body ground	Ignition switch off	Below 1 Ω
   A47-27 (GND2) - Body ground	Ignition switch off	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Front view of wire harness connector (to Inverter with Converter Assembly)

4. Connect the cable to the negative (-) auxiliary battery terminal.
5. Turn the ignition switch to ON (IG).
6. Measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   A47-10 (+B) - Body ground	Ignition switch On (IG)	Same as auxiliary battery voltage
   A47-9 (+B2) - Body ground	Ignition switch On (IG)	Same as auxiliary battery voltage

   NOTE: Turning the ignition switch to 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 ignition 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 

1. Check that the service plug grip is not installed.
   NOTE: After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.
2. Disconnect connector A47 from the inverter with converter assembly.
3. Disconnect connector A39 from the hybrid vehicle control ECU.
4. Measure the resistance according to the value(s) in the table below.

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   Standard Resistance (Check for Open)

   Tester Connection	Switch Condition	Specified Condition
   A47-8 (HTM+) - A39-24 (HTM+)	Ignition switch off	Below 1 Ω
   A47-18 (HTM-) - A39-25 (HTM-)	Ignition switch off	Below 1 Ω
   A47-7 (MTH+) - A39-23 (MTH+)	Ignition switch off	Below 1 Ω
   A47-17 (MTH-) - A39-22 (MTH-)	Ignition switch off	Below 1 Ω
   A47-6 (REQ+) - A39-31 (REQ+)	Ignition switch off	Below 1 Ω
   A47-16 (REQ-) - A39-30 (REQ-)	Ignition switch off	Below 1 Ω
   A47-5 (CLK+) - A39-33 (CLK+)	Ignition switch off	Below 1 Ω
   A47-15 (CLK-) - A39-32 (CLK-)	Ignition switch off	Below 1 Ω

   Standard Resistance (Check for Short)

   Tester Connection	Switch Condition	Specified Condition
   A47-8 (HTM+) or A39-24 (HTM+) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A47-18 (HTM-) or A39-25 (HTM-) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A47-7 (MTH+) or A39-23 (MTH+) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A47-17 (MTH-) or A39-22 (MTH-) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A47-6 (REQ+) or A39-31 (REQ+) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A47-16 (REQ-) or A39-30 (REQ-) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A47-5 (CLK+) or A39-33 (CLK+) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   A47-15 (CLK-) or A39-32 (CLK-) - Body ground and other terminals	Ignition switch off	10 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *a	Front view of wire harness connector (to Inverter with Converter Assembly)
   *b	Rear view of wire harness connector (to Hybrid Vehicle Control ECU)

5. Connect the cable to the negative (-) auxiliary battery terminal.
6. Turn the ignition switch to ON (IG).
7. Measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   A47-8 (HTM+) or A39-24 (HTM+) - Body ground	Ignition switch ON (IG)	Below 1 V
   A47-18 (HTM-) or A39-25 (HTM-) - Body ground	Ignition switch ON (IG)	Below 1 V
   A47-7 (MTH+) or A39-23 (MTH+) - Body ground	Ignition switch ON (IG)	Below 1 V
   A47-17 (MTH-) or A39-22 (MTH-) - Body ground	Ignition switch ON (IG)	Below 1 V
   A47-6 (REQ+) or A39-31 (REQ+) - Body ground	Ignition switch ON (IG)	Below 1 V
   A47-16 (REQ-) or A39-30 (REQ-) - Body ground	Ignition switch ON (IG)	Below 1 V
   A47-5 (CLK+) or A39-33 (CLK+) - Body ground	Ignition switch ON (IG)	Below 1 V
   A47-15 (CLK-) or A39-32 (CLK-) - Body ground	Ignition switch ON (IG)	Below 1 V

   NOTE: Turning the ignition switch to ON (IG) with the hybrid vehicle control ECU and inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.
8. Turn the ignition switch off.
9. Disconnect the cable from the negative (-) auxiliary battery terminal.
10. Connect the hybrid vehicle control ECU connector.
11. Connect the inverter with converter assembly connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Disconnect connector A39 from the hybrid vehicle control ECU.
2. Measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A39-24 (HTM+) - A39-25 (HTM-)	Ignition switch off	80 to 170 Ω
   A39-23 (MTH+) - A39-22 (MTH-)	Ignition switch off	80 to 170 Ω
   A39-31 (REQ+) - A39-30 (REQ-)	Ignition switch off	80 to 170 Ω
   A39-33 (CLK+) - A39-31 (CLK-)	Ignition switch off	80 to 170 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Component without harness connected (Hybrid Vehicle Control ECU)

3. Connect the hybrid vehicle control ECU connector.

NG → See step   33 

OK: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → CONNECT SECURELY 

OK → See step   34 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   31 

NG → CONNECT SECURELY 

OK: Go to next step 

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   31 

1. Check that the service plug grip is not installed.
   NOTE: After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.
2. Disconnect connector A47 from the inverter with converter assembly.
3. Measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A47-10 (+B) - Body ground	Ignition switch off	10 kΩ or higher
   A47-9 (+B2) - Body ground	Ignition switch off	10 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *a	Front view of wire harness connector (to Inverter with Converter Assembly)

4. Connect the inverter with converter assembly connector.

NG → See step   25 

OK: Go to next step 

Refer to COMPONENTS [12/2014 - ]

NEXT → REPLACE FUSE (PCU) 

NEXT → REPLACE FUSE (PCU) 

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 with converter assembly. Refer to COMPONENTS [12/2014 - ] .
3. Check that the bolts for the motor cable (for MG1) are tightened to the specified torque, the motor cable (for MG1) is connected securely, and there are no contact problems.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

   Bolt A 

   T=19.5 N*m (199 kgf*cm, 14 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 13.5 and 25 N*m (138 and 255 kgf*cm, 10 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 motor cable (for MG1) from the hybrid vehicle transaxle assembly.
5. Check for arc marks at the terminals for the motor cable (for MG1).

   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 (for MG1) 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 

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 motor cable. Refer to COMPONENTS [12/2014 - ] .
3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

   Courtesy 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
   a2-1 (W) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a2-2 (U) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a2-3 (V) - Body ground and shield ground	Ignition switch off	100 MΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shield ground
   *a	Motor Cable (for MG1) (Inverter with Converter Assembly Side)
   *b	Motor Cable (for MG1) (Hybrid Vehicle Transaxle Assembly Side)

   NOTE: Wrap the terminal of the motor cable (for MG1) 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
   a2-1 (W) - a1-1 (W)	Ignition switch off	Below 1 Ω
   a2-2 (U) - a1-2 (U)	Ignition switch off	Below 1 Ω
   a2-3 (V) - a1-3 (V)	Ignition switch off	Below 1 Ω
   a2-1 (W) - a1-2 (U)	Ignition switch off	100 MΩ or higher
   a2-2 (U) - a1-3 (V)	Ignition switch off	100 MΩ or higher
   a2-3 (V) - a1-1 (W)	Ignition switch off	100 MΩ or higher

5. Install the motor cable.

NG → See step   36 

OK → See step   31 

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 motor cable (for MG2) are tightened to the specified torque, the motor cable (for MG2) is connected securely, and there are no contact problems.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

   Bolt A 

   T=19.5 N*m (199 kgf*cm, 14 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 13.5 and 25 N*m (138 and 255 kgf*cm, 10 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).
3. Disconnect the motor cable (for MG2) from the hybrid vehicle transaxle assembly.
4. Check for arc marks at the terminals for the motor cable (for MG2).

   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 (for MG2) to the hybrid vehicle transaxle assembly.

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: Go to next step 

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 motor cable. Refer to COMPONENTS [12/2014 - ] .
3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

   Courtesy 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
   a4-1 (W) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a4-2 (U) - Body ground and shield ground	Ignition switch off	100 MΩ or higher
   a4-3 (V) - Body ground and shield ground	Ignition switch off	100 MΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shield ground
   *a	Motor Cable (for MG2) (Inverter with Converter Assembly Side)
   *b	Motor Cable (for MG2) (Hybrid Vehicle Transaxle Assembly Side)

   NOTE: Wrap the terminal of the motor cable (for MG2) 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
   a4-1 (W) - a3-1 (W)	Ignition switch off	Below 1 Ω
   a4-2 (U) - a3-3 (U)	Ignition switch off	Below 1 Ω
   a4-3 (V) - a3-2 (V)	Ignition switch off	Below 1 Ω
   a4-1 (W) - a3-3 (U)	Ignition switch off	100 MΩ or higher
   a4-2 (U) - a3-2 (V)	Ignition switch off	100 MΩ or higher
   a4-3 (V) - a3-1 (W)	Ignition switch off	100 MΩ or higher

5. Install the motor cable.

NG → See step   37 

OK → See step   31