DTC P0A78-121: Drive Motor "A" Inverter Performance [11/2016 - ]: Procedure

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.

   Powertrain > Hybrid Control > Trouble Codes 

   Result

   Result	Proceed to
   P0A78-121 is stored before any of the DTCs in the table below are stored.	A
   Any of the DTCs including pending DTCs in the table 1 below are stored before P0A78-121 is stored.	B
   Any of the DTCs including pending DTCs in the table 2 below are stored before P0A78-121 is stored.	C

   TABLE 1
   
   

   Relevant DTC
   P3000-388, 389, 603	Battery Control System
   P3004-133	High Voltage Power Resource

   TABLE 2
   
   

   Relevant DTC
   P0A95-123	High Voltage Fuse
   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
   P0AE9-123	Hybrid Battery Temperature Sensor "D" Range/Performance
   P0AEA-123	Hybrid Battery Temperature Sensor "D" Circuit Low
   P0AEB-123	Hybrid Battery Temperature Sensor "D" Circuit High
   P0AFC-123	Hybrid Battery Pack Sensor Module
   P0BC3-123	Hybrid Battery Temperature Sensor "E" Range/Performance
   P0BC4-123	Hybrid Battery Temperature Sensor "E" Circuit Low
   P0BC5-123	Hybrid Battery Temperature Sensor "E" Circuit High
   P0C34-123	Hybrid Battery Temperature Sensor "F" Range/Performance
   P0C35-123	Hybrid Battery Temperature Sensor "F" Circuit Low
   P0C36-123	Hybrid Battery Temperature Sensor "F" Circuit High
   P0C6E-123	Hybrid Battery Temperature Sensor "A" / "B" Correlation
   P0C70-123	Hybrid Battery Temperature Sensor "C" / "D" Correlation
   P0C72-123	Hybrid Battery Temperature Sensor "E" / "F" Correlation
   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	Battery Block # Becomes Weak
   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.
   • P0A78-121 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:  3

B 

GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2016 - 10/2017]  Refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2017 - ] 

Result:  2

C 

GO TO DTC CHART (HYBRID BATTERY SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2016 - ] 

Result:  1

A 

See step  2

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.

   Powertrain > Hybrid Control > Trouble Codes 

   Result

   Result	Proceed to
   P0A78-121 only is output, or DTCs except the ones in the table below are also output.	A
   Any of the following DTCs including pending DTCs are also output.	B

   Relevant DTC
   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
   P0A1C-118, 124, 169, 693, 709, 710, 713, 797, 812	Drive Motor "B" 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
   P0A45-669	Drive Motor "B" Position Sensor Circuit
   P0A46-120, 126, 171, 671, 695, 814	Drive Motor "B" Position Sensor Circuit Range / Performance
   P0A47-670	Drive Motor "B" Position Sensor Circuit Low
   P0A4B-253	Generator Position Sensor Circuit
   P0A4C-513, 518, 811	Generator Position Sensor Circuit Range / Performance
   P0A4D-255	Generator Position Sensor Circuit Low
   P0A78-113, 128, 279, 284, 286, 287, 548, 555, 807	Drive Motor "A" Inverter Performance
   P0A79-119, 125, 136, 170, 692, 694, 696, 712, 813	Drive Motor "B" Inverter Performance
   P0A7A-122, 130, 322, 324, 325, 810	Generator Inverter Performance
   P0A90-509	Drive Motor "A" Performance
   P0A91-702	Drive Motor "B" Performance
   P0A92-521	Hybrid Generator Performance
   P0A93-346	Inverter Cooling System Performance
   P0A94-172, 553, 557	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
   P0BEA-290	Drive Motor "A" Phase V Current Sensor Circuit Range / Performance
   P0BEE-298	Drive Motor "A" Phase W Current Sensor Circuit Range / Performance
   P0BF6-683	Drive Motor "B" Phase V Current Sensor Circuit Range / Performance
   P0BFA-685	Drive Motor "B" Phase W Current Sensor Circuit Range / Performance
   P0C19-306	Drive Motor "A" Torque Delivered Performance
   P0C1A-704	Drive Motor "B" Torque Delivered Performance
   P0C73-776	Motor Electronics Coolant Pump "A" Control 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
   P1C2C-706	Drive Motor "B" 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
   P1C6F-688	Drive Motor "B" Phase V Current Sensor Offset Range / Performance
   P1C70-689	Drive Motor "B" 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
   P1CA8-708	Drive Motor "B" Control Module Malfunction
   P1CAC-200	Generator Position Sensor Angle Malfunction
   P1CAD-168	Drive Motor "A" Position Sensor Angle Malfunction
   P1CAE-715	Drive Motor "B" Position Sensor Angle Malfunction
   P1CAF-792	Generator Position Sensor REF Signal Cycle Malfunction
   P1CB0-795	Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
   P1CB1-798	Drive Motor "B" 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
   P1CB4-799	Drive Motor "B" 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
   P314A-828	Inverter Coolant Pump Speed Signal
   P33C1-684	Drive Motor "B" Phase V Current Sensor Sub Circuit Range / Performance
   P33C6-686	Drive Motor "B" Phase W Current Sensor Sub Circuit Range / Performance
   P33D8-677	Drive Motor "B" Phase V Current Sensor Correlation
   P33D9-678	Drive Motor "B" Phase W Current Sensor Correlation

   HINT: 

   • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
   • P0A78-121 may be stored due to a malfunction which also causes DTCs in the preceding table to be stored. 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.

Result:  2

B 

GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2016 - 10/2017]  Refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2017 - ] 

Result:  1

A 

See step  3

Refer to PROCEDURE - Step 3

Result

Result:  2

B 

CONNECT SECURELY 

Result:  3

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

A 

See step  4

Refer to PROCEDURE - Step 3 Refer to PROCEDURE - Step 3

Result

Result:  2

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

OK 

See step  5

Refer to PROCEDURE - Step 4 Refer to PROCEDURE - Step 4

Result

Result:  2

NG 

See step  40

Result:  1

OK 

See step  6

Refer to PROCEDURE - Step 5 Refer to PROCEDURE - Step 5

Result

Result:  2

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

OK 

See step  7

Refer to PROCEDURE - Step 6 Refer to PROCEDURE - Step 6

Result

Result:  2

NG 

See step  38

Result:  1

OK 

See step  8

Refer to PROCEDURE - Step 7 Refer to PROCEDURE - Step 7

Result

Result:  2

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

OK 

See step  9

Refer to PROCEDURE - Step 8 Refer to PROCEDURE - Step 8

Result

Result:  2

NG 

See step  36

Result:  1

OK 

See step  10

See step  9

Result

Result:  2

B 

REPLACE MALFUNCTIONING PARTS 

Result:  3

C 

CONNECT SECURELY 

Result:  1

A 

See step  11

See step  10

Result

Result:  2

B 

REPLACE MALFUNCTIONING PARTS 

Result:  3

C 

CONNECT SECURELY 

Result:  1

A 

See step  12

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 terminal cover from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Check that the bolts for the No. 6 floor wire (rear motor cable) are tightened to the specified torque, the No. 6 floor wire (rear motor cable) is connected securely, and there are no contact problems.

   Courtesy 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 No. 6 floor wire (rear motor 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 No. 6 floor wire (rear motor cable) to the inverter with converter assembly.
7. Install the inverter terminal cover.

Result:  2

B 

REPLACE MALFUNCTIONING PARTS 

Result:  3

C 

CONNECT SECURELY 

Result:  1

A 

See step  13

See step  11

Result

Result:  2

NG 

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Result:  1

OK 

See step  14

See step  12

Result

Result:  2

NG 

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Result:  1

OK 

See step  15

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 terminal cover from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Disconnect the No. 6 floor wire (rear motor cable) from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Check the rear motor (MGR) for an interphase short using a milliohmmeter.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Shield Ground
   *a	No. 6 floor wire (rear 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 rear motor (MGR) temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

      Standard Resistance

      Tester Connection	Condition	Specified Condition
      R2-3 (R-U) - R2-2 (R-V)	Power switch off	163 to 176 mΩ
      R2-2 (R-V) - R2-1 (R-W)	Power switch off	163 to 176 mΩ
      R2-1 (R-W) - R2-3 (R-U)	Power switch off	163 to 176 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 (°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
   R2-3 (R-U) - Body ground and shield ground	Power switch off	100 MΩ or higher
   R2-2 (R-V) - Body ground and shield ground	Power switch off	100 MΩ or higher
   R2-1 (R-W) - Body ground and shield ground	Power switch off	100 MΩ or higher

6. Reconnect the No. 6 floor wire (rear motor cable).
7. Install the inverter terminal cover.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

See step  33

Result:  1

OK 

See step  16

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 terminal cover from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Check that the bolt for the No. 6 floor wire is tightened to the specified torque, the No. 6 floor wire is connected securely, and there are no contact problems.

   Courtesy 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 No. 6 floor wire from the inverter with converter assembly.
5. Check for arc marks at the bolt and terminals for the No. 6 floor wire.

   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. Reconnect the No. 6 floor wire.
7. Install the inverter terminal cover.

Result:  2

B 

REPLACE MALFUNCTIONING PARTS 

Result:  3

C 

CONNECT SECURELY 

Result:  1

A 

See step  17

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

   OK

   Dirt or foreign matter has not entered the connectors, and there is no evidence of contamination.

2. Install the service plug grip.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

REPLACE SERVICE PLUG GRIP. Refer to  COMPONENTS [02/2014 - ] 

Result:  1

OK 

See step  18

1. Remove the service plug grip.

   Refer to COMPONENTS [02/2014 - ]

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Service Plug Grip

   Standard Resistance

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

3. Install the service plug grip.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

REPLACE SERVICE PLUG GRIP. Refer to  COMPONENTS [02/2014 - ] 

Result:  1

OK 

See step  19

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 No. 8 hybrid vehicle battery shield panel.

   Refer to PROCEDURE - Step 34

3. Check that the No. 6 floor wire is connected securely, and there are no contact problems.
4. Disconnect the No. 6 floor wire from the hybrid battery junction block assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5. Check for arc marks on the terminals of the No. 6 floor wire.

   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. Reconnect the No. 6 floor wire.
7. Install the No. 8 hybrid vehicle battery shield panel.

Result:  2

B 

REPLACE MALFUNCTIONING PARTS 

Result:  3

C 

CONNECT SECURELY 

Result:  1

A 

See step  20

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 No. 8 hybrid vehicle battery shield panel.

   Refer to PROCEDURE - Step 34

3. Disconnect the No. 6 floor wire from the hybrid battery junction block assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Remove the inverter terminal cover from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5. Disconnect the No. 6 floor wire from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Red Mark
   *a	No. 6 Floor Wire (Inverter with Converter Assembly Side)
   *b	No. 6 Floor Wire (Hybrid Battery Junction Block Assembly Side)

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   R1-2 (CBI) - R6-1 (CBI)	Power switch off	Below 1 Ω
   R1-1 (CEI) - R7-1 (CEI)	Power switch off	Below 1 Ω

7. 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
   R6-1 (CBI) - Body ground and shield ground	Power switch off	10 MΩ or higher
   R7-1 (CEI) - Body ground and shield ground	Power switch off	10 MΩ or higher
   R6-1 (CBI) - R7-1 (CEI)	Power switch off	10 MΩ or higher

8. Reconnect the No. 6 floor wire to the hybrid battery junction block assembly.
9. Reconnect the No. 6 floor wire to the inverter with converter assembly.
10. Install the inverter terminal cover.
11. Install the No. 8 hybrid vehicle battery shield panel.

    Result

    Proceed to
    OK
    NG

Result:  2

NG 

REPLACE NO. 6 FLOOR WIRE. Refer to  COMPONENTS [11/2016 - ] 

Result:  1

OK 

See step  21

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 hybrid battery junction block assembly.

   Refer to COMPONENTS [02/2014 - ]

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Component without harness connected (Hybrid Battery Junction Block Assembly)

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   t1-1 (+) - R6-1 (CBI)	Auxiliary battery voltage not applied between terminals x3-4 (SMRB) and x3-2 (GND)	10 kΩ or higher
   t1-1 (+) - R6-1 (CBI)	Auxiliary battery voltage applied between terminals x3-4 (SMRB) and x3-2 (GND)	Below 1 Ω

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

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   x3-4 (SMRB) - x3-2 (GND)	-40 to 80°C (-40 to 176°F)	18.4 to 36.3 Ω

5. Install the hybrid battery junction block assembly.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  COMPONENTS [02/2014 - ] 

Result:  1

OK 

See step  22

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 hybrid battery junction block assembly.

   Refer to COMPONENTS [02/2014 - ]

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Component without harness connected (Hybrid Battery Junction Block Assembly)

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   u1-1 (-) - R7-1 (CEI)	Auxiliary battery voltage not applied between terminals x3-1 (SMRG) and x3-2 (GND)	10 kΩ or higher
   u1-1 (-) - R7-1 (CEI)	Auxiliary battery voltage applied between terminals x3-1 (SMRG) and x3-2 (GND)	Below 1 Ω

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

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   x3-1 (SMRG) - x3-2 (GND)	-40 to 80°C (-40 to 176°F)	18.4 to 36.3 Ω

5. Install the hybrid battery junction block assembly.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  COMPONENTS [02/2014 - ] 

Result:  1

OK 

See step  23

See step  13

Result

Result:  2

NG 

See step  30

Result:  1

OK 

See step  24

See step  14

Result

Result:  2

NG 

REPAIR OR REPLACE POWER SOURCE CIRCUIT 

Result:  1

OK 

See step  25

See step  15

Result

Result:  2

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

OK 

See step  26

See step  16

Result

Result:  2

NG 

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Result:  1

OK 

See step  27

Refer to PROCEDURE - Step 9 Refer to PROCEDURE - Step 9

Result

Result:  2

B 

CONNECT SECURELY 

Result:  3

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

A 

See step  28

Refer to PROCEDURE - Step 10 Refer to PROCEDURE - Step 10

Result

Result:  2

B 

CONNECT SECURELY 

Result:  3

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

A 

See step  29

Refer to PROCEDURE - Step 11 Refer to PROCEDURE - Step 12

Result

Result:  1

A 

REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Result:  2

B 

CONNECT SECURELY 

Result:  3

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

See step  19

Result

Result:  2

NG 

See step  32

Result:  1

OK 

See step  31

Refer to COMPONENTS [11/2016 - ]

Result

Result:  1

NEXT 

REPLACE FUSE (PCU) 

Result

Result:  1

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

2. Check that the bolts for the No. 6 floor wire (rear motor cable) are tightened to the specified torque, the No. 6 floor wire (rear motor cable) is connected securely, and there are no contact problems.

   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).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Disconnect the No. 6 floor wire (rear motor cable) from the rear traction motor with transaxle assembly
4. Check for arc marks at the bolts for the No. 6 floor wire (rear motor cable).

   Result

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

5. Connect the No. 6 floor wire (rear motor cable).

Result:  2

B 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  3

C 

CONNECT SECURELY 

Result:  1

A 

See step  34

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 terminal cover from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Disconnect the No. 6 floor wire (rear motor cable) from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Disconnect the No. 6 floor wire (rear motor cable) from the rear traction motor with transaxle assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
   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
   R2-3 (R-U) - Body ground and shield ground	Power switch off	100 MΩ or higher
   R2-2 (R-V) - Body ground and shield ground	Power switch off	100 MΩ or higher
   R2-1 (R-W) - Body ground and shield ground	Power switch off	100 MΩ or higher

   NOTE:

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Shield Ground
   *a	No. 6 floor wire (rear motor cable) (Inverter with Converter Assembly Side)
   *b	No. 6 floor wire (rear motor cable) (Rear Traction Motor with Transaxle Assembly Side)

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

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   R2-3 (R-U) - R3-3 (R-U)	Power switch off	Below 1 Ω
   R2-2 (R-V) - R3-2 (R-V)	Power switch off	Below 1 Ω
   R2-1 (R-W) - R3-1 (R-W)	Power switch off	Below 1 Ω
   R2-3 (R-U) - R3-2 (R-V)	Power switch off	10 kΩ or higher
   R2-2 (R-V) - R3-1 (R-W)	Power switch off	10 kΩ or higher
   R2-1 (R-W) - R3-3 (R-U)	Power switch off	10 kΩ or higher

7. Connect the No. 6 floor wire (rear motor cable) to the rear traction motor with transaxle assembly.
8. Connect the No. 6 floor wire (rear motor cable) to the inverter with converter assembly.
9. Install the inverter terminal cover.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

REPLACE NO. 6 FLOOR WIRE. Refer to  COMPONENTS [11/2016 - ] 

Result:  1

OK 

See step  35

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 extension wire assembly from the rear traction motor with transaxle assembly.

   Refer to COMPONENTS [11/2016 - ]

3. 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
   R-U - Shield shell	Power switch off	100 MΩ or higher
   R-V - Shield shell	Power switch off	100 MΩ or higher
   R-W - Shield shell	Power switch off	100 MΩ or higher

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Extension Wire Assembly
   *a	Shield Shell

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

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   R-U - R-U	Power switch off	Below 1 Ω
   R-V - R-V	Power switch off	Below 1 Ω
   R-W - R-W	Power switch off	Below 1 Ω
   R-U - R-V	Power switch off	100 kΩ or higher
   R-V - R-W	Power switch off	100 kΩ or higher
   R-W - R-U	Power switch off	100 kΩ or higher

5. Install the extension wire.

   Result

   Proceed to
   OK
   NG

Result:  1

OK 

REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Result:  2

NG 

REPLACE EXTENSION WIRE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Refer to PROCEDURE - Step 12 Refer to PROCEDURE - Step 12

Result

Result:  2

B 

CONNECT SECURELY 

Result:  3

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

A 

See step  37

Refer to PROCEDURE - Step 13 Refer to PROCEDURE - Step 13

Result

Result:  1

OK 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  2

NG 

REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Refer to PROCEDURE - Step 14 Refer to PROCEDURE - Step 14

Result

Result:  2

B 

CONNECT SECURELY 

Result:  3

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

A 

See step  39

Refer to PROCEDURE - Step 15 Refer to PROCEDURE - Step 15

Result

Result:  1

OK 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  2

NG 

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Refer to PROCEDURE - Step 16 Refer to PROCEDURE - Step 16

Result

Result:  2

B 

CONNECT SECURELY 

Result:  3

C 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  1

A 

See step  41

Refer to PROCEDURE - Step 17 Refer to PROCEDURE - Step 17

Result

Result:  1

OK 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result:  2

NG 

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2016 - ]