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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control System (2GR-FXE) - Diagnostic Codes (2 Of 7) >> Hybrid Control System >> DTC P0A7A-122: Generator Inverter Performance [11/2015 - 11/2016] >> Procedure

DTC P0A7A-122: Generator Inverter Performance [11/2015 - 11/2016]: 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.

      Powertrain > Hybrid Control > Trouble Codes 

      Result

      Result Proceed to
      P0A7A-122 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 P0A7A-122 is stored. B
      Any of the DTCs including pending DTCs in table 2 below are stored before P0A7A-122 is stored. C
      TABLE 1

      Relevant DTC
      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

      Relevant DTC
      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, P0314-123, P3015-123, P3016-123, P0317-123, P3018-123, P3019-123, P3020-123, P3021-123, P3022-123, P3023-123, P3024-123, P3025-123 Battery Block # Becomes Weak
      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.
      • P0A7A-122 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:  2

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2015 - 11/2016] 

    Result:  3

    C 

    GO TO DTC CHART (HYBRID BATTERY SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [02/2014 - 11/2016] 

    Result:  1

    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.

      Powertrain > Hybrid Control > Trouble Codes 

      Result

      Proceed to
      P0A7A-203 is not output.
      P0A7A-203 is also output.
      NOTE:
      • If P0A7A-203 is output, troubleshoot it first. After completing the troubleshooting for P0A7A-203, perform troubleshooting for this DTC.
      • Parts repaired or replaced during troubleshooting for P0A7A-203 do not need to be re-inspected in this diagnostic procedure.
    5. Turn the power switch off.

    Result:  2

    P0A7A-203 is also output. 

    GO TO DTC CHART (P0A7A-203). Refer to  DTC P0A7A-203: Generator Inverter Performance [11/2015 - 11/2016]  

    Result:  1

    P0A7A-203 is not output. 

    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.

      Powertrain > Hybrid Control > Trouble Codes 

      HINT: 

      • If P0A7A-203 was not output in step 2 of this diagnostic procedure, check Table 1 below.
      • If P0A7A-203 was output in step 2 of this diagnostic procedure, diagnose that DTC first, then check Table 2 below.

      Result

      Result Proceed to
      P0A7A-122 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

      Relevant DTC
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1C (all INF codes)*1 Drive Motor "B" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-671 Drive Motor "B" Position Sensor Circuit Range / Performance
      P0A47-670 Drive Motor "B" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A69 (all INF codes)*1 Drive Motor "B" Phase V Current
      P0A6C (all INF codes)*1 Drive Motor "B" Phase W Current
      P0A72 (all INF codes)*1 Generator Phase V Current
      P0A75 (all INF codes)*1 Generator Phase W Current
      P0A78-118, 119, 120, 266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-693, 694, 695, 704, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-325, 344, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A91-702 Drive Motor "B" Performance
      P0A92-521 Hybrid Generator Performance
      P0A94-124, 125, 126, 169, 170, 171, 442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource
      TABLE 2

      Relevant DTC
      P0A1A (all INF codes)*1 Generator Control Module
      P0A1B (all INF codes)*1 Drive Motor "A" Control Module
      P0A1C (all INF codes)*1 Drive Motor "B" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A45-669 Drive Motor "B" Position Sensor Circuit
      P0A46-671 Drive Motor "B" Position Sensor Circuit Range / Performance
      P0A47-670 Drive Motor "B" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A60 (all INF codes)*1 Drive Motor "A" Phase V Current
      P0A63 (all INF codes)*1 Drive Motor "A" Phase W Current
      P0A69 (all INF codes)*1 Drive Motor "B" Phase V Current
      P0A6C (all INF codes)*1 Drive Motor "B" Phase W Current
      P0A72-333 Generator Phase V Current
      P0A75-341 Generator Phase W Current
      P0A78-118, 119, 120, 266, 267, 279, 287, 306, 503, 504, 505, 506, 586, 806, 807, 808 Drive Motor "A" Inverter Performance
      P0A79-693, 694, 695, 704, 812, 813, 814 Drive Motor "B" Inverter Performance
      P0A7A-325, 517, 518, 809, 810, 811 Generator Inverter Performance
      P0A90-509 Drive Motor "A" Performance
      P0A91-702 Drive Motor "B" Performance
      P0A94-124, 125, 126, 169, 170, 171, 442, 547, 548, 549, 554, 555, 556, 585, 587, 589, 590 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-803 High Voltage Power Resource

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A7A-122 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:  2

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2015 - 11/2016] 

    Result:  1

    A 

    See step  4

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

    Refer to PROCEDURE - Step 3

    Result

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  5

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

    Refer to PROCEDURE - Step 3

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  6

  6. CHECK GENERATOR RESOLVER 

    Refer to PROCEDURE - Step 4

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  24

    Result:  1

    OK 

    See step  7

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

    Refer to PROCEDURE - Step 5

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  8

  8. CHECK MOTOR RESOLVER 

    Refer to PROCEDURE - Step 6

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  22

    Result:  1

    OK 

    See step  9

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

    See step  9

    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

    Result:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  10

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

    See step  10

    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

    Result:  2

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result:  3

    C 

    CONNECT SECURELY 

    Result:  1

    A 

    See step  11

  11. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) 

    See step  11

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2015 - 11/2016] 

    Result:  1

    OK 

    See step  12

  12. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) 

    See step  12

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2015 - 11/2016] 

    Result:  1

    OK 

    See step  13

  13. CHECK FUSE (PCU) 

    See step  13

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  19

    Result:  1

    OK 

    See step  14

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

    See step  14

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE POWER SOURCE CIRCUIT 

    Result:  1

    OK 

    See step  15

  15. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) 

    See step  15

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  16

  16. CHECK POWER MANAGEMENT CONTROL ECU 

    See step  16

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPLACE POWER MANAGEMENT CONTROL ECU. Refer to  COMPONENTS [02/2014 - 11/2016] 

    Result:  1

    OK 

    See step  17

  17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 9

    Result

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  18

  18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 10

    Result

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result:  1

    A 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS [02/2014 - 11/2016] 

    Result:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  19. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) 

    See step  19

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  21

    Result:  1

    OK 

    See step  20

  20. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to COMPONENTS [02/2014 - 11/2016]

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    REPLACE FUSE (PCU) 

  21. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    REPLACE FUSE (PCU) 

  22. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 14

    Result

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  23

  23. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER) 

    Refer to PROCEDURE - Step 15

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2015 - 11/2016] 

  24. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) 

    Refer to PROCEDURE - Step 16

    Result

    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result:  2

    B 

    CONNECT SECURELY 

    Result:  3

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    A 

    See step  25

  25. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER) 

    Refer to PROCEDURE - Step 17

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  2

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [11/2015 - 11/2016] 

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