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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-322: Generator Inverter Performance [11/2015 - 11/2016] >> Procedure

DTC P0A7A-322: 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

      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  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 

      HINT: 

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

      Result

      Result Proceed to
      P0A7A-322 only is output, or DTCs except the ones in the tables below are also output. A
      Any of the following 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
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P314A-828 Inverter Coolant Pump Speed Signal
      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
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P314A-828 Inverter Coolant Pump Speed Signal

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0A7A-322 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. After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.
    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  3

  3. 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  4

  4. CHECK QUANTITY OF HV COOLANT 

    Refer to PROCEDURE - Step 3

    Result

    Result Proceed to
    No leaks are found and the HV coolant level in the inverter reserve tank assembly is above the low line. A
    No leaks are found and the HV coolant level in the inverter reserve tank assembly is below the low line. B
    HV coolant leaks are evident. C

    Result:  2

    B 

    ADD HV COOLANT 

    Result:  3

    C 

    INSPECT FOR HV COOLANT LEAK AND ADD HV COOLANT 

    Result:  1

    A 

    See step  5

  5. CHECK COOLANT HOSE 

    Refer to PROCEDURE - Step 4

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    REPAIR OR REPLACE COOLANT HOSE 

    Result:  1

    OK 

    See step  6

  6. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE ELECTRIC COOLING FAN) 

    Refer to PROCEDURE - Step 5

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    CHECK COOLING FAN SYSTEM. Refer to  Cooling Fan Circuit [02/2014 - 11/2016] 

    Result:  1

    OK 

    See step  7

  7. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING) 

    Refer to PROCEDURE - Step 16

    Result

    Result Proceed to
    Ambient Temperature value is above freezing temperature of the HV coolant. A
    Ambient Temperature value is below freezing temperature of the HV coolant. B

    Result:  2

    B 

    See step  29

    Result:  1

    A 

    See step  8

  8. 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  9

  9. CHECK GENERATOR RESOLVER 

    Refer to PROCEDURE - Step 4

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  27

    Result:  1

    OK 

    See step  10

  10. 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  11

  11. CHECK MOTOR RESOLVER 

    Refer to PROCEDURE - Step 6

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  25

    Result:  1

    OK 

    See step  12

  12. 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  13

  13. 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  14

  14. 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  15

  15. 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  16

  16. CHECK FUSE (PCU) 

    See step  13

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  22

    Result:  1

    OK 

    See step  17

  17. 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  18

  18. 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  19

  19. 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  20

  20. 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  21

  21. 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 

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

    See step  19

    Result

    Proceed to
    OK
    NG

    Result:  2

    NG 

    See step  24

    Result:  1

    OK 

    See step  23

  23. REPLACE INVERTER WITH CONVERTER ASSEMBLY 

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

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    REPLACE FUSE (PCU) 

  24. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    REPLACE FUSE (PCU) 

  25. 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  26

  26. 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] 

  27. 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  28

  28. 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] 

  29. REPLACE HV COOLANT 

    Refer to PROCEDURE - Step 7

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    COMPLETED 

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