Inspection Procedure

HINT:

At least 5 minutes is required to discharge the high-voltage condenser inside the inverter.

1. READ OUTPUT DTC (HV ECU) 
   1. Connect the hand-held tester to the DLC3.
   2. Turn the power switch ON (IG).
   3. Turn the hand-held tester ON.
   4. On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO /CURRENT CODES.
   5. Read DTCs.
      1. Result: 
      DTCS OUTPUT
      
      

      DTC No.	Relevant Diagnosis
      P0A1D	Hybrid Powertrain Control Module
      P0A2B, P0A2C or P0A2D	Drive Motor "A" Temperature Sensor Circuit System
      P0A37, P0A38 or P0A39	Generator Temperature Sensor Circuit System
      P0A3F, P0A40 or P0A41	Drive Motor "A" Position Sensor Circuit System
      P0A4B, P0A4C or P0A4D	Generator Position Sensor Circuit System
      P0A60 or P0A63	Drive Motor "A" Current Sensor Circuit System
      P0A72 or P0A75	Generator Current Sensor Circuit System
      P0A78	Drive Motor "A" Inverter Performance
      P0A7A	Generator Inverter Performance
      P0A90	Drive Motor "A" Performance
      P0A92	Hybrid Generator Performance
      P0A93	Inverter Cooling System Malfunction
      P0A94	DC/DC Converter Malfunction
      P0AA1, P0AA2, P0AA4 or P0AA5	System Main Relay Circuit System
      P3000, P3004, P3009 or P3110	High Voltage System
      P3211	Drive Motor "A" Inverter Temperature Sensor Circuit System
      P3221	Generator Inverter Temperature Sensor Circuit System
      P3226	DC/DC Converter Temperature Sensor Circuit System

   YES: GO TO DTC CHART (See  DIAGNOSTIC TROUBLE CODE CHART   ). AND PROCEED TO ITS DIAGNOSTIC TROUBLESHOOTING FLOWCHART 

   NO: Go to Next Step 

2. CHECK QUANTITY OF HV COOLANT 
   1. Check that there is a sufficient amount of coolant for the inverter.
      1. OK: There is a sufficient amount of coolant for the inverter 

   NG: ADD HV COOLANT (See  COOLANT  ) 

   OK: Go to Next Step 

3. CHECK COOLANT HOSE 
   1. Check that the hoses of the cooling system are not bent or clogged (see the cooling system P0A93/346 INVERTER COOLING SYSTEM PERFORMANCE, P0A93/347 INVERTER COOLING SYSTEM PERFORMANCE  ).
      1. OK: The hoses of the cooling system are not bent or clogged 

   NG: CORRECT TO NORMAL CONDITION 

   OK: Go to Next Step 

4. CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) 
   1. Check the connection condition of the water pump connector.
      1. OK: Connector has been connected securely and there is no poor connection. 

   NG: CONNECT SECURELY 

   Fig 1: Locating Water Pump Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK: Go to Next Step 

5. CHECK WATER W/MOTOR & BRACKET PUMP ASSY 
   1. Turn the power switch ON (IG).
   2. Check the operation of the water pump.
      1. OK: Coolant is sloshing in the reservoir tank 

   NG: REPLACE WATER W/MOTOR & BRACKET PUMP ASSY 

   OK: Go to Next Step 

6. CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) 
   1. Check the connection condition of the cooling fan motor connectors.
      1. OK: Connectors have been connected securely and there is no poor connection. 

   NG: CONNECT SECURELY 

   OK: Go to Next Step 

   Fig 2: Checking Cooling Fan Motor Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSPECT COOLING FAN MOTOR 

   NG: REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT 

   OK: Go to Next Step 

8. INSPECT COOLING FAN MOTOR NO. 2  

   NG: REPLACE COOLING FAN MOTOR NO. 2 AND ADD ENGINE COOLANT 

   OK: Go to Next Step 

9. CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACTS 
   1. Check the connection condition of all the connectors at the HV control ECU.
      1. OK: Connectors have been connected securely and there is no poor connection. 

   NG: CONNECT SECURELY 

   Fig 3: Identifying HV Control ECU Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK: Go to Next Step 

10. CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Turn the power switch OFF.
    2. Remove the service plug grip (see SERVICE PLUG GRIP ).
       NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
    3. Remove the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM ).
    4. Check the connection condition of the I9 and I10 inverter connectors.
       1. OK: Connectors have been connected securely and there is no poor connection. 
    5. Reinstall the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM ).
    6. Reinstall the service plug grip (see SERVICE PLUG GRIP ).

    NG: CONNECT SECURELY 

    Fig 4: Checking Connection Condition Of I9 And I10 Inverter Connectors

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to Next Step 

11. CONFIRM INFORMATION (EXCLUSIVE INFO 4) 
    1. Connect the hand-held tester to the DLC3.
    2. Turn the power switch ON (IG).

       HINT:

       DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.

    3. Turn the hand-held tester ON.
    4. On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO /CURRENT CODES.
    5. Select DTC P0A7A to display its freeze frame data.
    6. Select the item that has INF code 322 from among INFORMATION 1 to 5, and press ENTER.
    7. Read EXCLUSIVE INFO 4.
       1. Result: 
       EXCLUSIVE INFORMATION
       
       

       Displayed in Exclusive Information 4	Go To
       -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104	A
       -119 to -112, -87 to-80 -55 to -48, -23 to-16, 9 to 16, 41 to 48, 73 to 80, 105 to 112	B
       -111 to -104, -79 to -72 -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120	C
       -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127	D

    B: REPLACE HYBRID VEHICLE CONTROL ECU (See  HYBRID VEHICLE CONTROL ECU  ) 

    C REPLACE W/CONVERTER INVERTER ASSY (See  W/CONVERTER INVERTER ASSY  in HYBRID CONTROL SYSTEM ) 

    D REPLACE HYBRID VEHICLE TRANSAXLE ASSY (See  HYBRID VEHICLE TRANSAXLE ASSY  ) 

    A: Go to Next Step 

12. INSPECT HYBRID VEHICLE GENERATOR ASSY 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Turn the power switch OFF.
    2. Remove the service plug grip (see SERVICE PLUG GRIP ).
       NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
    3. Remove the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM ).
    4. Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter.
    5. Using an ohmmeter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator.
       NOTE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped.