Inspection Procedure

HINT:

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

1. READ VALUE OF HAND-HELD TESTER (CONVERTER TEMP) 
   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 / DATA LIST.
   5. Read the CONVERTER TEMP value on the hand-held tester.
      1. Result: 
      TEMPERATURE DISPLAY
      
      

      Temperature Displayed	Go To
      -50°C (-58°F)	A
      205°C(401°F)	B
      -49°Cto204°C (-57° F to 400° F)	C

   HINT:

   • If there is a +B short circuit, the hand-held tester indicates -50°C (-58°F).
   • If there is an open or GND short circuit, the hand-held tester indicates 205°C (401 °F).

   B: Go to step   4 

   C CHECK FOR INTERMITTENT PROBLEMS (See  CHECK FOR INTERMITTENT PROBLEMS   ) 

   A: Go to Next Step 

2. READ VALUE OF HAND-HELD TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) 
   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 I10 inverter connector.
   5. 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.

   6. On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST.
   7. Read the CONVERTER TEMP value on the hand-held tester.
      Fig 1: Identifying Converter Temperature Circuit

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Standard: 205°C (401 °F) 
   8. Turn the power switch OFF.
   9. Reconnect the inverter connector
   10. Reinstall the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM )
   11. Reinstall the service plug grip (see SERVICE PLUG GRIP ).
   Fig 2: Disconnecting I10 Inverter Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NG: Go to step 3 

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

3. READ VALUE OF HAND-HELD TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) 
   1. Disconnect the H16 HV control ECU connector.
   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. On the hand-held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST.
   4. Read the CONVERTER TEMP value on the hand-held tester.
      Fig 3: Identifying Converter Temperature Circuit

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Standard: 205°C (401 °F) 
   5. Reconnect the HV control ECU connector.

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

   Fig 4: Disconnecting H16 HV Control ECU Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK: REPAIR OR REPLACE HARNESS OR CONNECTOR 

4. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU -INVERTER) 
   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 H16 HV control ECU connector.
   5. Disconnect the I10 inverter connector.
   6. Check the resistance between the wire harness side connectors.
      Fig 5: Disconnecting H16 Control ECU Connector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Standard (Check for open): 
      RESISTANCE CHECK
      
      

      Tester Connection	Specified Condition
      CT (H16-21) - CT (I10-14)	Below 1 Ω
      GCNV (H16-8) - GCNV (I10-32)	Below 1 Ω

      1. Standard (Check for short): 
      RESISTANCE CHECK
      
      

      Tester Connection	Specified Condition
      CT(H16-21) or CT (I10-14) - Body ground	10 kΩ or higher
      GCNV (M 6-8) or GCNV (I10-32) - Body ground	10 kΩ or higher

   7. Reconnect the inverter connector.
   8. Reconnect the HV control ECU connector
   9. Reinstall the inverter cover (see W/CONVERTER INVERTER ASSY in HYBRID CONTROL SYSTEM )
   10. Reinstall the service plug grip (see SERVICE PLUG GRIP ).
   Fig 6: Reconnecting I10 Converter Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

   OK: Go to Next Step 

5. INSPECT HYBRID VEHICLE CONTROL ECU (CT VOLTAGE) 
   1. 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.

   2. Measure the voltage between the terminals of the H16 HV control ECU connector.
      1. Standard: 
      VOLTAGE CHECK
      
      

      Tester Connection	Specified Condition
      CT (H16-21) - GCNV (H16-8)	2.0 to4.5V

      Fig 7: Identifying HV Control ECU Connectior Terminals

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NG: REPLACE W/CONVERTER INVERTER ASSY (SEE  W/CONVERTER INVERTER ASSY  in HYBRID CONTROL SYSTEM ) 

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