Inspection Procedure

• Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. 
• After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. 

HINT:

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

1. READ VALUE OF HAND-HELD TESTER (MG1 INVERT 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 MG1 INVERT TEMP value on the hand-held tester.
      1. Result: 
   MG1 INVERTER TEMP VALUE
   
   

   Temperature Displayed	Go To
   -50°C (-58°F)	A
   205°C (401°F)	B
   -49°C to 204°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   m 

   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 MG1 INVERT TEMP value on the hand-held tester.
      Fig 1: Disconnecting GIVT And GINV From Generator Inverter Temperature Sensor

      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 ).

       NG: Go to step 3 

       Fig 2: Identifying Inverter Connector Terminals

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   12. READ VALUE OF HAND-HELD TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) 
       1. Disconnect the H15 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 MG1 INVERT TEMP value on the hand-held tester.
          Fig 3: Disconnecting GIVT And GINV From Generator Inverter Temperature Sensor

          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: Identifying HV Control ECU Connector Terminals

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       OK: REPAIR OR REPLACE HARNESS OR CONNECTOR 

   13. 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 H15 HV control ECU connector.
       5. Disconnect the I10 inverter connector.
       6. Check the resistance between the wire harness side connectors.
          1. Standard (Check for open): 
          RESISTANCE CHECK
          
          

          Tester Connection	Specified Condition
          GIVT (H15-27) - GIVT (I10-21)	Below 1 Ω
          GINV (H15-23) - GINV (I10-16)	Below 1 Ω

          1. Standard (Check for short): 
          RESISTANCE CHECK
          
          

          Tester Connection	Specified Condition
          GIVT (H15-27) or GIVT (I10-21) - Body ground	10 kΩ or higher
          GINV (H15-23) or GINV (I10-16) - Body ground	10 kΩ or higher

          Fig 5: Identifying HV Control ECU Connector Terminals

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       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 ).

       NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

       Fig 6: Identifying Inverter Connector Terminals

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       OK: Go to Next Step 

   14. INSPECT HYBRID VEHICLE CONTROL ECU (GIVT 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 H15 HV control ECU connector.
          1. Standard: 
          VOLTAGE CHECK
          
          

          Tester Connection	Specified Condition
          GIVT (H15-27) - GINV (H15-23)	2.0 to 4.5 V

          Fig 7: Identifying HV Control ECU Connector 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  )