P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–1 HYBRID CONTROL SYSTEM PRECAUTION 1. Lever A083545E01 PRECAUTIONS FOR INSPECTING THE HYBRID CONTROL SYSTEM (a) Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip (see page IN-5). 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. NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, do not turn the power switch ON (READY) unless instructed by the repair manual. (b) After disconnecting the service plug grip, wait for at least 5 minutes before touching any of high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. (c) Since liquid leakage may occur, wear protective goggles when checking inside the HV battery. (d) Wear insulated gloves, turn the power switch OFF, and disconnect the negative terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system. (e) Turn the power switch OFF before performing a resistance check. (f) Turn the power switch OFF before disconnecting or reconnecting any connector. HV HV–2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (g) To install the service plug grip, the lever must be flipped and locked downward. Once it is locked in place, it turns the interlock switch ON. Make sure to lock it securely because if you leave it unlocked, the system will output a DTC pertaining to the interlock switch system. Lever Lock A089219E01 2. HV NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name See Procedure Power Window Control System IN-32 3. NOTICE FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first attempt. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–3 DEFINITION OF TERMS 1. DEFINITION OF TERMS Each monitor description follows a standardized format using these terms: Terms Definition Duration The minimum time that the HV control ECU must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Frequency of operation The number of times that the HV control ECU checks for malfunction per driving cycle. "Once per driving cycle" means that the HV control ECU detects malfunction only one time during a single driving cycle. "Continuous" means that the HV control ECU detects malfunction every time when enabling condition is met. MIL operation MIL illumination timing after a defect is detected. "Immediately" means that the HV control ECU illuminates the MIL the instant the HV control ECU determines that there is malfunction. "2 driving cycles" means that the HV control ECU illuminates the MIL if the same malfunction is detected again in the 2nd driving cycle. Monitor description Description of what the HV control ECU monitors and how it detects malfunction (monitoring purpose and its details). Related DTCs A group of DTCs that is classified by a system and a troubleshooting procedure. Required sensor / components The sensors and components that are used by the HV control ECU to detect malfunction. Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. Typical enabling condition Preconditions that allow the HV control ECU to detect malfunction. With all preconditions satisfied, the HV control ECU sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Typical malfunction thresholds Beyond this value, the HV control ECU will conclude that there is malfunction and set a DTC. HV HV–4 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM PARTS LOCATION ELECTRIC INVERTER COMPRESSOR (W/ MOTOR COMPRESSOR ASSEMBLY) INVERTER WITH CONVERTER ASSEMBLY FUSIBLE LINK BLOCK ASSEMBLY AUXILIARY BATTERY HV BATTERY HV FRAME WIRE ENGINE ROOM RELAY BLOCK COOLING FAN MOTOR - INTEGRATION RELAY - HEV FUSE NO. 2 COOLING FAN MOTOR WATER PUMP WITH MOTOR ASSEMBLY HYBRID VEHICLE TRANSAXLE ASSEMBLY A125398E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–5 RESERVOIR TANK INVERTER COVER NO. 1 CIRCUIT BREAKER SENSOR HYBRID VEHICLE GENERATOR (NO. 1 MOTOR GENERATOR [MG1]) HYBRID VEHICLE MOTOR (NO. 2 MOTOR GENERATOR [MG2]) HV GENERATOR RESOLVER MOTOR RESOLVER NO. 1 MOTOR TEMPERATURE SENSOR AND NO. 2 MOTOR TEMPERATURE SENSOR A125399E01 HV–6 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NO. 2 FRAME WIRE JUNCTION BLOCK BATTERY ECU BATTERY PLUG MAIN BATTERY CABLE HV SERVICE PLUG GRIP NO. 2 MAIN BATTERY CABLE SYSTEM MAIN RELAY NO. 3 SYSTEM MAIN RELAY NO. 2 SYSTEM MAIN RELAY SYSTEM MAIN RESISTOR A125400E01 HV–7 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM COMBINATION METER TRANSPONDER KEY ECU POWER SWITCH GATEWAY ECU MULTI-DISPLAY ECM ENTRY KEY ECU POWER SOURCE CONTROL ECU HYBRID VEHICLE CONTROL ECU P POSITION SWITCH TRANSMISSION CONTROL ECU ASSEMBLY SELECTOR LEVER DRIVER SIDE JUNCTION BLOCK DLC3 HV AIR CONDITIONING AMPLIFIER - BODY ECU CENTER AIRBAG SENSOR ASSEMBLY SKID CONTROL ECU ACCELERATOR PEDAL ROD POWER STEERING ECU A125401E01 HV–8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM SYSTEM DIAGRAM Hybrid Vehicle Control ECU BATT IG2 HEV IGCT AM2 +B1 +B2 IGN MREL Power Source Control ECU IGSW IG2D P/I AM2 IG1D AM1 STSW AM1 HV DC / DC ST2 Stop Light Switch ST1- STOP STP MAIN Water Pump Water Pump IG1 A/C (HTR) M Auxiliary Battery WP A133108E01 HV–9 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P Position Switch P1 Cruise Control Main Switch Spiral Cable CCS ECM NEO NEO GO GO CAN Communication CANH HV CANL Selector Lever VCX1 VCX1 VSX1 VSX1 E2X1 E2X1 VCX2 VCX2 VSX2 VSX2 E2X2 E2X2 VCX3 VCX3 VSX3 VSX3 VCX4 VCX4 VSX4 VSX4 A125636E01 HV–10 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Accelerator Pedal Rod VCPA VCP1 VPA VPA1 EPA EP1 VCP2 VCP2 VPA2 VPA2 EP2 EP2 Transmission Control ECU Assembly PCON PCON PPOS PPOS P RDY RDY Power Source Control ECU Transponder Key ECU HV HEV1 IMI HEV0 IMO Center Airbag Sensor GSW2 ABFS DLC3 TC TC Combination Meter SPDI A126762E01 HV–11 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Inverter with Converter Assembly DC / DC Converter A/C Inverter Boost Converter VLO VLO NODD NODD STB STB TOINV ETI TOECU ITE CLK CLK VL VL CPWM CPWM CSDN CSDN CT (+) Generator Inverter CT GCNV GCNV OVL OVL FCV FCV GSDN GSDN GIVT GIVT GUU GUU GVU GVU GWU GWU GIVA GIVA GIVB GIVB GIWA GIWA GIWB GIWB GFIV GFIV HV No. 1 Motor Generator (MG1) G-U (-) G-V G-W GRF GRF GRFG GRFG GSN GSN GSNG GSNG GCS GCS GCSG GCSG A125638E01 HV–12 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MIVT MIVT MSDN MSDN GINV GINV MUU MUU MVU MVU MWU MWU MIVA MIVA MIVB MIVB MIWA MIWA MIWB MIWB VH VH MFIV MFIV OVH OVH Motor Inverter HV No. 2 Motor Generator (MG2) M-U M-V M-W MRF MRF MRFG MRFG MSN MSN MSNG MSNG MCS MCS MCSG MCSG MMT MMT MMTG MMTG OMT OMT OMTG OMTG A125639E01 HV–13 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Interlock Switch No. 1 Circuit Breaker Sensor SFI+ AS1 SFI- AS1G ILK HV Battery Assembly No. 2 System Main Relay Inverter with Converter Interlock Switch (+) CON2 System Main Resistor HV CON1 Service Plug Grip No. 1 System Main Relay Inverter with Converter (-) CON3 No. 3 System Main Relay GND1 GND2 A125640E01 HV–14 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Communication Diagram: ECM Battery ECU Power Steering ECU HV Control ECU Skid Control ECU Gateway ECU Multi Display HV : CAN : BEAN Body ECU Air Conditioning Amplifier Transponder Key ECU Combination Meter Power Source Control ECU Entry Key ECU : AVC-LAN A093744E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–15 SYSTEM DESCRIPTION 1. GENERAL The THS-II control system consists of the following controls. Item Outline HV Control ECU Control • • • • • The HV control ECU controls the MG1, MG2, engine, regenerative brake control and HV battery SOC. These factors are determined by the shift position, accelerator pedal position and vehicle speed. The HV control ECU monitors the SOC and temperature of the HV battery, MG1 and MG2, in order to optimally control these items. When the shift position is in N, the HV control ECU effects shutdown control to electrically stop the MG1 and MG2. If there is no traction at the drive wheels, the HV control ECU performs a motor traction control function which restrains the rotation of MG2, in order to protect the planetary gear unit and prevent MG1 from generating excessive electricity. To protect the circuit from high voltage and to ensure circuit shutdown reliability, the HV control ECU effects SMR control using 3 relays to connect and shut down the high-voltage circuit. ECM Control The ECM receives the demand power value and the target rpm, which were sent from the HV control ECU, and controls the ETCS-i system, fuel injection volume, ignition timing and VVT-i system. Inverter Control • • • Boost Converter Control • • Converter Control • • In accordance with the signals provided by the HV control ECU, the inverter converts a direct current (HV battery) into an alternating current (MG1 and MG2), or vice versa. In addition, the inverter supplies the AC (MG1) power to the AC (MG2). However, when electricity is supplied from MG1 to MG2, the electricity is converted into DC inside the inverter. The HV control ECU sends the signal to the power transistor in the inverter for switching the U, V and W phase of the MG1 and MG2 in order to drive the MG1 and MG2. The HV control ECU shuts down if it receives an overheating, over current, or fault voltage signal from the inverter. In accordance with the signals provided by the HV control ECU, the boost converter boosts the nominal voltage of DC 201.6 V (for HV battery) up to the maximum voltage of DC 500 V. The maximum voltage of AC 500 V generated by the MG1 or MG2 is converted into a direct current by the inverter, the boost converter reduces the direct current to DC 201.6 V (for HV battery) based on the signals from the HV control ECU. The DC / DC converter reduces the nominal voltage of DC 201.6 V to DC 12 V in order to supply electricity to body electrical components, as well as to recharge the auxiliary battery (DC 12 V). This converter maintains a constant voltage at the terminals of the auxiliary battery. A/C Inverter Control A/C inverter converts the nominal voltage of the HV battery from DC 201.6 to AC 201.6 V and supplies power to operate the electric compressor of the A/C system. MG1 and MG2 Main Control • • • • MG1, which is rotated by the engine, generates high voltage (maximum voltage of AC 500 V) in order to operate the MG2 and charge the HV battery. Also, it functions as a starter to start the engine. MG2 primarily provides additional power to the engine in order to increase the overall drive force. During braking, or when the accelerator pedal is not depressed, it generates electricity to recharge the HV battery (regenerative brake system). Speed sensors detect the speed and position of the MG1 and MG2 and output them to the HV control ECU. A temperature sensor mounted on the MG2 detects a MG2 temperature and transmits it to the HV control ECU. HV HV–16 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Item Outline Skid Control ECU Control During braking, the skid control ECU calculates the total braking force and transmits a regenerative brake force request to the HV control ECU. Upon receiving this signal, the HV control ECU calculates the magnitude of regeneration brake force required and transmits it to the skid control ECU. Based on this, the skid control ECU calculates and executes the required hydraulic pressure brake force. Battery ECU Control The battery ECU monitors the condition of the HV battery and controls the cooling fan to keep the HV battery at a predetermined temperature. Thus, it optimally controls these components. Shift Control • • The HV control ECU detects the shift position (P, R, N, D, or B) in accordance with the signal provided by the shift position sensor, and controls the MG1, MG2, and engine, in order to create the driving conditions that suit the selected shift position. The transmission control ECU assembly detects that the driver has pressed the P position switch through a signal provided by the HV control ECU. The transmission control ECU assembly then operates the shift control actuator in order to mechanically lock the transaxle. During Collision Control At the time of a collision, if the HV control ECU receives an airbag deployment signal from the center airbag sensor or an actuation signal from the circuit breaker sensor located in the inverter, it turns OFF the SMR and power switch in order to shut off the entire power supply. Cruise Control System Operation Control When the cruise control ECU built into the HV control ECU receives a cruise control switch signal, it calculates the cruise control request value, and calculates the motive forces of the engine, MG1, and MG2 to achieve an optimal combination. Indicator and Warning Light Illumination Control Illuminates or blinks the lights to inform the driver of the vehicle condition or a system malfunction. Diagnosis When the HV control ECU detects a malfunction, the HV control ECU diagnoses and stores values corresponding to the failure. Fail-safe When the HV control ECU detects a malfunction, the HV control ECU stops or controls the actuator and ECUs according to the data already stored in its memory. HV 2. Inverter Planetary Gear MG1 HV Battery Engine MG2 Wheel A125406E01 BASIC OPERATION (a) This system controls the following modes in order to achieve the most efficient operations to match the driving conditions: (1) Supply of electrical power from the HV battery to MG2 provides force to drive the wheels. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (2) While the wheels are being driven by the engine via the planetary gear, MG1 is rotated by the engine via the planetary gears, in order to supply the generated electricity to MG2. Inverter Planetary Gear HV–17 MG1 HV Battery Engine MG2 Wheel A125407E01 (3) MG1 is rotated by the engine via the planetary gear, in order to charge the HV battery. Inverter Planetary Gear MG1 HV Battery Engine MG2 Wheel HV A125408E01 Inverter Planetary Gear MG1 HV Battery Engine MG2 Wheel A125409E01 (4) When the vehicle is decelerating, kinetic energy from the wheels is recovered and converted into electrical energy and used to recharge the HV battery by means of MG2. (b) The HV control ECU switches between these modes ((1), (2), (3), (1) + (2) + (3), or (4)) according to the driving condition. However, when the SOC (State of Charge) of the HV battery is low, the HV battery is charged by the engine by turning MG1. As a result, it achieves far greater fuel economy compared to conventional gasoline engine vehicles, at a reduced level of exhaust gas emissions. Furthermore, this revolutionary powertrain has eliminated the constraints that are associated with electric vehicles (such as their short cruising range or their reliance on external recharging units). HV–18 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3. SYSTEM DIAGRAM Shift Position Sensor Inverter Assembly Accelerator Pedal Position Sensor Inverter A/C Inverter Engine Condition Electric Inverter Compressor (for A/C) Boost Converter ECM Engine Control - Speed Sensor - Yaw Rate and Deceleration Rate Sensor* - Steering Angle Sensor* - Brake Pedal Stroke Sensor Skid Control ECU DC / DC Converter HV Control ECU *1 *2 Resistor SMR1 SMR2 SMR3 Auxiliary Battery Brake Actuator HV MG1 MG2 Engine : CAN Current Sensor Battery ECU HV Battery To Rear Wheel : Mechanical Power Path : Hydraulic Power Path : Electrical Signal *1: Regenerative Brake Force Request *2: Actual Regenerative Braking Control Valve : Only on model with Enhanced VSC system A126252E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 4. HV–19 FUNCTION OF MAIN COMPONENTS Item Outline MG1 MG1, which is rotated by the engine, generates high-voltage electricity in order to operate the MG2 or charge the HV battery. Also, it functions as a starter to start the engine. MG2 • • Driven by electrical power from the MG1 or HV battery, and generates motive force for the vehicle. During braking, or when the accelerator pedal is not depressed, it generates electricity to recharge the HV battery (regenerative brake control). Planetary Gear Unit Distributes the engine's drive force as appropriate to directly drive the vehicle as well as the generator. HV Battery Supplies electric power to the MG2 during start-off, acceleration, and uphill driving. Recharged during braking or when the accelerator pedal is not depressed. Inverter Converts the high-voltage DC (HV battery) into AC (MG1 and MG2) and vice versa (converts AC into DC). Boost Converter Boosts the nominal voltage of the HV battery from DC 201.6 to DC 500 V and vice versa (reduces voltage from DC 500 V to DC 201.6 V). DC / DC Converter Reduces the nominal voltage of DC 201.6 V to DC 12 V in order to supply electricity to body electrical components, as well as to recharge the auxiliary battery (DC 12 V). A/C Inverter Converts the nominal voltage of DC 201.6 V of the HV battery to AC 201.6 V and supplies power to operate the electric inverter compressor of the A/C system. HV Control ECU Receives information from each sensor as well as from the ECUs (ECM, battery ECU, skid control ECU, and EPS ECU), and based on this information, required torque and output power are calculated. Sends the calculated result to the ECM, inverter assembly, battery ECU and skid control ECU. ECM Activates the ETCS-i (Electronic Throttle Control System-intelligent) in accordance with the target engine speed and required engine motive force received from the HV control ECU. Battery ECU Monitors the charging condition of the HV battery. Skid Control ECU Controls the regenerative brake that is effected by the MG2 and the hydraulic brake so that the total braking force equals that of a conventional vehicle that is equipped only with hydraulic brakes. Also, performs the brake system control (ABS with EBD, Brake Assist, and Enhanced VSC*) conventionally. Accelerator Pedal Position Sensor Converts the accelerator pedal position angle into an electrical signal and outputs it to the HV control ECU. Shift Position Sensor Converts the shift position into an electrical signal and outputs it to the HV control ECU. SMR (System Main Relay) Connects and disconnects the high-voltage power circuit between the battery and the inverter assembly, using a signal from the HV control ECU. Interlock Switch (for Inverter Cover and Service Plug Grip) Verifies that the cover of both the inverter and the service plug grip have been installed. Circuit Breaker Sensor The high-voltage circuit is interrupted if a vehicle collision has been detected. Service Plug Grip Shuts off the high-voltage circuit of the HV battery when this plug is removed for vehicle inspection or maintenance. HINT: *: Only on model with Enhanced VSC System HV HV–20 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3. NEXT 4 CHECK AND RECORD DTC AND FREEZE FRAME DATA* HINT: If a DTC related to the CAN communication system malfunction is output, first troubleshoot and repair the CAN communication (see page CA-6). HV NEXT 5 CLEAR DTC* NEXT 6 PROBLEM SYMPTOM CONFIRMATION (a) When the malfunction does not occur, go to A. (b) When the malfunction occurs, go to B. B A 7 NEXT SYMPTOM SIMULATION Go to step 8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 8 HV–21 CHECK DTC* NEXT 9 DTC CHART NEXT 10 CIRCUIT INSPECTION NEXT 11 IDENTIFICATION OF PROBLEM NEXT 12 ADJUSTMENT AND / OR REPAIR NEXT 13 NEXT END CONFIRMATION TEST HV HV–22 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK FOR INTERMITTENT PROBLEMS 1. HV CHECK FOR INTERMITTENT PROBLEMS (a) Perform a simulation test (see page IN-36). (1) In the simulation test, reproduce the driving condition at the trouble occurrence according to the customer's comments and freeze frame data recorded with DTCs, such as an opening angle of the accelerator pedal, SOC, engine coolant temperature, engine rpm, and MG1/MG2 rpm and torque. (b) Check the connector(s) and terminal(s) (see pageIN-45). (c) Wiggle the harness and connector(s) (see page IN45). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–23 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement HV control ECU. HINT: The VIN is a 17-digit alphanumeric vehicle identification number. The intelligent tester is required to register the VIN. 1. 2. INPUT INSTRUCTIONS (a) Explains the general VIN input instructions using the intelligent tester. (b) Intelligent Tester The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used to input the VIN. (c) Cursor Operation To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (d) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (2) After selection, the cursor should move. (e) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons. HINT: Numerical characters can be selected by using the UP and DOWN buttons. (f) Correction (1) After input, the cursor should move. (2) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT buttons. (g) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. (2) Press the ENTER button on the tester. READ VIN (Vehicle Identification Number) (a) Explains the VIN reading process in a flowchart. Reading the VIN stored in the HV control ECU is necessary when comparing it to the VIN provided with the vehicle. (b) Read VIN using the intelligent tester. (c) Check the vehicle's VIN. (d) Connect the intelligent tester to the DLC3. (e) Turn the power switch ON (IG). (f) Turn the tester ON. HV HV–24 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN READ VIN Previously Stored DTC P0630 Set VIN Not Stored 17-digit VIN displayed HV [EXIT] [EXIT] [EXIT] To Menu Screen A103812E03 3. WRITE VIN (a) Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the HV control ECU. If the HV control ECU is changed, or the HV control ECU VIN and Vehicle VIN do not match, the VIN can be registered, or overwritten in the HV control ECU by following this procedure. (b) Write VIN using the intelligent tester. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Turn the tester ON. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (f) HV–25 Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN WRITE VIN Previously Stored [NO] [YES] [YES] [YES] To Menu Screen 17-digit VIN displayed [NO] Continue to next illustration To Menu Screen A103813E01 HV HV–26 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM New Registration [ENTER] Input Instructions [ENTER] [ENTER] [ENTER] Input Error HV [EXIT] Continue to next illustration A103814E03 HV–27 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Writing Successful Writing Error Communication Error [ENTER] [EXIT] [EXIT] To Menu Screen To Menu Screen To Menu Screen A103815E03 HV HV–28 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TERMINALS OF ECU H17 H16 H15 H14 A066714E30 HV Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) ST2 (H14-5) - GND1 (H14-1) Y - W-B Starter signal Power switch ON (READY) 9 to 14 IGSW (H14-7) - GND1 (H14-1) O - W-B IG signal Power switch ON (IG) 9 to 14 BATT (H15-6) - GND1 (H14-1) Y - W-B Auxiliary battery (for measuring the battery voltage and for the HV control ECU memory) Always 9 to 14 +B1 (H16-7) - GND1 (H14-1) L - W-B Power source of HV control ECU Power switch ON (IG) 9 to 14 +B2 (H16-6) - GND1 (H14-1) L - W-B Power source of HV control ECU Power switch ON (IG) 9 to 14 MREL (H16-4) - GND1 (H14-1) O - W-B Main relay Power switch ON (IG) 9 to 14 CANH (H14-8) - GND1 (H14-1) B - W-B HIGH-level CAN bus line Power switch ON (IG) Pulse generation (see waveform 1) CANL (H14-9) - GND1 (H14-1) W - W-B LOW-level CAN bus line Power switch ON (IG) Pulse generation (see waveform 2) NEO (H16-12) - GND1 (H14-1) LG - W-B Engine speed signal Engine running Pulse generation (see waveform 3) GO (H16-13) - GND1 (H14-1) Y - W-B G signal Engine running Pulse generation (see waveform 4) SPDI (H14-19) - GND1 (H14-1) V - W-B Vehicle speed signal Driving at approximately 12 mph (20 km/h) Pulse generation (see waveform 5) VPA1 (H16-26) - EP1 (H16-27) L-B Accelerator pedal position Power switch ON (IG), sensor (for the HV system) accelerator pedal released 0.5 to 1.1 VPA1 (H16-26) - EP1 (H16-27) L-B Accelerator pedal position sensor (for the HV system) Power switch ON (IG), engine stopped in P position, accelerator pedal fully depressed 2.6 to 4.5 VPA2 (H16-34) - EP2 (H16-35) W-R Accelerator pedal position sensor (for the sensor malfunction detection) Power switch ON (IG), accelerator pedal fully depressed 1.2 to 2.0 VPA2 (H16-34) - EP2 (H16-35) W-R Accelerator pedal position sensor (for the sensor malfunction detection) Power switch ON (IG), engine stopped in P position, accelerator pedal released 3.4 to 5.3 VCP1 (H16-25) - EP1 (H16-27) Y-B Power source of accelerator pedal position sensor (for VPA1) Power switch ON (IG) 4.5 to 5.5 HV–29 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) VCP2 (H16-33) - EP2 (H16-35) G-R Power source of accelerator pedal position sensor (for VPA2) Power switch ON (IG) 4.5 to 5.5 VSX1 (H14-25) - E2X1 (H14-15) B-R Shift position sensor (main) Power switch ON (IG), selector lever home position 2.0 to 3.0 VSX1 (H14-25) - E2X1 (H14-15) B-R Shift position sensor (main) Power switch ON (IG), selector lever moved to R position 4.0 to 4.8 VSX1 (H14-25) - E2X1 (H14-15) B-R Shift position sensor (main) Power switch ON (IG), selector lever moved to B or D position 0.2 to 1.0 VSX2 (H14-24) - E2X2 (H14-14) L-Y Shift position sensor (sub) Power switch ON (IG), selector lever home position 2.0 to 3.0 VSX2 (H14-24) - E2X2 (H14-14) L-Y Shift position sensor (sub) Power switch ON (IG), selector lever moved to R position 4.0 to 4.8 VSX2 (H14-24) - E2X2 (H14-14) L-Y Shift position sensor (sub) Power switch ON (IG), selector lever moved to B or D position 0.2 to 1.0 VCX1 (H14-17) - E2X1 (H14-15) W-R Power source of shift position sensor (for VSX1) Power switch ON (IG) 4.5 to 5.5 VCX2 (H14-16) - E2X2 (H14-14) G-Y Power source of shift position sensor (for VSX2) Power switch ON (IG) 4.5 to 5.5 VSX3 (H14-23) - GND1 (H14-1) BR - W-B Select position sensor (main) Power switch ON (IG), selector lever home position 0.5 to 2.0 VSX3 (H14-23) - GND1 (H14-1) BR - W-B Select position sensor (main) Power switch ON (IG), selector lever moved to R, N or D position 3.0 to 4.85 VSX4 (H14-30) - GND1 (H14-1) SB - W-B Select position sensor (sub) Power switch ON (IG), selector lever home position 0.5 to 2.0 VSX4 (H14-30) - GND1 (H14-1) SB- W-B Select position sensor (sub) Power switch ON (IG), selector lever moved to R, N or D position 3.0 to 4.85 VCX3 (H14-21) - GND1 (H14-1) W - W-B Power source of select position sensor (for VSX3) Power switch ON (IG) 9 to 14 VCX4 (H14-31) - GND1 (H14-1) P - W-B Power source of select position sensor (for VSX4) Power switch ON (IG) 9 to 14 NODD (H16-24) - GND1 (H14-1) V - W-B DC / DC movement monitor or stop request signal When converter is in normal operation 5 to 7 NODD (H16-24) - GND1 (H14-1) V - W-B DC / DC movement monitor or stop request signal When converter is improper 2 to 4 NODD (H16-24) - GND1 (H14-1) V - W-B DC / DC movement monitor or stop request signal When converter is required to stop 0.1 to 0.5 VLO (H16-31) - GND1 (H14-1) L - W-B Two-stage selector signal Converter switching to 14 V output 13 to 14 VLO (H16-31) - GND1 (H14-1) L - W-B Two-stage selector signal Converter switching to 13.5 V output Below 0.5 TC (H14-6) - GND1 (H141) P - W-B Terminal TC of DLC3 Power switch ON (IG) 9 to 14 STP (H15-3) - GND1 (H14-1) L - W-B Stop light switch Brake pedal depressed 9 to 14 STP (H15-3) - GND1 (H14-1) L - W-B Stop light switch Brake pedal released 2 to 3 HV HV–30 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) ABFS (H14-20) - GND1 (H14-1) L - W-B Airbag deployment signal Power switch ON (READY) (2 seconds after ON [ACC] ) Pulse generation (see waveform 6, 7, 8) AS1 (H16-15) - AS1G (H16-16) Y-W No. 1 circuit breaker sensor Satellite signal system normal 2.5 to 2.9 ILK (H15-1) - GND1 (H141) V - W-B Interlock switch Power switch ON (IG), inverter cover and service plug grip installed normally Below 1 ILK (H15-1) - GND1 (H141) V - W-B Interlock switch Power switch ON (IG), inverter cover or service plug grip detached 9 to 14 CON1 (H16-1) - GND1 (H14-1) R - W-B No. 1 system main relay Power switch OFF to ON (READY) Pulse generation (see waveform 9) CON2 (H16-2) - GND1 (H14-1) G - W-B No. 2 system main relay Power switch OFF to ON (READY) Pulse generation (see waveform 9) CON3 (H16-3) - GND1 (H14-1) Y - W-B No. 3 system main relay Power switch OFF to ON (READY) Pulse generation (see waveform 9) VH (H15-26) - GINV (H1523) Y - W-B Inverter condenser voltage monitor Power switch ON (READY) 1.6 to 3.8 GUU (H15-15) - GINV (H15-23) B-Y Generator switch U signal Power switch ON (IG) Pulse generation (see waveform 10) GVU (H15-14) - GINV (H15-23) G-Y Generator switch V signal Power switch ON (IG) Pulse generation (see waveform 10) GWU (H15-13) - GINV (H15-23) Y-Y Generator switch W signal Power switch ON (IG) Pulse generation (see waveform 10) GIVA (H15-34) - GINV (H15-23) W-Y Generator V phase current Power switch ON (IG) Approximately 0 GIVB (H15-33) - GINV (H15-23) B-Y Generator V phase current Power switch ON (IG) Approximately 0 GIWA (H15-32) - GINV (H15-23) R-Y Generator W phase current Power switch ON (IG) Approximately 0 GIWB (H15-31) - GINV (H15-23) G-Y Generator W phase current Power switch ON (IG) Approximately 0 GIVT (H15-27) - GINV (H15-23) W-Y Generator inverter temperature sensor Power switch ON (IG) 2 to 4.5 GSDN (H15-16) - GINV (H15-23) R - W-B Generator shutdown signal Power switch ON (READY), N position 0.2 to 0.7 GSDN (H15-16) - GINV (H15-23) R - W-B Generator shutdown signal Power switch ON (READY), P position 5.1 to 13.6 GFIV (H15-35) - GINV (H15-23) GR - W-B Generator inverter fail signal Power switch ON (IG), inverter normal 5.4 to 7.4 GFIV (H15-35) - GINV (H15-23) GR - W-B Generator inverter fail signal Power switch ON (IG), inverter abnormal 2 to 3 GRF (H17-27) - GRFG (H17-26) B-W Generator resolver signal Generator resolver stopped or rotating Pulse generation (see waveform 11, 12) GSN (H17-22) - GSNG (H17-21) R-G Generator resolver signal Generator resolver stopped or rotating Pulse generation (see waveform 11, 12) GCS (H17-23) - GCSG (H17-24) Y - BR Generator resolver signal Generator resolver stopped or rotating Pulse generation (see waveform 11, 12) OMT (H17-30) - OMTG (H17-29) B-G No. 2 motor temperature sensor Refer to DATA LIST (see page HV-49) - MUU (H15-9) - GINV (H15-23) B-Y Motor switch U signal Power switch ON (IG) Pulse generation (see waveform 13) MVU (H15-10) - GINV (H15-23) W-Y Motor switch V signal Power switch ON (IG) Pulse generation (see waveform 13) MWU (H15-11) - GINV (H15-23) R-Y Motor switch W signal Power switch ON (IG) Pulse generation (see waveform 13) HV–31 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) MIVA (H15-30) - GINV (H15-23) G-Y Motor V phase current Power switch ON (IG) Approximately 0 MIVB (H15-21) - GINV (H15-23) W-Y Motor V phase current Power switch ON (IG) Approximately 0 MIWA (H15-29) - GINV (H15-23) R-Y Motor W phase current Power switch ON (IG) Approximately 0 MIWB (H15-20) - GINV (H15-23) B-Y Motor W phase current Power switch ON (IG) Approximately 0 MIVT (H15-19) - GINV (H15-23) L-Y Motor inverter temperature sensor Power switch ON (IG) 2 to 4.5 MSDN (H15-8) - GINV (H15-23) G - W-B Motor shutdown signal Power switch ON (READY), N position 0.2 to 0.7 MSDN (H15-8) - GINV (H15-23) G - W-B Motor shutdown signal Power switch ON (READY), P position 5.1 to 13.6 OVH (H15-22) - GINV (H15-23) BR - W-B Motor inverter over voltage signal Power switch ON (IG), inverter normal 5.3 to 7.3 OVH (H15-22) - GINV (H15-23) BR - W-B Motor inverter over voltage signal Power switch ON (IG), inverter abnormal 1.9 to 2.9 MFIV (H15-18) - GINV (H15-23) G - W-B Motor inverter fail signal Power switch ON (IG), inverter normal 5.4 to 7.4 MFIV (H15-18) - GINV (H15-23) G - W-B Motor inverter fail signal Power switch ON (IG), inverter abnormal 2 to 3 MRF (H17-34) - MRFG (H17-33) L-P Motor resolver signal Motor resolver stopped or rotating Pulse generation (see waveform 11, 12) MSN (H17-20) - MSNG (H17-19) G-R Motor resolver signal Motor resolver stopped or rotating Pulse generation (see waveform 11, 12) MCS (H17-32) - MCSG (H17-31) Y - BR Motor resolver signal Motor resolver stopped or rotating Pulse generation (see waveform 11, 12) MMT (H17-18) - MMTG (H17-28) B-R No. 1 motor temperature sensor Refer to DATA LIST (see page HV-49) - VL (H16-30) - GCNV (H16-8) Y-G Boost converter input voltage Power switch ON (READY) 1.9 to 3.4 OVL (H16-22) - GCNV (H16-8) B-G Boost converter over voltage signal Power switch ON (IG), boost converter normal 5.3 to 7.7 OVL (H16-22) - GCNV (H16-8) B-G Boost converter over voltage signal Power switch ON (IG), boost converter abnormal 1.9 to 3.0 FCV (H16-20) - GCNV (H16-8) W-G Boost converter fail signal Power switch ON (IG), boost converter normal 5.3 to 7.7 FCV (H16-20) - GCNV (H16-8) W-G Boost converter fail signal Power switch ON (IG), boost converter abnormal 1.9 to 3.0 CT (H16-21) - GCNV (H16-8) R-G Boost converter temperature sensor Power switch ON (IG) 2.0 to 4.5 CPWM (H16-10) - GCNV (H16-8) B-G Boost converter PWM switch signal Power switch ON (READY), parking brake ON, D position, brake pedal and accelerator pedal depressed Pulse generation (see waveform 14) CSDN (H16-9) - GCNV (H16-8) W-G Boost converter shutdown signal Power switch ON (IG) 5.6 or higher CSDN (H16-9) - GCNV (H16-8) W-G Boost converter shutdown signal Power switch ON (READY) Below 0.7 ST1- (H15-2) - GND1 (H14-1) G - W-B Stop light switch (opposite to STP) Power switch ON (IG) and brake pedal depressed Below 0.5 ST1- (H15-2) - GND1 (H14-1) G - W-B Stop light switch (opposite to STP) Power switch ON (IG) and brake pedal released 9 to 14 CCS (H14-13) - GND1 (H14-1) V - W-B Cruise control switch Cruise control system Terminal of ECU - CCS terminal (see page CC-9) - HV HV–32 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) IMI (H14-18) - GND1 (H14-1) W - W-B Immobiliser communication Immobiliser communicating Pulse generation (see waveform 15) IMO (H14-26) - GND1 (H14-1) R - W-B Immobiliser communication Immobiliser communicating Pulse generation (see waveform 15) P1 (H15-17) - GND1 (H141) Y - W-B P position switch Power switch ON (IG), P position switch ON 3 to 5 P1 (H15-17) - GND1 (H141) Y - W-B P position switch Power switch ON (IG), P position switch OFF 7 to 12 PCON (H17-9) - GND1 (H14-1) LG - W-B P position control signal Power switch ON (IG) Pulse generation (see waveform 16) PPOS (H17-10) - GND1 (H14-1) W - W-B P position signal Power switch ON (IG) Pulse generation (see waveform 16) RDY (H14-28) - GND1 (H14-1) R - W-B READY control signal Power switch ON (IG) Pulse generation (see waveform 17) RDY (H14-28) - GND1 (H14-1) R - W-B READY control signal Power switch ON (READY) Pulse generation (see waveform 18) CLK (H16-17) - GND1 (H14-1) G - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) ITE (H16-14) - GND1 (H14-1) Y - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) ETI (H15-24) - GND1 (H14-1) R - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) STB (H15-25) - GND1 (H14-1) W - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) WP (H16-5) - GND1 (H141) O - W-B Water pump relay control Power switch ON (IG), A/C operating Below 2 GND1 (H14-1) - Body ground W-B - Body ground Ground Always (resistance check) Below 5 Ω GND2 (H14-4) - Body ground W-B - Body ground Ground Always (resistance check) Below 5 Ω 1. Oscilloscope waveforms HINT: In the oscilloscope waveform samples, which are provided here for informational purposes. Noise and fluttering waveforms have been omitted. 2. Waveform 1 HIGH-level CAN bus line HV GND A092069E01 Item Contents Terminal CANH - GND1 Equipment Setting 1 V/Division, 2 µs/Division Condition Power switch ON (IG) HINT: The waveform varies depending on the contents of communication. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3. GND HV–33 Waveform 2 LOW-level CAN bus line Item Contents Terminal CANL - GND1 Equipment Setting 1 V/Division, 2 µs/Division Condition Power switch ON (IG) HINT: The waveform varies depending on the contents of communication. A092070E01 4. Waveform 3 Engine speed signal Item Contents Terminal NEO - GND1 Equipment Setting 1 V/Division, 2 ms/Division Condition Engine idling HINT: The pulse cycle becomes shorter as the engine speed increases. GND A092071E01 5. Waveform 4 G signal Item Contents Terminal GO - GND1 Equipment Setting 2 V/Division, 20 ms/Division Condition Engine idling HV GND A092072E01 6. Waveform 5 Vehicle speed signal Item GND Contents Terminal SPDI - GND1 Equipment Setting 5 V/Division, 20 ms/Division Condition Driving at approximately 20 km/h (12 mph) HINT: The higher the vehicle speed, the shorter the cycle and higher the voltage. A092073E01 7. *1 Waveform 6 Airbag deployment signal Item GND *2 *2 A092074E01 Contents Terminal ABFS - GND1 Equipment Setting 1 V/Division, 500 ms/Division Condition Power switch ON (READY) (2 seconds after ON [ACC]) Airbag system normal *1: 1 frame *2: 500 ms HV–34 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: The waveform on the left is repeated when the airbag system is normal. 8. *1 GND *2 *3 Item Contents Terminal ABFS - GND1 Equipment Setting 1 V/Division, 50 ms/Division Condition Power switch ON (READY) (2 seconds after ON [ACC]) Airbag system abnormal *1: 1 frame *2: 40 ms *3: 60 ms HINT: The waveform on the left is repeated when the airbag system is abnormal. A092075E01 9. *1 GND *2 *3 *4 Waveform 7 Airbag deployment signal Waveform 8 Airbag deployment signal Item Contents Terminal ABFS - GND1 Equipment Setting 1 V/Division, 50 ms/Division Condition Power switch ON (READY) (2 seconds after ON [ACC]) Airbag system deployed (during collision) *5 *1: 1 frame *2: 20 ms *3: 140 ms *4: 100 ms *5: 60 ms HINT: When the airbag system is deployed, after 1 frame of transmission indicating a normal condition is completed, the waveform on the left is repeated for 50 frames. After that, normal transmission returns. A092076E01 HV 10. Waveform 9 System main relay signal CH1 GND CH2 GND CH3 GND CH4 GND A092077E01 Item Contents Terminal CH1: IGSW - GND1 CH2: CON1 - GND1 CH3: CON2 - GND1 CH4: CON3 - GND1 Equipment Setting 10 V/Division, 100 ms/Division Condition Power switch OFF to ON (READY) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–35 11. Waveform 10 Generator switch U, V, and W signal CH1 GND CH2 GND CH3 GND Item Contents Terminal CH1: GUU - GINV CH2: GVU - GINV CH3: GWU - GINV Equipment Setting 10 V/Division, 20 µs/Division Condition Power switch ON (IG) A092078E01 12. Waveform 11 Generator or motor resolver CH1 GND CH2 GND CH3 GND Item Contents Terminal (Generator Resolver) CH1: GRF - GRFG CH2: GSN - GSNG CH3: GCS - GCSG Terminal (Motor Resolver) CH1: MRF - MRFG CH2: MSN - MSNG CH3: MCS - MCSG Equipment Setting CH1: 10 V/Division, 1 ms/Division CH2, 3: 5 V/Division, 1 ms/Division Condition Generator or motor stopped A092079E01 HINT: The phases and the waveform height of the GSN and GCS, or the MSN and MCS change depending on the stopped position of the rotor. 13. Waveform 12 Generator or motor resolver CH1 GND CH2 GND CH3 GND A Item Contents Terminal (Generator Resolver) CH1: GRF - GRFG CH2: GSN - GSNG CH3: GCS - GCSG Terminal (Motor Resolver) CH1: MRF - MRFG CH2: MSN - MSNG CH3: MCS - MCSG Equipment Setting CH1: 10 V/Division, 1 ms/Division CH2, 3: 5 V/Division, 1 ms/Division Condition Generator or motor rotating A092080E01 HINT: Distance "A" in the diagram becomes shorter as the rotor speed increases. 14. Waveform 13 Motor switch U, V, and W signal CH1 CH2 GND GND CH3 GND A092081E01 Item Contents Terminal CH1: MUU - GINV CH2: MVU - GINV CH3: MWU - GINV Equipment Setting 10 V/Division, 50 µs/Division Condition Power switch ON (IG) HV HV–36 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 15. Waveform 14 Boost converter PWM switch signal GND Item Contents Terminal CPWM - GCNV Equipment Setting 10 V/Division, 50 µs/Division Condition Power switch ON (READY), parking brake ON, D position, brake pedal and accelerator pedal depressed A092082E01 16. Waveform 15 Immobiliser communication CH1 GND CH2 Item Contents Terminal CH1: IMO - GND1 CH2: IMI - GND1 Equipment Setting 5 V/Division, 200 ms/Division Condition Immobiliser communicating GND A092083E01 17. Waveform 16 P position control signal, P position signal CH1 GND CH2 HV Item Contents Terminal CH1: PCON - GND1 CH2: PPOS - GND1 Equipment Setting 5 V/Division, 20 ms/Division Condition Power switch ON (IG) GND A092084E01 18. Waveform 17 READY control signal Item Contents Terminal RDY - GND1 Equipment Setting 2 V/Division, 20 ms/Division Condition Power switch ON (IG) GND A092085E01 19. Waveform 18 READY control signal GND A092086E01 Item Contents Terminal RDY - GND1 Equipment Setting 2 V/Division, 20 ms/Division Condition Power switch ON (READY) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–37 20. Waveform 19 A/C communication CH1 Item Contents Terminal CH1: IGSW - GND1 CH2: ITE - GND1 CH3: CLK - GND1 CH4: ETI - GND1 CH5: STB - GND1 CH2 GND GND CH3 CH4 CH5 GND GND Equipment Setting 10 V/Division, 50 ms/Division GND Condition Power switch ON (IG) and A/C operating A092087E01 DIAGNOSIS SYSTEM 1. Master Warning Light A014089E01 DESCRIPTION (a) The HV control ECU has a self-diagnosis system. If the computer, hybrid vehicle control system or the components are not working properly, the ECU carries out a diagnosis to detect the malfunctions, and illuminates the master warning light in the combination meter together with indicators on the multi display, the HV system warning, the HV battery warning or the discharge warning. HINT: The master warning light illuminates when THS II fails and it blinks when in inspection mode. Discharge Warning HV System Warning HV Battery Warning HV A087660E01 FI00534E01 • When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you need to connect the OBD II scan tool complying with ISO 15031-4 or the intelligent tester to the vehicle, and read various data output from the vehicle's ECUs • OBD II regulations require that the vehicle's onboard computer illuminates the Malfunction Indicator Lamp (MIL) in the instrument panel when the computer detects a malfunction in: 1) the emission control systems/components, or 2) the powertrain control components (which affect vehicle emissions), or 3) the computers. In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by ISO 15031-4 are recorded in the HV control ECU memory (see page HV-55). If the malfunction does not recur in 3 consecutive trips, the MIL will go off automatically. However, the DTCs remain recorded in the HV control ECU memory. HV–38 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM • To check the DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) with the CAN vehicle interface module (CAN VIM). The intelligent tester enables you to erase the DTCs and check the freeze frame data and various forms of THS II data (for operating instructions, refer to their respective instruction manuals). The DTCs include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set by a manufacturer within the prescribed limits (see page HV-55). • Freeze frame data: The freeze frame data records the driving condition when malfunction is detected. When troubleshooting, it can help determine if the vehicle was moving, braking, stationary, or reversing. Intelligent Tester CAN VIM DLC3 A082795E01 2. DLC3 CHECK DLC3 The HV control ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with ISO 15031-03 and matches the ISO 15765-4 format. 1 2 3 4 5 6 7 8 9 10 1112131415 16 A082779E98 HV Symbol Terminal No. Name Reference Terminal Result Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive Body ground 11 to 14 V Always CANH 6 HIGH-level CAN bus line 14 - LOW-level CAN bus line 54 to 69 Ω Power switch OFF* CANH 6 HIGH-level CAN bus line 16 - Battery positive 1 MΩ or higher Power switch OFF* CANH 6 HIGH-level CAN bus line 4 - Chassis ground 200 Ω or higher Power switch OFF* CANL 14 LOW-level CAN bus line 16 - Battery positive 1 MΩ or higher Power switch OFF* CANL 14 LOW-level CAN bus line 4 - Chassis ground 200 Ω or higher Power switch OFF* NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, other switches or doors. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3. 4. HV–39 If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: If the display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the intelligent tester to the DLC3, turned the power switch ON (IG) and operated the tester, there is a problem on the vehicle side or tester side. • If communication is normal when the tester or scan tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester or scan tool is connected to another vehicle, the problem is probably in the tester or scan tool itself, so consult the Service Department listed in its instruction manual. INSPECT AUXILIARY BATTERY (a) Measure the voltage of the auxiliary battery. Standard voltage: 11 to 14 V (b) Inspect the auxiliary battery, fusible links, wire harness, connectors and ground. CHECK MIL (a) The MIL illuminates when the power switch is turned ON (IG) and the "READY" light is OFF. If the MIL is not illuminated, troubleshoot the MIL circuit (see page ES-428). HV FI00534E01 (b) When the "READY" light turns on, the MIL should turn off. If the MIL remains on, the diagnosis system has detected a malfunction or abnormality in the system. A087700E01 HV–40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC CHECK / CLEAR Intelligent Tester DLC3 1. CHECK DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Using the intelligent tester, check the DTCs and freeze frame data and then write them down. For the intelligent tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (d) Confirm the details of the DTCS (see page HV-55). 2. CHECK FREEZE DATA AND INFORMATION (a) If a DTC is present, select that DTC in order to display its freeze frame data. CAN VIM A082795E01 A136965 HV INF Code A136966E01 (b) Read freeze frame data recorded when the DTC was set. NOTICE: An information code (INF code) is displayed in one of the INFORMATION lines 1 to 5. Check the details by following the procedures in the following steps. HINT: In the case shown in the illustration, refer to troubleshooting for DTC P3140 and INF code 350. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–41 (c) Read the information. (1) Select the item that has an INF code from among INFORMATION 1 to 5 on the freeze frame data screen. (2) Press ENTER. INF Code A136966E01 3. A136967 4. (3) Information is displayed as shown in the illustration. CHECK DTC (SYSTEMS OTHER THAN HV ECU) HINT: The HV control ECU maintains mutual communication with the computers, including the ECM, battery ECU, skid control ECU, power steering ECU and other components. Therefore, if the HV control ECU outputs a warning, it is necessary to check and record the DTCs of all the systems. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) For the intelligent tester, enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (ALL). (d) If DTCs are present, check the relevant systems. HINT: If DTCs for the CAN communication system are present in addition to other DTCs, first troubleshoot and repair any malfunctions in the CAN communication (see page CA-6). CLEAR DTC NOTICE: Clearing the DTCs will also clear the freeze frame data, information (see page HV-86) and operation history data (see page HV-89). (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Check that the shift position is in P. (d) Clear DTCs and freeze frame data with the intelligent tester. For the intelligent tester: (1) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CLEAR CODES. (2) Press YES. HV HV–42 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM FAIL-SAFE CHART 1. FAIL-SAFE CHART DTC No. Detection Item INF Code Driving Condition B2799 Immobiliser malfunction 539 Impossible to drive B2799 Immobiliser malfunction 540 Impossible to drive B2799 Immobiliser malfunction 541 Impossible to drive B2799 Immobiliser malfunction 542 Impossible to drive B2799 Immobiliser malfunction 543 Impossible to drive B2799 Immobiliser malfunction 544 Impossible to drive P0336 Crankshaft Position Sensor "A" Circuit Range / Performance 137 Normal driving P0338 Crankshaft Position Sensor "A" Circuit High Input 600 Normal driving P0340 Camshaft Position Sensor "A" Circuit 532 Normal driving P0343 Camshaft Position Sensor "A" Circuit High Input 601 Normal driving P0500 Vehicle Speed Sensor "A" 352 Cruise control driving impossible P0560 System Voltage 117 Normal driving P0571 Brake Switch "A" Circuit 115 Cruise control driving impossible P0607 Control Module Performance 116 Cruise control driving impossible P0705 Transmission Range Sensor Circuit 571 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 572 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 573 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 574 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 575 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 576 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 577 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 578 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 595 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–43 DTC No. Detection Item INF Code Driving Condition P0705 Transmission Range Sensor Circuit 596 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0851 Park / Neutral Switch Input Circuit Low 579 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0852 Park / Neutral Switch Input Circuit High 580 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0A08 DC / DC Converter Status Circuit 264 Normal driving P0A09 DC / DC Converter Status Circuit Low Input 265 Normal driving P0A09 DC / DC Converter Status Circuit Low Input 591 Normal driving P0A0D High Voltage System Inter-lock Circuit High 350 Normal driving P0A0D High Voltage System Inter-lock Circuit High 351 Normal driving P0A0F Engine Failed to Start 204 Limited driving P0A0F Engine Failed to Start 205 Limited driving P0A0F Engine Failed to Start 238 Limited driving P0A0F Engine Failed to Start 533 Limited driving P0A0F Engine Failed to Start 534 Limited driving P0A10 DC / DC Converter Status Circuit High Input 263 Normal driving P0A10 DC / DC Converter Status Circuit High Input 592 Normal driving P0A1D Hybrid Powertrain Control Module 134 Impossible to drive P0A1D Hybrid Powertrain Control Module 135 Impossible to drive P0A1D Hybrid Powertrain Control Module 139 Normal driving P0A1D Hybrid Powertrain Control Module 140 Impossible to drive P0A1D Hybrid Powertrain Control Module 141 Impossible to drive P0A1D Hybrid Powertrain Control Module 142 Impossible to drive P0A1D Hybrid Powertrain Control Module 143 Impossible to drive P0A1D Hybrid Powertrain Control Module 144 Impossible to drive P0A1D Hybrid Powertrain Control Module 145 Impossible to drive P0A1D Hybrid Powertrain Control Module 148 Impossible to drive P0A1D Hybrid Powertrain Control Module 149 Impossible to drive P0A1D Hybrid Powertrain Control Module 150 Limited driving P0A1D Hybrid Powertrain Control Module 151 Limited driving P0A1D Hybrid Powertrain Control Module 152 Limited driving P0A1D Hybrid Powertrain Control Module 155 Limited driving P0A1D Hybrid Powertrain Control Module 156 Limited driving P0A1D Hybrid Powertrain Control Module 158 Limited driving P0A1D Hybrid Powertrain Control Module 159 Impossible to drive P0A1D Hybrid Powertrain Control Module 160 Impossible to drive P0A1D Hybrid Powertrain Control Module 163 Impossible to drive P0A1D Hybrid Powertrain Control Module 164 Impossible to drive P0A1D Hybrid Powertrain Control Module 165 Limited driving P0A1D Hybrid Powertrain Control Module 166 Normal driving P0A1D Hybrid Powertrain Control Module 167 Limited driving HV HV–44 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A1D Hybrid Powertrain Control Module 168 Limited driving P0A1D Hybrid Powertrain Control Module 177 Impossible to drive P0A1D Hybrid Powertrain Control Module 178 Impossible to drive P0A1D Hybrid Powertrain Control Module 180 Limited driving P0A1D Hybrid Powertrain Control Module 181 Limited driving P0A1D Hybrid Powertrain Control Module 182 Limited driving P0A1D Hybrid Powertrain Control Module 183 Limited driving P0A1D Hybrid Powertrain Control Module 184 Limited driving P0A1D Hybrid Powertrain Control Module 185 Limited driving P0A1D Hybrid Powertrain Control Module 186 Limited driving P0A1D Hybrid Powertrain Control Module 187 Impossible to drive P0A1D Hybrid Powertrain Control Module 188 Limited driving P0A1D Hybrid Powertrain Control Module 189 Limited driving P0A1D Hybrid Powertrain Control Module 192 Limited driving P0A1D Hybrid Powertrain Control Module 193 Limited driving P0A1D Hybrid Powertrain Control Module 195 Limited driving P0A1D Hybrid Powertrain Control Module 196 Limited driving P0A1D Hybrid Powertrain Control Module 197 Limited driving P0A1D Hybrid Powertrain Control Module 198 Normal driving P0A1D Hybrid Powertrain Control Module 199 Limited driving P0A1D Hybrid Powertrain Control Module 200 Limited driving P0A1D Hybrid Powertrain Control Module 390 Limited driving P0A1D Hybrid Powertrain Control Module 392 Impossible to drive P0A1D Hybrid Powertrain Control Module 393 Impossible to drive P0A1D Hybrid Powertrain Control Module 511 Impossible to drive P0A1D Hybrid Powertrain Control Module 512 Impossible to drive P0A1D Hybrid Powertrain Control Module 564 Limited driving P0A1D Hybrid Powertrain Control Module 565 Limited driving P0A1D Hybrid Powertrain Control Module 567 Impossible to drive P0A1D Hybrid Powertrain Control Module 568 Limited driving P0A1D Hybrid Powertrain Control Module 569 Limited driving P0A1D Hybrid Powertrain Control Module 570 Impossible to drive P0A1D Hybrid Powertrain Control Module 615 Limited driving P0A1F Battery Energy Control Module 123 Limited driving P0A1F Battery Energy Control Module 129 Limited driving P0A1F Battery Energy Control Module 593 Normal driving P0A2B Drive Motor "A" Temperature Sensor Circuit Range / Performance 248 Normal driving P0A2B Drive Motor "A" Temperature Sensor Circuit Range / Performance 250 Normal driving P0A2C Drive Motor "A" Temperature Sensor Circuit Low 247 Normal driving P0A2D Drive Motor "A" Temperature Sensor Circuit High 249 Normal driving P0A37 Generator Temperature Sensor Circuit Range / Performance 258 Normal driving P0A37 Generator Temperature Sensor Circuit Range / Performance 260 Normal driving P0A38 Generator Temperature Sensor Circuit Low 257 Normal driving P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A39 Generator Temperature Sensor Circuit High 259 Normal driving P0A3F Drive Motor "A" Position Sensor Circuit 243 Limited driving P0A40 Drive Motor "A" Position Sensor Circuit Range / Performance 500 Limited driving P0A41 Drive Motor "A" Position Sensor Circuit Low 245 Limited driving P0A4B Generator Position Sensor Circuit 253 Limited driving P0A4C Generator Position Sensor Circuit Range / Performance 513 Limited driving P0A4D Generator Position Sensor Circuit Low 255 Limited driving P0A51 Drive Motor "A" Current Sensor Circuit 174 Limited driving P0A60 Drive Motor "A" Phase V Current 288 Limited driving P0A60 Drive Motor "A" Phase V Current 289 Limited driving P0A60 Drive Motor "A" Phase V Current 290 Limited driving P0A60 Drive Motor "A" Phase V Current 292 Limited driving P0A60 Drive Motor "A" Phase V Current 294 Limited driving P0A60 Drive Motor "A" Phase V Current 501 Limited driving P0A63 Drive Motor "A" Phase W Current 296 Limited driving P0A63 Drive Motor "A" Phase W Current 297 Limited driving P0A63 Drive Motor "A" Phase W Current 298 Limited driving P0A63 Drive Motor "A" Phase W Current 300 Limited driving P0A63 Drive Motor "A" Phase W Current 302 Limited driving P0A63 Drive Motor "A" Phase W Current 502 Limited driving P0A72 Generator Phase V Current 326 Limited driving P0A72 Generator Phase V Current 327 Limited driving P0A72 Generator Phase V Current 328 Limited driving P0A72 Generator Phase V Current 330 Limited driving P0A72 Generator Phase V Current 333 Limited driving P0A72 Generator Phase V Current 515 Limited driving P0A75 Generator Phase W Current 334 Limited driving P0A75 Generator Phase W Current 335 Limited driving P0A75 Generator Phase W Current 336 Limited driving P0A75 Generator Phase W Current 338 Limited driving P0A75 Generator Phase W Current 341 Limited driving P0A75 Generator Phase W Current 516 Limited driving P0A78 Drive Motor "A" Inverter Performance 266 Limited driving P0A78 Drive Motor "A" Inverter Performance 267 Limited driving P0A78 Drive Motor "A" Inverter Performance 272 Normal driving P0A78 Drive Motor "A" Inverter Performance 278 Normal driving P0A78 Drive Motor "A" Inverter Performance 279 Limited driving P0A78 Drive Motor "A" Inverter Performance 280 Normal driving P0A78 Drive Motor "A" Inverter Performance 282 Limited driving HV–45 HV HV–46 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A78 Drive Motor "A" Inverter Performance 283 Normal driving P0A78 Drive Motor "A" Inverter Performance 284 Limited driving P0A78 Drive Motor "A" Inverter Performance 285 Normal driving P0A78 Drive Motor "A" Inverter Performance 286 Limited driving P0A78 Drive Motor "A" Inverter Performance 287 Limited driving P0A78 Drive Motor "A" Inverter Performance 304 Normal driving P0A78 Drive Motor "A" Inverter Performance 305 Normal driving P0A78 Drive Motor "A" Inverter Performance 306 Limited driving P0A78 Drive Motor "A" Inverter Performance 308 Impossible to drive P0A78 Drive Motor "A" Inverter Performance 503 Limited driving P0A78 Drive Motor "A" Inverter Performance 504 Limited driving P0A78 Drive Motor "A" Inverter Performance 505 Limited driving P0A78 Drive Motor "A" Inverter Performance 506 Limited driving P0A78 Drive Motor "A" Inverter Performance 507 Normal driving P0A78 Drive Motor "A" Inverter Performance 508 Normal driving P0A78 Drive Motor "A" Inverter Performance 510 Normal driving P0A78 Drive Motor "A" Inverter Performance 523 Limited driving P0A78 Drive Motor "A" Inverter Performance 586 Limited driving P0A7A Generator Inverter Performance 309 Limited driving P0A7A Generator Inverter Performance 321 Normal driving P0A7A Generator Inverter Performance 322 Limited driving P0A7A Generator Inverter Performance 323 Normal driving P0A7A Generator Inverter Performance 324 Limited driving P0A7A Generator Inverter Performance 325 Limited driving P0A7A Generator Inverter Performance 342 Limited driving P0A7A Generator Inverter Performance 343 Limited driving P0A7A Generator Inverter Performance 344 Limited driving P0A7A Generator Inverter Performance 517 Limited driving P0A7A Generator Inverter Performance 518 Limited driving P0A7A Generator Inverter Performance 519 Limited driving P0A7A Generator Inverter Performance 520 Limited driving P0A7A Generator Inverter Performance 522 Normal driving P0A90 Drive Motor "A" Performance 239 Limited driving P0A90 Drive Motor "A" Performance 240 Limited driving P0A90 Drive Motor "A" Performance 241 Limited driving P0A90 Drive Motor "A" Performance 242 Limited driving P0A90 Drive Motor "A" Performance 251 Limited driving P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A90 Drive Motor "A" Performance 509 Limited driving P0A90 Drive Motor "A" Performance 602 Limited driving P0A90 Drive Motor "A" Performance 604 Limited driving P0A90 Drive Motor "A" Performance 605 Limited driving P0A92 Hybrid Generator Performance 261 Limited driving P0A92 Hybrid Generator Performance 521 Limited driving P0A92 Hybrid Generator Performance 606 Limited driving P0A92 Hybrid Generator Performance 607 Limited driving P0A93 Inverter Cooling System Performance 346 Limited driving P0A93 Inverter Cooling System Performance 347 Limited driving P0A94 DC / DC Converter Performance 442 Limited driving P0A94 DC / DC Converter Performance 545 Limited driving P0A94 DC / DC Converter Performance 546 Limited driving P0A94 DC / DC Converter Performance 547 Limited driving P0A94 DC / DC Converter Performance 548 Limited driving P0A94 DC / DC Converter Performance 549 Limited driving P0A94 DC / DC Converter Performance 550 Limited driving P0A94 DC / DC Converter Performance 551 Limited driving P0A94 DC / DC Converter Performance 552 Limited driving P0A94 DC / DC Converter Performance 553 Limited driving P0A94 DC / DC Converter Performance 554 Limited driving P0A94 DC / DC Converter Performance 555 Limited driving P0A94 DC / DC Converter Performance 556 Limited driving P0A94 DC / DC Converter Performance 557 Limited driving P0A94 DC / DC Converter Performance 558 Normal driving P0A94 DC / DC Converter Performance 559 Limited driving P0A94 DC / DC Converter Performance 560 Normal driving P0A94 DC / DC Converter Performance 561 Limited driving P0A94 DC / DC Converter Performance 583 Normal driving P0A94 DC / DC Converter Performance 584 Normal driving P0A94 DC / DC Converter Performance 585 Normal driving P0A94 DC / DC Converter Performance 587 Limited driving P0A94 DC / DC Converter Performance 588 Limited driving P0A94 DC / DC Converter Performance 589 Normal driving P0A94 DC / DC Converter Performance 590 Normal driving P0AA1 Hybrid Battery Positive Contactor Circuit Stuck Closed 231 Impossible to drive P0AA1 Hybrid Battery Positive Contactor Circuit Stuck Closed 233 Impossible to drive P0AA4 Hybrid Battery Negative Contactor Circuit Stuck Closed 232 Limited driving P0AA6 Hybrid Battery Voltage System Isolation Fault 526 Normal driving* P0AA6 Hybrid Battery Voltage System Isolation Fault 611 Normal driving* P0AA6 Hybrid Battery Voltage System Isolation Fault 612 Normal driving* P0AA6 Hybrid Battery Voltage System Isolation Fault 613 Normal driving* HV–47 HV HV–48 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0AA6 Hybrid Battery Voltage System Isolation Fault 614 Normal driving* P0ADB Hybrid Battery Positive Contactor Control Circuit Low 227 Impossible to drive P0ADC Hybrid Battery Positive Contactor Control Circuit High 226 Impossible to drive P0ADF Hybrid Battery Negative Contactor Control Circuit Low 229 Impossible to drive P0AE0 Hybrid Battery Negative Contactor Control Circuit High 228 Impossible to drive P0AE6 Hybrid Battery Precharge Contactor Control Circuit Low 225 Normal driving P0AE7 Hybrid Battery Precharge Contactor Control Circuit High 224 Normal driving P0AEE Motor Inverter Temperature Sensor "A" Circuit Range / Performance 276 Normal driving P0AEE Motor Inverter Temperature Sensor "A" Circuit Range / Performance 277 Normal driving P0AEF Drive Motor Inverter Temperature Sensor "A" Circuit Low 275 Normal driving P0AF0 Drive Motor Inverter Temperature Sensor "A" Circuit High 274 Normal driving P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit 111 Limited driving P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 106 Limited driving P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 114 Limited driving P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input 104 Limited driving P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input 105 Limited driving P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit 112 Limited driving P2126 Throttle / Pedal Position Sensor / Switch "E" Circuit Range / Performance 109 Limited driving P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input 107 Limited driving P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input 108 Limited driving P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation 110 Limited driving P3000 HV Battery Malfunction 123 Limited driving P3000 HV Battery Malfunction 125 Limited driving P3000 HV Battery Malfunction 388 Limited driving P3000 HV Battery Malfunction 389 Limited driving P3000 HV Battery Malfunction 603 Limited driving P3004 Power Cable Malfunction 131 Impossible to drive P3004 Power Cable Malfunction 132 Normal driving P3004 Power Cable Malfunction 133 Limited driving P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–49 DTC No. Detection Item INF Code Driving Condition P3102 Transmission Control ECU Malfunction 524 Impossible to drive P3102 Transmission Control ECU Malfunction 525 Impossible to drive P3102 Transmission Control ECU Malfunction 581 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 582 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 597 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 598 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 599 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3107 Airbag ECU Communication Circuit Malfunction 213 Normal driving P3107 Airbag ECU Communication Circuit Malfunction 214 Normal driving P3107 Airbag ECU Communication Circuit Malfunction 215 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 535 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 536 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 537 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 538 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 594 Normal driving P3110 IGCT Relay Malfunction 223 Normal driving P3110 HV Main Relay Malfunction 527 Impossible to drive P3137 Collision Sensor Low Input 348 Normal driving P3138 Collision Sensor High Input 349 Normal driving P3221 Generator Inverter Temperature Sensor Circuit Range / Performance 314 Normal driving P3221 Generator Inverter Temperature Sensor Circuit Range / Performance 315 Normal driving P3222 Generator Inverter Temperature Sensor Circuit High / Low 313 Normal driving P3223 Generator Inverter Temperature Sensor Circuit High 312 Normal driving P3226 DC / DC Boost Converter Temperature Sensor Malfunction 562 Normal driving P3226 DC / DC Boost Converter Temperature Sensor Malfunction 563 Normal driving HV HV–50 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition U0100 Lost Communication with ECM / PCM "A" 211 Limited driving U0100 Lost Communication with ECM / PCM "A" 212 Limited driving U0100 Lost Communication with ECM / PCM "A" 530 Limited driving U0111 Lost Communication with Battery Energy Control Module "A" 208 Limited driving U0111 Lost Communication with Battery Energy Control Module "A" 531 Limited driving U0129 Lost Communication with Brake System Control Module 220 Regenerative brake ineffective U0129 Lost Communication with Brake System Control Module 222 Regenerative brake ineffective U0129 Lost Communication with Brake System Control Module 528 Regenerative brake ineffective U0129 Lost Communication with Brake System Control Module 529 Regenerative brake ineffective U0131 Lost Communication with Power Steering Control Module 433 Normal driving U0131 Lost Communication with Power Steering Control Module 434 Normal driving U0146 Lost Communication with Gateway "A" 435 Normal driving HINT: *: Normal driving occurs but turning the power switch OFF once causes driving to become impossible. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–51 DATA LIST / ACTIVE TEST 1. DATA LIST NOTICE: • The value of the DATA LIST may vary significantly if there are slight differences in measurement, differences in the environment in which the measurements are obtained, or the aging of the vehicle. Thus, definite standards or judgment values are unavailable. Therefore, there may be a malfunction even if a measured value is within the reference range. • In the event of intricate symptoms, collect sample data from another vehicle of the same model operating under identical conditions, in order to reach an overall judgment by comparing all the items of DATA LIST. HINT: Using the DATA LIST displayed on the intelligent tester, you can read values including those of the switches, sensors, actuators, without removing any parts . Reading the DATA LIST as the first step of troubleshooting is one method to shorten diagnostic time. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DATA LIST. (e) Check the results by referring to the following table. Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note COOLANT TEMP Engine coolant temperature / Min.: -40°C, Max.: 140°C After warming up: 80 to 100°C (176 to 212°F) • • VEHICLE SPD Vehicle speed / Min.: 0 km/h, Max.: 255 km/h Vehicle stopped: 0 km/h (0 mph) - ENG RUN TIME Elapsed time after starting engine / Min.: 0 s, Max.: 65,535 s - - +B Auxiliary battery voltage / Min.: 0 V, Max.: 65.535 V Constant: Auxiliary battery voltage +-3 V - ACCEL POS #1 No. 1 accelerator pedal position sensor / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - ACCEL POS #2 No. 2 accelerator pedal position sensor / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - AMBIENT TEMP Ambient air temperature / Min.: -40°C, Max.: 215°C Power switch ON (IG): Same as ambient air temperature - INTAKE AIR TEMP Intake air temperature / Min.: -40°C, Max.: 140°C Constant: Same as ambient air temperature - DTC CLEAR WARM The number of times engine is warmed up after clearing DTCs / Min.: 0, Max.: 255 MIL OFF, engine coolant temperature increases from below 22°C (71.6°F) before starting the engine to above 70°C (158°F) after starting the engine: Increases once - The value is -40°C (-40°F): Open in sensor circuit If the value is 140°C (284°F): Short in sensor circuit HV HV–52 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note DTC CLEAR RUN Drive distance after clearing DTCs / Min.: 0 km, Max.: 65,535 km - - DTC CLEAR MIN Elapsed time after clearing DTCs / Min.: 0 min, Max.: 65,535 min - - MIL ON RUN DIST Drive distance after malfunction occurrence / Min.: 0 km, Max.: 65,535 km - - MIL ON ENG TIME Elapsed time after starting engine with MIL ON / Min.: 0 min, Max.: 65,535 min - - MIL Status MIL status / ON or OFF MIL ON: ON Constant ON: Repair in accordance with detected DTCs MG2 REV MG2 revolution / Min.: -16,383 rpm, Max.: 16,383 rpm - - MG2 TORQ MG2 torque / Min.: -500 Nm, Max.: 500 Nm - - MG2 TRQ EXC VAL MG2 torque execution value / Min.: -512 Nm, Max.: 508 Nm After full-load acceleration with READY light ON and engine stopped: Less than +-20% of MG2 TORQ - MG1 REV MG1 revolution / Min.: -16,383 rpm, Max.: 16,383 rpm - - MG1 TORQ MG1 torque / Min.: -500 Nm, Max.: 500 Nm - - MG1 TRQ EXC VAL MG1 torque execution value / Min.: -512 Nm, Max.: 508 Nm 1 second has elapsed after the engine was started automatically with READY light ON, engine stopped, A/C fan Hi, headlight ON and the P position: Less than +-20% of MG1 TORQ - REGEN EXEC TORQ Regenerative brake execution torque / Min.: 0 Nm, Max.: 186 Nm - - REGEN RQST TORQ Regenerative brake request torque / Min.: 0 Nm, Max.: 186 Nm Vehicle speed 30 km/h (19 mph) and master cylinder hydraulic pressure -200 Nm: Changes with brake pedal pressure - MG1 INVERT TEMP MG1 inverter temperature / Min.: -50°C, Max.: 205°C • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • HV • MG2 INVERT TEMP MG2 inverter temperature / Min.: -50°C, Max.: 205°C • • MOTOR2 TEMP Transaxle fluid temperature / Min.: -50°C, Max.: 205°C • • • • • If the value is -50°C (-58°F): +B short in sensor circuit If the value is 205°C (401°F): Open or GND short in sensor circuit If the value is -50°C (-58°F): +B short in sensor circuit If the value is 205°C (401°F): Open or GND short in sensor circuit If the value is -50°C (-58°F): Open or +B short in sensor circuit If the value is 205°C (401°F): GND short in sensor circuit P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note MOTOR1 TEMP MG2 motor temperature / Min.: -50°C, Max.: 205°C • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 60°C (77 to 140°F) • • CONVERTER TEMP Boost converter temperature / Min.: -50°C, Max.: 205°C • • • • ACCEL DEG Accelerator pedal depressed angle / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - POWER RQST Engine power output request value / Min.: 0 W, Max.: 320,000 W - - TARGET ENG SPD Target engine speed / Min.: 0 rpm, Max.: 8,000 rpm - - ENGINE SPD Engine speed / Min.: 0 rpm, Max.: 8,000 rpm Idling*: 950 to 1,050 rpm - VEHICLE SPD Resolver vehicle speed / Min.: -256 km/h, Max.: 254 km/h Driving at 40 km/h (25 mph): 40 km/h (25 mph) - MCYL CTRL POWER Braking torque that is equivalent to the master cylinder hydraulic pressure / Min.: -512 Nm, Max.: 508 Nm Brake pedal depressed: Changes with brake pedal pressure - SOC Battery state of charge / Min.: 0%, Max.: 100% Constant: 0 to 100% - WOUT CTRL POWER Discharge control power value / Min.: 0 W, Max.: 81,600 W 21,000 W or less - WIN CTRL POWER Charge control power value / Min.: -40,800 W, Max.: 0 W -25,000 W or more - DCHG RQST SOC Discharge request to adjust SOC / Min.: -20,480 W, Max.: 20,320 W • Uniform on-board charging: 4,400 W Usually: 0 W - PWR RESOURCE VB HV battery voltage / Min.: 0 V, Max.: 510 V READY light ON and P position: 150 to 300 V - PWR RESOURCE IB HV battery current / Min.: -256 A, Max.: 254 A - - VL High voltage before it is boosted / Min.: 0 V, Max.: 510 V Power switch ON (READY): Practically the same as the HV battery voltage • • • VH High voltage after it is boosted / Min.: 0 V, Max.: 765 V Engine revved up in P position: HV battery voltage to 500 V • • RAIS PRES RATIO Boost ratio / Min.: 0%, Max.: 100% The pre-boost voltage and the post-boost voltage are equal: 0 to 10% - DRIVE CONDITION Drive condition ID / Min.: 0, Max.: 6 • • - • • • • Engine stopped: 0 Engine about to be stopped: 1 Engine about to be started: 2 Engine operated or operating: 3 Generating or loading movement: 4 Revving up with P position: 6 HV–53 If the value is -50°C (-58°F): Open or +B short in sensor circuit If the value is 205°C (401°F): GND short in sensor circuit If the value is -50°C (-58°F): +B short in sensor circuit If the value is 205°C (401°F): Open or GND short in sensor circuit HV If the value is 0 V: Open or GND short in sensor circuit If the value is 510 V: +B short in sensor circuit If the value is 0 V: Open or GND short in sensor circuit If the value is 765 V: +B short in sensor circuit HV–54 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note M SHIFT SENSOR Output voltage of the shift position sensor (main) / Min.: 0 V, Max.: 5 V • Selector lever in home position: 2.0 to 3.0 V Shifting into R position: 4.0 to 4.8 V Shifting into B or D position: 0.2 to 1.0 V - Selector lever in home position: 2.0 to 3.0 V Shifting into R position: 4.0 to 4.8 V Shifting into B or D position: 0.2 to 1.0 V - Selector lever in home position: 0.5 to 2.0 V Shifting into R, N or D position: 3.0 to 4.85 V - Selector lever in home position: 0.5 to 2.0 V Shifting into R, N or D position: 3.0 to 4.85 V - • • S SHIFT SENSOR Output voltage of the shift position sensor (sub) / Min.: 0 V, Max.: 5 V • • • SM SHIFT SENSOR Output voltage of the select position sensor (main) / Min.: 0 V, Max.: 5 V • • SS SHIFT SENSOR Output voltage of the select position sensor (sub) / Min.: 0 V, Max.: 5 V • • SHIFT POSITION Shift position P, R, N, D or B - A/C CONSMPT PWR A/C consumption power / Min.: 0 kW, Max.: 5 kW - - DRIVE CONDITION Driving condition • • SHORT WAVE HIGH Waveform voltage in leak detection circuit in battery ECU / Min.: 0 V, Max.: 5 V READY light is left ON for 2 minutes, and the pre-boost voltage and the post-boost voltage are equal: 4 V or more ECU TYPE Type of ECU HV ECU - CURRENT DTC The number of current DTCs / Min.: 0, Max.: 255 - - HISTORY DTC The number of history DTCs / Min.: 0, Max.: 255 - - CHECK MODE Check mode / ON or OFF - - ENG STOP RQST Engine stop request / NO or RQST Requesting engine stop: RQST - IDLING REQUEST Engine idling request / NO or RQST Requesting idle: RQST - HV BATT CH RQST HV battery charging request / NO or RQST Requesting HV battery charging: RQST - AIRCON REQUEST Engine starting request from air conditioning amplifier / NO or RQST Requesting engine start from air conditioning amplifier: RQST - ENG WARM UP RQT Engine warm-up request / NO or RQST Requesting engine warm-up: RQST - SMR CONT1 Operating condition of No. 1 system main relay / ON or OFF Power switch ON (READY): OFF - SMR CONT2 Operating condition of No. 2 system main relay / ON or OFF Power switch ON (READY): ON - HV MG1 load: MG1 MG2 load: MG2 - P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note SMR CONT3 Operating condition of No. 3 system main relay / ON or OFF Power switch ON (READY): ON - MG1 GATE MG1 gate status / ON or OFF ON - MG2 GATE MG2 gate status / ON or OFF Shutting down motor inverter: ON - CNV GATE Boost converter gate status / ON or OFF Shutting down boost converter: ON - A/C GATE A/C gate status / ON or OFF Shutting down A/C inverter: ON - ENTRY KEY ECU Electronic key ID code check status / ON or OFF When electronic key ID code corresponds to ID code registered in ECU: ON - 2. HV–55 HINT: *: If no conditions are specifically stated for "Idling", it means the engine for inspection mode, the shift position is in P, the A/C switch is OFF, and accelerator pedal is not depressed. ACTIVE TEST NOTICE: Beware that if the connector to the intelligent tester becomes disconnected or a communication error occurs during the ACTIVE TEST, the vehicle could become inoperative (READY light OFF). HINT: Performing the ACTIVE TEST using the intelligent tester enables components including the relay, VSV, and actuator, to be operated without removing any parts. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten diagnostic time. It is possible to display items in the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / ACTIVE TEST. (e) According to the display on the tester, perform the ACTIVE TEST. Intelligent Tester Display Purpose Test Details Test Condition INSPECTION MOD1*1, *2 • • Power switch ON (IG), HV system normal, not in inspection mode, and other Active Tests not being executed • To check its operation while the engine is running To disable traction control while performing a speedometer test or other test • Runs the engine continuously (P position) Cancels the traction control that is effected when the rotational difference between the front and rear wheels is excessive (other than the P position) HV HV–56 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Purpose Test Details Test Condition INSPECTION MOD2*1, *2 To disable traction control while performing a speedometer test or the like Cancels the traction control that is effected when the rotational difference between the front and rear wheels is excessive (other than the P position) Power switch ON (IG), HV system normal, not in inspection mode, and other Active Tests not being executed INVERTER STOP*1 To determine if there is an internal leak in the inverter or the HV control ECU Keeps the inverter power transistor actuation signal ON Power switch ON (IG), P position, HV system normal, inverter actuation not being disabled, shutting down inverter, and other Active Tests not being executed COMPRESS TEST*1, *3, *4 To crank the engine continuously in order to measure the compression Allows the engine to continue cranking by activating the generator continuously Power switch ON (IG), HV system normal, not in cranking mode, and other Active Tests not being executed NOTICE: *1: The intelligent tester displays a communication error and the vehicle's READY light turns OFF when the ACTIVE TEST is completed. Therefore, in order to use the tester again, turn the power switch OFF, and restart by turning it ON. *2: After turning on INSPECTION MOD1 or MOD2, push the power switch while depressing the brake pedal. *3: After turning on COMPRESS TEST, push the power switch while depressing the brake pedal. To stop engine cranking, push the power switch again. *4: COMPRESS TEST may not be activated depending on the condition of the engine or the HV battery. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–57 DIAGNOSTIC TROUBLE CODE CHART DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0336-137 Crankshaft Position Sensor "A" Circuit Range / Performance Engine speed sensor deviation malfunction (CAN communication ) - Wire harness or connector - Crankshaft position sensor - Camshaft position sensor - HV control ECU Comes on - DTC stored HV-91 P0338-600 Crankshaft Position Sensor "A" Circuit High Input NEO signal circuit malfunction - Wire harness or connector - HV control ECU Comes on - DTC stored HV-94 P0340-532 Camshaft Position Sensor "A" Circuit Engine speed sensor deviation malfunction (pulse signal) - Wire harness or connector - Crankshaft position sensor - Camshaft position sensor - HV control ECU Comes on - DTC stored HV-91 P0343-601 Camshaft Position Sensor "A" Circuit High Input GO signal circuit malfunction - Wire harness or connector - HV control ECU Comes on - DTC stored HV-94 P0560-117 System Voltage HV control ECU back-up power source circuit malfunction - Wire harness or connector - HEV fuse Comes on Comes on DTC stored HV-97 P0630-804 VIN not Programmed or Mismatch-ECM / PCM - VIN not stored in HV control ECU - Input VIN in HV control ECU not accurate - HV control ECU Comes on Comes on DTC stored HV-101 P0705-571 Transmission Range Sensor Circuit Open or GND short in shift main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-572 Transmission Range Sensor Circuit +B short in shift main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-573 Transmission Range Sensor Circuit Open or GND short in shift sub sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-574 Transmission Range Sensor Circuit +B short in shift sub sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-575 Transmission Range Sensor Circuit Open or GND short in select main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 HV HV–58 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0705-576 Transmission Range Sensor Circuit +B short in select main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on P0705-577 Transmission Range Sensor Circuit Open or GND short in select sub sensor circuit - Wire harness or connector - Selector lever - HV control ECU P0705-578 Transmission Range Sensor Circuit +B short in select sub sensor circuit P0705-595 Transmission Range Sensor Circuit P0705-596 MIL Memory See page - DTC stored HV-102 Comes on - DTC stored HV-102 - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 Difference between shift main sensor value and shift sub sensor value is large - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 Transmission Range Sensor Circuit Difference between select main sensor value and select sub sensor value is large - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0851-579 Park / Neutral Switch Input Circuit Low GND short in P position switch circuit - Wire harness or connector - P position switch - HV control ECU Comes on - DTC stored HV-112 P0852-580 Park / Neutral Switch Input Circuit High Open or +B short in P position switch circuit - Wire harness or connector - P position switch - HV control ECU Comes on - DTC stored HV-112 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A08-264 DC / DC Converter Status Circuit DC / DC converter malfunction - Auxiliary battery - Fusible link block assembly - HV control ECU - Fuse (for 12 V electrical equipment) - Engine room relay block - Inverter cooling hose - Water pump with motor assembly - Cooling fan motor - No.2 cooling fan motor - Wire harness or connector - Inverter with converter assembly (DC / DC converter) Comes on P0A09-265 DC / DC Converter Status Circuit Low Input Open or GND short in NODD signal circuit of DC / DC converter - Wire harness or connector - Inverter with converter assembly P0A09-591 DC / DC Converter Status Circuit Low Input Open or GND short in VLO signal circuit of DC / DC converter P0A0D-350 High Voltage System InterLock Circuit High P0A0D-351 MIL HV–59 Memory See page - DTC stored HV-115 Comes on - DTC stored HV-124 - Wire harness or connector - Inverter with converter assembly Comes on - DTC stored HV-127 Operating safety devices with vehicle stopped (ILK signal is ON) - Service plug grip installation - Inverter cover installation Comes on - DTC stored HV-129 High Voltage System InterLock Circuit High Open in interlock signal circuit while vehicle is running - Wire harness or connector - Battery plug (No. 2 interlock switch) - Inverter with converter assembly (No. 1 interlock switch) Comes on - DTC stored HV-130 P0A0F-204 Engine Failed to Start Abnormal signal input from ECM (abnormal engine output) - ECM - SFI system Comes on - DTC stored HV-134 P0A0F-205 Engine Failed to Start Abnormal signal input from ECM (engine is unable to start) - ECM - SFI system Comes on - DTC stored HV-134 HV HV–60 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A0F-238 Engine Failed to Start Engine does not start even though cranking it (transaxle input malfunction [engine system]) - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on P0A0F-533 Engine Failed to Start Abnormal signal input from ECM (abnormal engine output by running out of fuel) - ECM - SFI system P0A0F-534 Engine Failed to Start Abnormal signal input from ECM (engine is unable to start by running out of fuel) P0A10-263 DC / DC Converter Status Circuit High Input P0A10-592 MIL Memory See page - DTC stored HV-135 Comes on - DTC stored HV-134 - ECM - SFI system Comes on - DTC stored HV-134 +B short in NODD signal circuit of DC / DC converter - Wire harness or connector - Inverter with converter assembly Comes on - DTC stored HV-124 DC / DC Converter Status Circuit High Input +B short in NODD signal circuit of DC / DC converter - Wire harness or connector - Inverter with converter assembly Comes on - DTC stored HV-127 P0A1D-134 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-141 P0A1D-135 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-141 P0A1D-139 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-143 P0A1D-140 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-144 P0A1D-141 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-145 P0A1D-142 Hybrid Powertrain Control Module ST signal of HV control ECU is ON with power switch OFF - Wire harness or connector - Power source control ECU Comes on Comes on DTC stored HV-146 P0A1D-143 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-149 P0A1D-144 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-150 P0A1D-145 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-150 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A1D-148 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU P0A1D-149 Hybrid Powertrain Control Module HV control ECU internal error P0A1D-150 Hybrid Powertrain Control Module P0A1D-151 HV–61 MIL Memory See page Comes on Comes on DTC stored HV-152 - HV control ECU Comes on Comes on DTC stored HV-152 HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-152 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-155 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-156 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-158 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-159 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-156 P0A1D-160 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-156 P0A1D-163 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-158 P0A1D-164 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-158 P0A1D-165 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-166 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-167 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-168 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-177 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-178 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-180 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-181 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 HV HV–62 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A1D-182 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-183 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-184 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-185 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-186 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-187 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-168 P0A1D-188 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-189 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-192 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-193 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-195 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-196 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-197 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-198 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-199 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-200 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-390 Hybrid Powertrain Control Module Charge control malfunction - HV control ECU Comes on Comes on DTC stored HV-171 P0A1D-392 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-393 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-172 P0A1D-511 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-158 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A1D-512 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU P0A1D-564 Hybrid Powertrain Control Module HV control ECU internal error P0A1D-565 Hybrid Powertrain Control Module P0A1D-567 HV–63 MIL Memory See page Comes on Comes on DTC stored HV-158 - HV control ECU Comes on Comes on DTC stored HV-154 HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-568 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-173 P0A1D-569 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-173 P0A1D-570 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-141 P0A1D-615 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-175 P0A1F-123 Battery Energy Control Module Abnormal signal input from battery ECU (ROM/ RAM malfunction) - HV battery system - Battery ECU Comes on Comes on DTC stored HV-177 P0A1F-129 Battery Energy Control Module HV battery voltage circuit malfunction - HV battery voltage circuit - Service plug grip - High voltage fuse - Battery plug - Battery ECU Comes on Comes on DTC stored HV-179 HV P0A1F-593 Battery Energy Control Module IG2 signal circuit of battery ECU malfunction - Wire harness or connector - Battery ECU Comes on Comes on DTC stored HV-183 P0A2B-248 Drive Motor "A" Temperature Sensor Circuit Range / Performance No. 1 motor temperature sensor malfunction - Hybrid vehicle motor Comes on - DTC stored HV-186 P0A2B-250 Drive Motor "A" Temperature Sensor Circuit Range / Performance No. 1 motor temperature sensor performance problem - Hybrid vehicle motor Comes on - DTC stored HV-186 P0A2C-247 Drive Motor "A" Temperature Sensor Circuit Low GND short in No. 1 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on - DTC stored HV-187 HV–64 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A2D-249 Drive Motor "A" Temperature Sensor Circuit High Open or +B short in No. 1 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on P0A37-258 Generator Temperature Sensor Circuit Range / Performance No. 2 motor temperature sensor malfunction - Hybrid vehicle motor P0A37-260 Generator Temperature Sensor Circuit Range / Performance No. 2 motor temperature sensor performance problem P0A38-257 Generator Temperature Sensor Circuit Low P0A39-259 MIL Memory See page - DTC stored HV-187 Comes on - DTC stored HV-193 - Hybrid vehicle motor - Transaxle fluid leakage - HV transaxle assembly Comes on - DTC stored HV-194 GND short in No. 2 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on - DTC stored HV-195 Generator Temperature Sensor Circuit High Open or +B short in No. 2 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on - DTC stored HV-195 P0A3F-243 Drive Motor "A" Position Sensor Circuit Interphase short in motor resolver circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on Comes on DTC stored HV-200 P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance Motor resolver output is out of normal range - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on Comes on DTC stored HV-200 P0A41-245 Drive Motor "A" Position Sensor Circuit Low Open or short in motor resolver circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on Comes on DTC stored HV-200 P0A4B-253 Generator Position Sensor Circuit Interphase short in generator resolver circuit - Wire harness or connector - Hybrid vehicle generator - HV control ECU Comes on Comes on DTC stored HV-205 P0A4C-513 Generator Position Sensor Circuit Range / Performance Generator resolver output is out of normal range - Wire harness or connector - Hybrid vehicle generator - HV control ECU Comes on Comes on DTC stored HV-205 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A4D-255 Generator Position Sensor Circuit Low Open or short in generator resolver circuit - Wire harness or connector - Hybrid vehicle generator - HV control ECU P0A51-174 Drive Motor "A" Current Sensor Circuit HV control ECU internal error P0A60-288 Drive Motor "A" Phase V Current P0A60-289 HV–65 MIL Memory See page Comes on Comes on DTC stored HV-205 - HV control ECU Comes on - DTC stored HV-209 Phase V current sub sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 Drive Motor "A" Phase V Current Open in phase V current sub sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A60-290 Drive Motor "A" Phase V Current Phase V current main sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A60-292 Drive Motor "A" Phase V Current Open in phase V current main sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A60-294 Drive Motor "A" Phase V Current Phase V current main and sub sensors of motor inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 HV P0A60-501 Drive Motor "A" Phase V Current Phase V current main and sub sensors of motor inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-296 Drive Motor "A" Phase W Current Phase W current sub sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-297 Drive Motor "A" Phase W Current Open in phase W current sub sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-298 Drive Motor "A" Phase W Current Phase W current main sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 HV–66 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A63-300 Drive Motor "A" Phase W Current Open in phase W current main sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-302 Drive Motor "A" Phase W Current Phase W current main and sub sensors of motor inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-502 Drive Motor "A" Phase W Current Phase W current main and sub sensors of motor inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A72-326 Generator Phase V Current Phase V current sub sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-327 Generator Phase V Current Open in phase V current sub sensor circuit of generator inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-328 Generator Phase V Current Phase V current main sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-330 Generator Phase V Current Open in phase V current main sensor circuit of generator inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-333 Generator Phase V Current Phase V current main and sub sensors of generator inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-515 Generator Phase V Current Phase V current main and sub sensors of generator inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A75-334 Generator Phase W Current Phase W current sub sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly P0A75-335 Generator Phase W Current Open in phase W current sub sensor circuit of generator inverter current sensor P0A75-336 Generator Phase W Current P0A75-338 HV–67 MIL Memory See page Comes on Comes on DTC stored HV-215 - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 Phase W current main sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 Generator Phase W Current Open in phase W current main sensor circuit of generator inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A75-341 Generator Phase W Current Phase W current main and sub sensors of generator inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A75-516 Generator Phase W Current Phase W current main and sub sensors of generator inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A78-266 Drive Motor "A" Inverter Performance Open or GND short in inverter voltage (VH) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-220 P0A78-267 Drive Motor "A" Inverter Performance +B short in inverter voltage (VH) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-220 P0A78-272 Drive Motor "A" Inverter Performance Abnormality in motor PWM circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-228 HV HV–68 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A78-278 Drive Motor "A" Inverter Performance +B short in motor inverter over-voltage (OVH) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-231 P0A78-279 Drive Motor "A" Inverter Performance Motor inverter over-voltage (OVH) signal detection (overvoltage by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-234 P0A78-280 Drive Motor "A" Inverter Performance Open or GND short in motor inverter overvoltage (OVH) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-231 P0A78-282 Drive Motor "A" Inverter Performance Motor inverter over voltage (OVH) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-243 P0A78-283 Drive Motor "A" Inverter Performance +B short in motor inverter fail (MFIV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-247 P0A78-284 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (inverter overheating) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - HV transaxle assembly - Hybrid vehicle motor - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-250 P0A78-285 Drive Motor "A" Inverter Performance Open or GND short in motor inverter fail (MFIV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-247 P0A78-286 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-258 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A78-287 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (over current by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - HV control ECU - Inverter with converter assembly P0A78-304 Drive Motor "A" Inverter Performance Open or +B short in motor gate shutdown (MSDN) signal circuit P0A78-305 Drive Motor "A" Inverter Performance P0A78-306 HV–69 MIL Memory See page Comes on Comes on DTC stored HV-261 - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-268 GND short in motor gate shutdown (MSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-268 Drive Motor "A" Inverter Performance Failure in monitoring MG2 torque performance - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-271 P0A78-308 Drive Motor "A" Inverter Performance Collision signal input from center airbag sensor or No. 1 circuit breaker sensor - Supplemental restraint system - No. 1 circuit breaker sensor Comes on Comes on DTC stored HV-274 P0A78-503 Drive Motor "A" Inverter Performance Motor inverter over-voltage (OVH) signal detection (overvoltage by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-234 Drive Motor "A" Inverter Performance Motor inverter over-voltage (OVH) signal detection (overvoltage by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on P0A78-504 HV Comes on DTC stored HV-234 HV–70 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A78-505 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (over current by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-261 P0A78-506 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (over current by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-261 P0A78-507 Drive Motor "A" Inverter Performance Open in motor gate shutdown (MSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-268 P0A78-508 Drive Motor "A" Inverter Performance Motor gate shutdown (MSDN) signal malfunction - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-275 P0A78-510 Drive Motor "A" Inverter Performance Motor inverter gate malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-278 P0A78-523 Drive Motor "A" Inverter Performance Inverter voltage (VH) sensor offset malfunction - System main relay - Inverter with converter assembly Comes on Comes on DTC stored HV-280 P0A78-586 Drive Motor "A" Inverter Performance Inverter voltage (VH) sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-282 P0A7A-309 Generator Inverter Performance Abnormality in generator PWM circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-285 P0A7A-321 Generator Inverter Performance +B short in generator inverter fail (GFIV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-288 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A7A-322 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (inverter overheating) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly P0A7A-323 Generator Inverter Performance Open or GND short in generator inverter fail (GFIV) signal circuit P0A7A-324 Generator Inverter Performance P0A7A-325 Generator Inverter Performance HV–71 MIL Memory See page Comes on Comes on DTC stored HV-291 - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-288 Generator inverter fail (GFIV) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-299 Generator inverter fail (GFIV) signal detection (over current by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-302 HV P0A7A-342 Generator Inverter Performance Open or +B short in generator gate shutdown (GSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-309 P0A7A-343 Generator Inverter Performance GND short in generator gate shutdown (GSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-309 P0A7A-344 Generator Inverter Performance Failure in monitoring MG1 torque performance - Hybrid vehicle generator - Inverter with converter assembly Comes on Comes on DTC stored HV-312 HV–72 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A7A-517 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (over current by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-302 P0A7A-518 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (over current by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-302 P0A7A-519 Generator Inverter Performance Open in generator gate shutdown (GSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-309 P0A7A-520 Generator Inverter Performance Generator gate shutdown (GSDN) signal malfunction - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-315 P0A7A-522 Generator Inverter Performance Generator inverter gate malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-318 P0A90-239 Drive Motor "A" Performance HV transaxle input malfunction (shaft damaged) - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-321 P0A90-240 Drive Motor "A" Performance Generator locked - Hybrid vehicle generator Comes on Comes on DTC stored HV-328 P0A90-241 Drive Motor "A" Performance HV transaxle input malfunction (torque limiter slipping) - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-321 P0A90-242 Drive Motor "A" Performance Planetary gear locked - HV transaxle assembly Comes on Comes on DTC stored HV-329 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A90-251 Drive Motor "A" Performance MG2 magnetic force deterioration or same phase short circuit - Hybrid vehicle motor P0A90-509 Drive Motor "A" Performance MG2 system malfunction P0A90-602 Drive Motor "A" Performance P0A90-604 HV–73 MIL Memory See page Comes on Comes on DTC stored HV-330 - Hybrid vehicle motor - Inverter with converter assembly Comes on Comes on DTC stored HV-332 HV transaxle output malfunction - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-321 Drive Motor "A" Performance MG2 power balance malfunction (small power balance) - Battery current sensor - Hybrid vehicle motor Comes on Comes on DTC stored HV-335 P0A90-605 Drive Motor "A" Performance MG2 power balance malfunction (large power balance) - Battery current sensor - Hybrid vehicle motor Comes on Comes on DTC stored HV-335 P0A92-261 Hybrid Generator Performance MG1 magnetic force deterioration or same phase short circuit - Hybrid vehicle generator Comes on Comes on DTC stored HV-338 P0A92-521 Hybrid Generator Performance MG1 system malfunction - Hybrid vehicle generator - Inverter with converter assembly Comes on Comes on DTC stored HV-340 P0A92-606 Hybrid Generator Performance MG1 power balance malfunction (small power balance) - Battery current sensor - Hybrid vehicle generator Comes on Comes on DTC stored HV-343 P0A92-607 Hybrid Generator Performance MG1 power balance malfunction (large power balance) - Battery current sensor - Hybrid vehicle generator Comes on Comes on DTC stored HV-343 HV HV–74 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A93-346 Inverter Cooling System Performance Inverter cooling system malfunction (water pump system malfunction) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on Comes on DTC stored HV-346 P0A93-347 Inverter Cooling System Performance Inverter cooling system malfunction (electric cooling fan system malfunction) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on Comes on DTC stored HV-346 P0A94-442 DC / DC Converter Performance Abnormal voltage execution value - Inverter with converter assembly Comes on Comes on DTC stored HV-350 P0A94-545 DC / DC Converter Performance Open or GND short in boost converter overvoltage (OVL) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-352 P0A94-546 DC / DC Converter Performance +B short in boost converter over-voltage (OVL) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-352 P0A94-547 DC / DC Converter Performance Boost converter over voltage (OVL) signal detection (over voltage by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-355 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A94-548 DC / DC Converter Performance Boost converter over voltage (OVL) signal detection (over voltage by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly P0A94-549 DC / DC Converter Performance Boost converter over voltage (OVL) signal detection (over voltage by HV transaxle assembly malfunction) P0A94-550 DC / DC Converter Performance P0A94-551 HV–75 MIL Memory See page Comes on Comes on DTC stored HV-355 - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-355 Boost converter over-voltage (OVL) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-363 DC / DC Converter Performance Open or GND short in boost converter fail (FCV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-366 P0A94-552 DC / DC Converter Performance +B short in boost converter fail (FCV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-366 P0A94-553 DC / DC Converter Performance Boost converter fail (FCV) signal detection (boost converter overheating) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-369 HV HV–76 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A94-554 DC / DC Converter Performance Boost converter fail (FCV) signal detection (over current by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-378 P0A94-555 DC / DC Converter Performance Boost converter fail (FCV) signal detection (over current by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-378 P0A94-556 DC / DC Converter Performance Boost converter fail (FCV) signal detection (over current by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-378 P0A94-557 DC / DC Converter Performance Boost converter fail (FCV) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-386 P0A94-558 DC / DC Converter Performance GND short in boost converter gate shutdown (CSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-389 P0A94-559 DC / DC Converter Performance Open or +B short in boost converter gate shutdown (CSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-389 P0A94-560 DC / DC Converter Performance Open in boost converter gate shutdown (CSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-389 P0A94-561 DC / DC Converter Performance Abnormal boost converter gate shutdown (CSDN) signal - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-392 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0A94-583 DC / DC Converter Performance Open or GND short in boost converter temperature sensor circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU P0A94-584 DC / DC Converter Performance +B short in boost converter temperature sensor circuit P0A94-585 DC / DC Converter Performance P0A94-587 HV–77 MIL Memory See page Comes on Comes on DTC stored HV-395 - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-395 Boost converter voltage (VL) sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-401 DC / DC Converter Performance Difference between voltages from HV battery voltage (VB) sensor and boost converter voltage (VL) sensor is large - Wire harness or connector - Inverter with converter assembly - Service plug grip - High voltage fuse - Battery ECU Comes on Comes on DTC stored HV-404 P0A94-588 DC / DC Converter Performance Abnormality in boost converter PWM circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-409 P0A94-589 DC / DC Converter Performance Open or GND short in boost converter voltage (VL) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-412 P0A94-590 DC / DC Converter Performance +B short in boost converter voltage (VL) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-412 P0AA1-231 Hybrid Battery Positive Contactor Circuit Stuck Closed System main relay terminal of HV battery positive side stuck closed - No. 1 system main relay - No. 2 system main relay Comes on - DTC stored HV-418 P0AA1-233 Hybrid Battery Positive Contactor Circuit Stuck Closed System main relay terminals of HV battery positive and negative sides stuck closed - No. 1 system main relay - No. 2 system main relay - No. 3 system main relay Comes on - DTC stored HV-419 P0AA4-232 Hybrid Battery Negative Contactor Circuit Stuck Closed System main relay terminal of HV battery negative side stuck closed - No. 3 system main relay Comes on Comes on DTC stored HV-420 HV HV–78 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0AA6-526 Hybrid Battery Voltage System Isolation Fault Insulation resistance of high voltage circuit and body is low - Frame wire - System main relay - System main resistor - HV battery assembly - Electric inverter compressor - Battery ECU - HV transaxle assembly - Inverter with converter assembly - Main battery cable - No. 2 main battery cable - Battery plug - No. 2 frame wire - Junction block Comes on P0AA6-611 Hybrid Battery Voltage System Isolation Fault Insulation resistance of A/ C compressor motor or A/C inverter is low - Electric inverter compressor - Inverter with converter assembly P0AA6-612 Hybrid Battery Voltage System Isolation Fault Insulation resistance of HV battery, battery ECU, system main relay, or system main resistor is low P0AA6-613 Hybrid Battery Voltage System Isolation Fault Insulation resistance of HV transaxle or motor and generator inverters is low HV MIL Memory See page - DTC stored HV-421 Comes on - DTC stored HV-421 - HV battery assembly - Battery ECU - System main relay - System main resistor - Main battery cable - No. 2 main battery cable - Battery plug - No. 2 frame wire - Junction block Comes on - DTC stored HV-421 - HV transaxle assembly - Inverter with converter assembly Comes on - DTC stored HV-421 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0AA6-614 Hybrid Battery Voltage System Isolation Fault Insulation resistance of motor and generator inverters, A/C inverter, system main relay, system main resistor, or frame wire is low - Frame wire - System main relay - System main resistor - HV battery assembly - Inverter with converter assembly - Main battery cable - No. 2 main battery cable - Battery plug - No. 2 frame wire - Junction block Comes on P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low GND short in No. 2 system main relay circuit - Wire harness or connector - No. 2 system main relay - HV control ECU P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High Open or +B short in No. 2 system main relay circuit P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low P0AE0-228 MIL HV–79 Memory See page - DTC stored HV-421 Comes on - DTC stored HV-439 - Wire harness or connector - No. 2 system main relay - HV control ECU Comes on - DTC stored HV-439 GND short in No. 3 system main relay circuit - Wire harness or connector - No. 3 system main relay - HV control ECU Comes on - DTC stored HV-441 Hybrid Battery Negative Contactor Control Circuit High Open or +B short in No. 3 system main relay circuit - Wire harness or connector - No. 3 system main relay - HV control ECU Comes on Comes on DTC stored HV-441 P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low GND short in No. 1 system main relay circuit - Wire harness or connector - No. 1 system main relay - HV control ECU Comes on - DTC stored HV-444 P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High Open or +B short in No. 1 system main relay circuit - Wire harness or connector - No. 1 system main relay - HV control ECU Comes on - DTC stored HV-444 HV HV–80 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P0AEE-276 Motor Inverter Temperature Sensor "A" Circuit Range / Performance Sudden change in motor inverter temperature sensor output - Wire harness or connector - Inverter cooling system - Water pump w/ motor and bracket assembly - Cooling fan motor - No. 2 Cooling fan motor - w/ Converter inverter assembly Comes on P0AEE-277 Motor Inverter Temperature Sensor "A" Circuit Range / Performance Motor inverter temperature sensor output deviation - Wire harness or connector - Inverter cooling system - Water pump w/ motor and bracket assembly - Cooling fan motor - No. 2 Cooling fan motor - w/ Converter inverter assembly P0AEF-275 Drive Motor Inverter Temperature Sensor "A" Circuit Low Open or GND short in motor inverter temperature sensor circuit Memory See page - DTC stored HV-448 Comes on - DTC stored HV-448 - Wire harness or connector - w/ Converter inverter assembly - HV control ECU Comes on - DTC stored HV-453 P0AF0-274 Drive Motor Inverter Temperature Sensor "A" Circuit High +B short in monitor inverter temperature sensor circuit - Wire harness or connector - w/ Converter inverter assembly - HV control ECU Comes on - DTC stored HV-453 P2120-111 Throttle / Pedal Position Sensor / Switch "D" Circuit Accelerator pedal position main sensor value does not change while its sub sensor value changes - Accelerator pedal rod Comes on - DTC stored HV-458 P2121-106 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance Internal error of accelerator pedal position main sensor - Accelerator pedal rod Comes on - DTC stored HV-458 P2121-114 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance Accelerator pedal not smoothly returning to its original position - Accelerator pedal rod Comes on - DTC stored HV-458 HV MIL P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P2122-104 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input Open or GND short in accelerator pedal position main sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU Comes on P2123-105 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input +B short in accelerator pedal position main sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU P2125-112 Throttle / Pedal Position Sensor / Switch "E" Circuit Accelerator pedal position sub sensor value does not change while its main sensor value changes P2126-109 Throttle / Pedal Position Sensor / Switch "E" Circuit Range / Performance P2127-107 MIL HV–81 Memory See page - DTC stored HV-460 Comes on - DTC stored HV-460 - Accelerator pedal rod Comes on - DTC stored HV-458 Internal error of accelerator pedal position sub sensor - Accelerator pedal rod Comes on - DTC stored HV-458 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input Open or GND short in accelerator pedal position sub sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU Comes on - DTC stored HV-460 P2128-108 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input +B short in accelerator pedal position sub sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU Comes on - DTC stored HV-460 P2138-110 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation Difference between main sensor value and sub sensor value is large - Accelerator pedal rod Comes on - DTC stored HV-458 P3000-123 HV Battery Malfunction Abnormal signal input from battery ECU (HV battery system malfunction) - HV battery system - Battery ECU Comes on Comes on DTC stored HV-466 P3000-125 HV Battery Malfunction Abnormal signal input from battery ECU (High voltage fuse blown out) - HV battery system - Battery ECU Comes on Comes on DTC stored HV-466 P3000-388 HV Battery Malfunction Abnormal signal input from battery ECU (discharge inhibition control malfunction) - HV control system - Fuel shortage - HV battery assembly Comes on - DTC stored HV-467 HV HV–82 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P3000-389 HV Battery Malfunction Abnormal signal input from battery ECU (drop of high voltage) - HV control system - HV battery assembly Comes on P3000-603 HV Battery Malfunction Abnormal signal input from battery ECU (HV battery cooling system malfunction) - HV battery system - Battery ECU P3004-131 Power Cable Malfunction High voltage fuse has blown out, service plug grip is disconnected or limiter resistance is cut off P3004-132 Power Cable Malfunction Memory See page - DTC stored HV-469 Comes on Comes on DTC stored HV-466 - HV battery system - System main resistor - No. 1 system main relay - No. 3 system main relay - Main battery cable - No. 2 main battery cable - Frame wire - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-470 Inverter voltage sensor malfunction, or limiter resistance increases - HV battery system - System main resistor - No. 1 system main relay - No. 3 system main relay - Main battery cable - No. 2 main battery cable - Frame wire - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-477 P3004-133 Power Cable Malfunction Abnormal signal input from battery ECU - HV battery system - Battery ECU - - DTC stored HV-483 P3102-524 Transmission Control ECU Malfunction BEAN communication problem of transmission control ECU assembly - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 HV MIL P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P3102-525 Transmission Control ECU Malfunction Transmission control ECU IG OFF command malfunction - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on P3102-581 Transmission Control ECU Malfunction Transmission control ECU malfunction - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU P3102-582 Transmission Control ECU Malfunction P position (PPOS) signal is logically inconsistent P3102-597 Transmission Control ECU Malfunction P3102-598 MIL HV–83 Memory See page - DTC stored HV-484 Comes on - DTC stored HV-484 - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 GND short in P position (PPOS) signal circuit - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 Transmission Control ECU Malfunction +B short in P position (PPOS) signal circuit - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3102-599 Transmission Control ECU Malfunction P position (PPOS) signal malfunction (output pulse is abnormal) - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3107-213 Airbag ECU Communication Circuit Malfunction GND short in communication circuit between center airbag sensor and HV control ECU - Wire harness or connector - Center airbag sensor Comes on - DTC stored HV-489 HV HV–84 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P3107-214 Airbag ECU Communication Circuit Malfunction Open or +B short in communication circuit between center airbag sensor and HV control ECU - Wire harness or connector - Center airbag sensor Comes on P3107-215 Airbag ECU Communication Circuit Malfunction Abnormal communication signals between center airbag sensor and HV control ECU - Wire harness or connector - Center airbag sensor P3108-535 A/C Amplifier Communication Circuit Malfunction Serial communication malfunction P3108-536 A/C Amplifier Communication Circuit Malfunction P3108-537 Memory See page - DTC stored HV-489 Comes on - DTC stored HV-489 - Wire harness or connector - Inverter with converter assembly - - DTC stored HV-491 A/C inverter malfunction - Wire harness or connector - Inverter with converter assembly - - DTC stored HV-491 A/C Amplifier Communication Circuit Malfunction Air conditioning amplifier malfunction - Air conditioning amplifier - - DTC stored HV-494 P3108-538 A/C Amplifier Communication Circuit Malfunction Open in STB signal circuit - Wire harness or connector - Inverter with converter assembly - - DTC stored HV-491 P3108-594 A/C Amplifier Communication Circuit Malfunction CAN communication malfunction - CAN communication system - - DTC stored HV-495 P3110-223 IGCT Relay Malfunction IGCT relay is always closed - Wire harness or connector - Integration relay (IGCT relay) Comes on - DTC stored HV-496 P3110-527 HV Main Relay Malfunction IG2 logical inconsistency - Wire harness or connector - Integration relay (IG2 relay) Comes on - DTC stored HV-496 P3137-348 Collision Sensor Low Input GND short in No. 1 circuit breaker sensor circuit - Wire harness or connector - No. 1 circuit breaker sensor Comes on - DTC stored HV-498 P3138-349 Collision Sensor High Input Open or +B short in No. 1 circuit breaker sensor circuit - Wire harness or connector - No. 1 circuit breaker sensor Comes on - DTC stored HV-498 HV MIL P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P3221-314 Generator Inverter Temperature Sensor Circuit Range / Performance Sudden change in generator inverter temperature sensor output - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on P3221-315 Generator Inverter Temperature Sensor Circuit Range / Performance Generator inverter temperature sensor output deviation - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly P3222-313 Generator Inverter Temperature Sensor Circuit High / Low Open or GND short in generator inverter temperature sensor circuit P3223-312 Generator Inverter Temperature Sensor Circuit High P3226-562 DC/DC Boost Converter Temperature Sensor MIL HV–85 Memory See page - DTC stored HV-500 Comes on - DTC stored HV-500 - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-505 +B short in generator inverter temperature sensor circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-505 Sudden change in boost converter temperature sensor output - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on - DTC stored HV-510 HV HV–86 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light P3226-563 DC/DC Boost Converter Temperature Sensor Boost converter temperature sensor output deviation - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on U0100-211 Lost Communication with ECM / PCM "A" CAN communication problem between ECM and HV control ECU (no signal input) - CAN communication system U0100-212 Lost Communication with ECM / PCM "A" CAN communication problem between ECM and HV control ECU (transmission error) U0100-530 Lost Communication with ECM / PCM "A" Memory See page - DTC stored HV-510 Comes on Comes on DTC stored HV-515 - CAN communication system Comes on Comes on DTC stored HV-515 CAN communication problem between ECM and HV control ECU (CAN communication system malfunction) - CAN communication system Comes on Comes on DTC stored HV-515 U0111-208 Lost Communication with Battery Energy Control Module "A" CAN communication problem between battery ECU and HV control ECU (no signal input) - CAN communication system Comes on Comes on DTC stored HV-515 U0111-531 Lost Communication with Battery Energy Control Module "A" CAN communication problem between battery ECU and HV control ECU (CAN communication system malfunction) - CAN communication system Comes on Comes on DTC stored HV-515 U0129-220 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (no signal input) - CAN communication system Comes on - DTC stored HV-515 HV MIL P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light U0129-222 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (CAN communication system malfunction) - CAN communication system Comes on U0129-528 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (transmission error) - CAN communication system U0129-529 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (regenerative torque malfunction) U0131-433 Lost Communication with Power Steering Control Module U0131-434 U0146-435 MIL HV–87 Memory See page - DTC stored HV-515 Comes on - DTC stored HV-515 - CAN communication system Comes on - DTC stored HV-515 CAN communication problem between power steering ECU and HV control ECU (no signal input) - CAN communication system - - DTC stored HV-515 Lost Communication with Power Steering Control Module CAN communication problem between power steering ECU and HV control ECU (CAN communication system malfunction) - CAN communication system - - DTC stored HV-515 Lost Communication with Gateway "A" CAN communication problem between gateway ECU and HV control ECU (no signal input) - CAN communication system Comes on - DTC stored HV-515 HV HV–88 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INFORMATION / FREEZE FRAME DATA 1. FREEZE FRAME DATA HINT: The freeze frame data records the driving condition when the DTC was set. It is used for estimating or simulating the condition of the vehicle when the malfunction occurred. To check the details of the hybrid vehicle control system, check the detailed information for the DTC (Information). (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select a DTC in order to display its freeze frame data. (f) Check the freeze frame data of the DTC that has been detected. (g) Check information of the DTC (see below). Freeze frame data: HV Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs FREEZE DTC DTC corresponding to displayed freeze frame data - COOLANT TEMP Engine coolant temperature / Min.: -40°C, Max.: 140°C Cold or warm engine VEHICLE SPD Vehicle speed / Min.: 0 km/h, Max.: 255 km/h Stopped, or driving (low, medium, and high speeds) ENG RUN TIME Elapsed time after starting engine / Min.: 0 s, Max.: 65,535 s Elapsed time from engine start +B Auxiliary battery voltage / Min.: 0 V, Max.: 65.535 V Condition of auxiliary battery ACCEL POS #1 No. 1 accelerator pedal position sensor / Min.: 0%, Max.: 100% Idling, accelerating, or decelerating ACCEL POS #2 No. 2 accelerator pedal position sensor / Min.: 0%, Max.: 100% Idling, accelerating or decelerating (For comparison with above to detect failure of No. 1 accelerator pedal position sensor) AMBIENT TEMP Ambient air temperature / Min.: -40°C, Max.: 215°C Ambient air temperature INTAKE AIR TEMP Intake air temperature / Min.: -40°C, Max.: 140°C Ambient air temperature DTC CLEAR WARM The number of times engine is warmed up after clearing DTCs / Min.: 0, Max.: 255 Frequency of the malfunction recurrence after clearing DTCs DTC CLEAR RUN Drive distance after clearing DTCs / Min.: 0 km, Max.: 65,535 km Frequency of the malfunction recurrence after clearing DTCs DTC CLEAR MIN Elapsed time after clearing DTCs / Min.: 0 min, Max.: 65,535 min Frequency of the malfunction recurrence after clearing DTCs ECU TYPE Type of ECU - INFORMATION 1 to 5 Information code - 2. INFORMATION HINT: Similar to freeze frame data, information records operating condition of the HV system and components at the time of detection of a DTC. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–89 (a) Select one which has an INF code from among INFORMATION 1 to 5. (b) Check the information of the DTC. Information: Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs INFORMATION N Information code Indication of system with malfunction MG1 REV MG1 revolution / Min.: -16,384 rpm, Max.: 16,256 rpm MG1 speed • Forward rotation appears as "+" • Backward rotation appears as "-" MG2 REV MG2 revolution / Min.: -16,384 rpm, Max.: 16,256 rpm MG2 speed (proportionate to vehicle speed) • Forward rotation appears as "+" • Backward rotation appears as "-" Moving direction of vehicle • Forward direction appears as "+" • Backward direction appears as "-" MG1 TORQ MG1 torque / Min.: -512 Nm, Max.: 508 Nm When MG1 rotation in + direction: • Torque appears as "+" while MG1 discharges • Torque appears as "-" while MG1 charges When MG1 rotation in - direction: • Torque appears as "-" while MG1 discharges • Torque appears as "+" while MG1 charges MG2 TORQ MG2 torque / Min.: -512 Nm, Max.: 508 Nm When MG2 rotation in + direction: • Torque appears as "+" while MG2 discharges • Torque appears as "-" while MG2 charges When MG2 rotation in - direction: • Torque appears as "-" while MG2 discharges • Torque appears as "+" while MG2 charges INVERT TEMP-MG1 MG1 inverter temperature / Min.: -50°C, Max.: 205°C MG1 inverter temperature INVERT TEMP-MG2 MG2 inverter temperature / Min.: -50°C, Max.: 205°C MG2 inverter temperature MG2 TEMP (No2) Transaxle fluid temperature / Min.: -50°C, Max.: 205°C Transaxle fluid temperature MG2 TEMP (No1) MG2 temperature / Min.: -50°C, Max.: 205°C MG2 temperature POWER RQST Request engine power / Min.: 0 W, Max.: 255 kW Engine power output requested to ECM ENGINE SPD Engine speed / Min.: 0 rpm, Max.: 16,320 rpm Engine speed MCYL CTRL POWER Master cylinder control torque / Min.: -512 Nm, Max.: 508 Nm Brake force requested by driver SOC Battery state of charge / Min.: 0%, Max.: 100% State of charge of HV battery WOUT CTRL POWER Power value discharge control / Min.: 0 W, Max.: 81,600 W Discharge amount of HV battery WIN CTRL POWER Power value charge control / Min.: -40,800 W, Max.: 0 W Charge amount of HV battery DRIVE CONDITION Drive condition ID • Engine stopped: 0 • Engine about to be stopped: 1 • Engine about to be started: 2 • Engine operated or operating: 3 • Generating or loading movement: 4 • Revving up with P position: 6 Engine operating condition PWR RESOURCE VB HV battery voltage / Min.: 0 V, Max.: 510 V HV battery voltage HV HV–90 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs PWR RESOURCE IB HV battery current / Min.: -256 A, Max.: 254 A Charging / discharging state of HV battery • Discharging amperage indicated by a positive value • Charging amperage indicated by a negative value SHIFT POSITION Shift position (P, R, N, D or B position) P: 0, R: 1, N: 2, D: 3, B: 4 Shift position ACCEL SENSOR M Accelerator pedal position sensor main / Min.: 0%, Max.: 100% Idling, accelerating, or decelerating AUX. BATT V Auxiliary battery voltage / Min.: 0 V, Max.: 20 V State of auxiliary battery CONVERTER TEMP Boost converter temperature / Min.: -50°C, Max.: 205°C Boost converter temperature VL High voltage before it is boosted / Min.: 0 V, Max.: 510 V High voltage level before it is boosted VH High voltage after it is boosted / Min.: 0 V, Max.: 765 V High voltage level after it is boosted IG ON TIME The time after power switch ON (IG) / Min.: 0 min, Max.: 255 min Time elapsed with power switch ON (IG) VEHICLE SPD-MAX Maximum vehicle speed / Min.: -256 km/h, Max.: 254 km/h Maximum vehicle speed A/C CONSMPT PWR A/C consumption power / Min.: 0 kW, Max.: 5 kW A/C load ENG STOP RQST Engine stop request / NO or YES Presence of engine stop request IDLING REQUEST Engine idling request / NO or YES Presence of idle stop request ENGINE FUEL CUT Engine fuel cut request / NO or YES Presence of fuel cut request HV BATT CH RQST HV battery charging request / NO or YES Presence of HV battery charging request ENG WARM UP RQT Engine warming up request / NO or YES Presence of engine warm-up request STOP SW COND Stop light switch ON condition / NO or YES Brake pedal depressed or released CRUISE CONTROL Cruise control active condition / NO or YES Operation under cruise control ON or OFF EXCLUSIVE INFO 1 to 7 Exclusive information (in form of numerical data) Exclusive Information linked to Information OCCURRENCE ORDER Occurrence sequence of information Occurrence sequence of information INVT TMP-MG1 IG MG1 inverter temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C MG1 inverter temperature soon after power switch ON (IG) INVT TMP-MG2 IG MG2 inverter temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C MG2 inverter temperature soon after power switch ON (IG) MG2 TEMP IG MG2 temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C MG2 temperature soon after power switch ON (IG) CONVRTR TEMP IG Boost converter temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C Boost converter temperature soon after power switch ON (IG) SOC IG Battery state of charge after power switch ON (IG) / Min.: 0%, Max.: 100% Battery state of charge soon after power switch ON (IG) INVT TMP-MG1MAX MG1 inverter maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of MG1 inverter P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs INVT TMP-MG2MAX MG2 inverter maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of MG2 inverter MG2 TEMP MAX MG2 maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of MG2 CONVRTR TMP MAX Boost converter maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of boost converter SOC MAX Maximum status of charge / Min.: 0%, Max.: 100% Over-charging of HV battery SOC MIN Minimum status of charge / Min.: 0%, Max.: 100% Over-discharging of HV battery HV–91 HV HV–92 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OPERATION HISTORY DATA 1. (a) (b) (c) (d) Intelligent Tester CAN VIM DLC3 OPERATION HISTORY DATA HINT: The operation history data records the special operations performed by the driver and the number of abnormal conditions that have been input into the HV control ECU. A082795E01 Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DATA LIST. (e) Select the menu to view the number of special operations or controls that have been effected. HINT: • LATEST OPER: Among the past occurrences, the number of special operations or controls that have been effected during the most recent 1 trip detection. • LATEST TRIP: The number of trips after the occurrence of LATEST OPER. • BEF LATEST OPER: The number of occurrences 1 previously from the LATEST OPER. • BEF LATEST TRIP: The number of trips after the occurrence of BEF LATEST OPER. Operation history data: Intelligent Tester Display HV Count Condition SHIFT BEF READY Shift lever moved with READY light blinking N RANGE CTRL 2 N position control effected due to frequent shifting operation STEP ACCEL IN N Accelerator pedal depressed in N position AUX. BATT LOW Auxiliary battery voltage below 9.5 V HV INTERMITTENT Instantaneous open at IGSW terminal of HV control ECU MG2 (NO1) TEMP HI Motor temperature rose above 174°C (345°F) MG2 (NO2) TEMP HI Transaxle fluid temperature rose above 162°C (324°F) MG2 INV TEMP HI Motor inverter temperature rose above 111°C (232°F) MG1 INV TEMP HI Generator inverter temperature rose above 111°C (232°F) MAIN BATT LOW Battery state of charge dropped below 30% RESIST OVR HEAT Limit resistor forecast temperature rose above 120°C (248°F) COOLANT HEAT Inverter coolant forecast temperature rose above 65°C (149°F) CONVERTER HEAT Boost converter temperature rose above 111°C (232°F) SHIFT P IN RUN Shifted to P while driving BKWRD DIR SHIFT Shifted to R while moving forward or to D or B while moving in reverse PREVENT STAYING Engine speed stays in resonance frequency band HV–93 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Crankshaft Position Sensor "A" Circuit Range / Performance DTC P0336-137 DTC P0340-532 Camshaft Position Sensor "A" Circuit DESCRIPTION If there is any malfunction in the communication values or pulse inputs, the HV control ECU detects it by comparing the following three speeds: the engine speed transmitted by the ECM via CAN (Controller Area Network) communication, the engine speed obtained through pulse inputs, and the engine speed calculated from the MG1 and MG2 speeds. DTC No. INF Code DTC Detection Condition Trouble Area P0336 137 Engine speed sensor deviation malfunction (CAN communication) • • • • Wire harness or connector Crankshaft position sensor Camshaft position sensor HV control ECU P0340 532 Engine speed sensor deviation malfunction (pulse signal) • • • • Wire harness or connector Crankshaft position sensor Camshaft position sensor HV control ECU WIRING DIAGRAM HV Control ECU ECM 1 NEO E7 LG 12 H16 NEO HV 2 GO E7 Y 13 H16 GO A014121E01 INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output. YES GO TO RELEVANT DTC CHART HV–94 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 GO NEO HV Control ECU Connector A065745E34 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 GO NEO Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω GO (H16-13) - GO (E7-2) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E18 HV Tester Connection Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) - Body ground 10 kΩ or higher GO (H16-13) or GO (E7-2) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT CRANKSHAFT POSITION SENSOR (a) Inspect crankshaft position sensor (see page ES-443). NG REPLACE CRANKSHAFT POSITION SENSOR OK 4 INSPECT CAMSHAFT POSITION SENSOR (a) Inspect camshaft position sensor (see page ES-440). NG REPLACE CAMSHAFT POSITION SENSOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–95 OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–96 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0338-600 Crankshaft Position Sensor "A" Circuit High Input DTC P0343-601 Camshaft Position Sensor "A" Circuit High Input DESCRIPTION Refer to DTC P0336 (INF 137) (see page HV-91). DTC No. INF Code DTC Detection Condition Trouble Area P0338 600 NEO signal circuit malfunction • • Wire harness or connector HV control ECU P0343 601 GO signal circuit malfunction • • Wire harness or connector HV control ECU WIRING DIAGRAM Refer to DTC P0336 (INF 137) (see page HV-91). INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output HV YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 GO NEO HV Control ECU Connector A065745E34 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 Tester Connection GO HV–97 NEO Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω GO (H16-13) - GO (E7-2) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E18 Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) - Body ground 10 kΩ or higher GO (H16-13) or GO (E7-2) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK HV HV–98 3 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT OUTPUT WAVEFORM H16 H14 (a) Inspect the ECM using an oscilloscope. (1) While the engine is idling, check the waveform between the terminals of the HV control ECU connector. Standard voltage Tester Connection GO NEO GND1 NEO Signal Waveform NEO (H16-12) - GND1 (H14-1) Correct waveform appears as shown GO (H16-13) - GND1 (H14-1) Correct waveform appears as shown NG HV Control ECU Connector 1 V/DIV. GND 2 msec./DIV. GO Signal Waveform HV Specified Condition 2 V/DIV. GND 20 msec./DIV. A133405E02 OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE ECM P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–99 P0560-117 System Voltage DESCRIPTION Since the ECU back-up power source is used for DTCs and freeze frame data memory, the back-up power source (BATT) continues to be supplied to the HV control ECU even if the power switch is turned OFF. DTC No. INF Code DTC Detection Condition Trouble Area P0560 117 HV control ECU back-up power source circuit malfunction • • Wire harness or connector HEV fuse MONITOR DESCRIPTION If 3 or more seconds have elapsed with a voltage of less than 2.5 V at the BATT terminal at the HV control ECU, the HV control ECU will determine that a malfunction has occurred in the back-up power supply system, and set a DTC. It will illuminate the MIL the next time the engine is started. MONITOR STRATEGY Related DTCs P0560 (INF 117): Battery signal malfunction Required sensor / components Main: Back-up power source circuit Sub: Hybrid vehicle control ECU Frequency of operation Continuous Duration 3 seconds MIL operation Immediate after next power switch ON (IG) Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property A/D converter Normal Auxiliary battery voltage More than 9.5 V TYPICAL MALFUNCTION THRESHOLDS Condition (a) or (b) is met - (a) Input voltage for BATT signal Less than 2.5 V (b) Abnormal flag for SRAM ON COMPONENT OPERATING RANGE Auxiliary battery voltage Between 9 and 14 V HV HV–100 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU B 1 BE1 1 B 120 A MAIN F15 Fusible Link Block Assembly 1 3M 1 Auxiliary Battery Y W 1 3A 60 A P/I 2 1 3J 1 3K 1 20 A HEV J6 J/C 6 H15 BATT A A Y 2 Engine Room Relay Block A092092E01 INSPECTION PROCEDURE 1 INSPECT FUSE (HEV 20 A) (a) Remove the HEV fuse from the engine room relay block. (b) Measure the resistance of the HEV fuse. Standard resistance: Below 1 Ω (c) Reinstall the HEV fuse. Engine Room Relay Block: NG HV Go to step 3 HEV Fuse A092025E01 OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - AUXILIARY BATTERY) (a) Disconnect the negative auxiliary battery terminal. (b) Disconnect the positive auxiliary battery terminal. Positive Terminal A081781E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–101 (c) Remove the HEV fuse from the engine room relay block. Engine Room Relay Block: HEV Fuse A092026E01 (d) Disconnect the H15 HV control ECU connector. (e) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) H15 Tester Connection Specified Condition BATT (H15-6) - HEV fuse (2) Below 1 Ω BATT HV Control ECU Connector A065744E17 (f) NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition HEV fuse (1) - Positive auxiliary battery terminal Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (g) Reconnect the HV control ECU connector. (h) Reinstall the HEV fuse. (i) Reconnect the positive auxiliary battery terminal. (j) Reconnect the negative auxiliary battery terminal. NG OK CHECK AND REPAIR CONNECTOR CONNECTION REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–102 3 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HEV FUSE) (a) Disconnect the H15 HV control ECU connector. H15 BATT HV Control ECU Connector A065744E17 (b) Remove the HEV fuse from the engine room relay block. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for short) Engine Room Relay Block: HEV Fuse A092026E01 Tester Connection Specified Condition BATT (H15-6) or HEV fuse (2) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the HEV fuse. (e) Reconnect the HV control ECU connector. NG HV OK REPLACE FUSE (HEV 20 A) AFTER REPAIRING OR REPLACING HARNESS OR CONNECTOR, REPLACE FUSE (HEV 20 A) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–103 P0630-804 VIN not Programmed or Mismatch-ECM / PCM DESCRIPTION DTC P0630 is set if the Vehicle Identification Number (VIN) is not stored in the HV control ECU or the input VIN is not accurate. Input the VIN with the intelligent tester (see page HV-22). DTC No. P0630 INF No. 804 DTC Detection Condition • • Trouble Area VIN not stored in HV control ECU Input VIN in HV control ECU not accurate HV control ECU INSPECTION PROCEDURE 1 READ CURRENT DTC NOTICE: If P0630 is set, the VIN must be input to the HV control ECU using the intelligent tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630-804 are set, check them first. NEXT 2 INPUT VIN WITH INTELLIGENT TESTER (a) Input the VIN with intelligent tester (see page HV-22). NOTICE: Be sure to check the auxiliary battery voltage before performing VIN writing because VIN writing cannot be performed if the auxiliary battery voltage is below 10 V. NEXT 3 READ OUTPUT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES. (d) Read output DTC (see page HV-39). OK: DTC P0630-804 is not output. NG OK END REPLACE HYBRID VEHICLE CONTROL ECU HV HV–104 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0705-571 Transmission Range Sensor Circuit DTC P0705-572 Transmission Range Sensor Circuit DTC P0705-573 Transmission Range Sensor Circuit DTC P0705-574 Transmission Range Sensor Circuit DTC P0705-575 Transmission Range Sensor Circuit DTC P0705-576 Transmission Range Sensor Circuit DTC P0705-577 Transmission Range Sensor Circuit DTC P0705-578 Transmission Range Sensor Circuit DTC P0705-595 Transmission Range Sensor Circuit DTC P0705-596 Transmission Range Sensor Circuit DESCRIPTION HINT: • The shift control system is a linkless type that does not use a shift cable. • The shift and select sensors are a non-contact type. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–105 The selector lever is a momentary type, which returns to its home position by spring reaction as the driver's hand is released from the selector lever after shifting. The selector lever contains a shift sensor and a select sensor to detect the selector lever position (R, N, D or B). Because both sensors are controlled electrically by Hall elements, they can accurately detect shift positions in a reliable manner. Both sensors contain two systems of detection circuits, main and sub. Shift Sensor: Selector Lever: Hall IC Select Sensor Yoke Magnet Select Sensor: Shift Sensor Hall IC Magnet Slider A087734E01 HV HV–106 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The shift sensor outputs voltage, which varies between 0 and 5 V in accordance with the vertical movement of the selector lever, to the HV control ECU. The HV control ECU interprets low level voltage input from the shift sensor as the D or B position, middle level voltage as the home or N position, and high level voltage as the R position. Shift Sensor Output Voltage (V) HV Control ECU Shift Sensor Hall IC VCX1 4.0 to 4.8 High 2.5 5V Middle Low 0.2 to 1.0 Magnet VSX1 Operation Range E2X1 VCX2 7.24 0 7.24 5V Shift Sensor Rotational Angle (deg) Home Position VSX2 Magnet Hall IC 5V E2X2 H R HV Shift Sensor Output Voltage M L 0V N D B A125423E01 HV–107 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The select sensor outputs voltage, which varies between 0 and 5 V in accordance with the horizontal movement of the selector lever, to the HV control ECU. The HV control ECU interprets low level voltage input from the select sensor as the home or B position, and high level voltage as the R, N, or D position. The HV control ECU determines the position of the selector lever in accordance with the combination of the signals from the shift sensor and select sensor. Select Sensor HV Control ECU Hall IC VCX3 VSX3 VCX4 VSX3 Slide +B +B Hall IC Magnetic Slider Undetermined Home or B R, N or D Home Position R Output Voltage (V) 4.85 High 3.0 2.0 0.5 Low Operation Range N D HV B H L Signal Amount Home Position A125424E01 DTC No. INF Code DTC Detection Condition Trouble Area P0705 571 Open or GND short in shift main sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 572 +B short in shift main sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 573 Open or GND short in shift sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 574 +B short in shift sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 575 Open or GND short in select main sensor circuit • • • Wire harness or connector Selector lever HV control ECU HV–108 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area P0705 576 +B short in select main sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 577 Open or GND short in select sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 578 +B short in select sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 595 Difference between shift main sensor value and shift sub sensor value is large • • • Wire harness or connector Selector lever HV control ECU P0705 596 Difference between select main sensor value and select sub sensor value is large • • • Wire harness or connector Selector lever HV control ECU HINT: After confirming DTC P0705 (INF 571, 572, 573, or 574), confirm M and S SHIFT SENSOR voltages using the intelligent tester. M and S SHIFT SENSOR HV R Position (Main) Home or N Position (Main) D or B Position (Main) R Position (Sub) Home or N Position (Sub) D or B Position (Sub) Trouble Area 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V Open in VCX1 circuit 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V Open in VCX2 circuit 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V Open or short in VSX1 circuit 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V Open or short in VSX2 circuit 4.8 to 5.0 V 4.8 to 5.0 V 4.8 to 5.0 V 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V Open in E2X1 circuit 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V 4.8 to 5.0 V 4.8 to 5.0 V 4.8 to 5.0 V Open in E2X2 circuit HINT: After confirming DTC P0705 (INF 575, 576, 577, or 578), confirm SM and SS SHIFT SENSOR voltages using the intelligent tester. SM and SS SHIFT SENSOR R, N or D Position (Select Main) Home or B Position (Select Main) R, N or D Position (Select Sub) Home or B Position (Select Sub) Trouble Area 0 to 0.5 V 0 to 0.5 V 3.0 to 4.85 V 0.5 to 2.0 V Open or GND short in VCX3 or VSX3 circuit 3.0 to 4.85 V 0.5 to 2.0 V 0 to 0.5 V 0 to 0.5 V Open or GND short in VCX4 or VSX4 circuit HV–109 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM S5 Shift Sensor HV Control ECU (Shielded) VCX1 3 W 17 VCX1 H14 VSX1 1 B 25 VSX1 H14 E2X1 2 R 15 E2X1 H14 VCX2 6 G 16 VCX2 H14 VSX2 4 L 24 VSX2 H14 5V 14 E2X2 Y H14 No. 1 Center Connector E2X2 5 S4 Select Sensor 5V 14 4E W-B VCX3 3 W VSX3 5 BR 4 W-B 4H A A J25 J/C 21 VCX3 H14 +B 23 VSX3 H14 W-B VCX4 6 P 31 VCX4 H14 VSX4 8 SB 30 VSX4 H14 +B HV IH A092093E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (M AND S SHIFT SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the M and S SHIFT SENSOR voltage values. Result: Shift Position M Shift Sensor S Shift Sensor R position 4.0 to 4.8 V 4.0 to 4.8 V HV–110 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Shift Position M Shift Sensor S Shift Sensor Home or N position 2.0 to 3.0 V 2.0 to 3.0 V D or B position 0.2 to 1.0 V 0.2 to 1.0 V OK Go to step 4 NG 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - SHIFT SENSOR) (a) Disconnect the H14 HV control ECU connector. H14 VCX2 VCX1 HV Control VSX1 ECU Connector VSX2 E2X2 E2X1 A065748E31 Wire Harness Side: S5 VSX1 VCX2 E2X2 VSX2 VCX1 Shift Sensor Connector E2X1 HV (b) Disconnect the S5 shift sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition VCX1 (H14-17) - Body ground Below 1 V VSX1 (H14-25) - Body ground Below 1 V E2X1 (H14-15) - Body ground Below 1 V A092027E01 VCX2 (H14-16) - Body ground Below 1 V VSX2 (H14-24) - Body ground Below 1 V E2X2 (H14-14) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VCX1 (H14-17) - VCX1 (S5-3) Below 1 Ω VSX1 (H14-25) - VSX1 (S5-1) Below 1 Ω E2X1 (H14-15) - E2X1 (S5-2) Below 1 Ω VCX2 (H14-16) - VCX2 (S5-6) Below 1 Ω VSX2 (H14-24) - VSX2 (S5-4) Below 1 Ω E2X2 (H14-14) - E2X2 (S5-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VCX1 (H14-17) or VCX1 (S5-3) - Body ground 10 kΩ or higher VSX1 (H14-25) or VSX1 (S5-1) - Body ground 10 kΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition E2X1 (H14-15) or E2X1 (S5-2) - Body ground 10 kΩ or higher VCX2 (H14-16) or VCX2 (S5-6) - Body ground 10 kΩ or higher VSX2 (H14-24) or VSX2 (S5-4) - Body ground 10 kΩ or higher E2X2 (H14-14) or E2X2 (S5-5) - Body ground 10 kΩ or higher HV–111 (g) Reconnect the shift sensor connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HYBRID VEHICLE CONTROL ECU (VCX1 AND VCX2 VOLTAGE) (a) Disconnect the S5 shift sensor connector. (b) Turn the power switch ON (IG). (c) Measure the voltage between the terminals of the shift sensor connector. Standard voltage Wire Harness Side: S5 E2X1 VCX2 E2X2 VCX1 Shift Sensor Connector A092027E02 Tester Connection Specified Condition VCX1 (S5-3) - E2X1 (S5-2) 4.5 to 5.5 V VCX2 (S5-6) - E2X2 (S5-5) 4.5 to 5.5 V (d) Reconnect the shift sensor connector. OK Go to step 7 NG REPLACE HYBRID VEHICLE CONTROL ECU 4 READ VALUE OF INTELLIGENT TESTER (SM AND SS SHIFT SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the SM and SS SHIFT SENSOR voltage values. Result: Shift Position SM Shift Sensor SS Shift Sensor R, N or D position 3.0 to 4.85 V 3.0 to 4.85 V Home or B position 0.5 to 2.0 V 0.5 to 2.0 V OK Go to step 7 HV HV–112 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG 5 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - SELECT SENSOR) (a) Disconnect the H14 HV control ECU connector. H14 VSX3 VCX4 VCX3 VSX4 HV Control ECU Connector A065748E32 (b) Disconnect the S4 select sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: S4 VSX4 VCX3 VSX3 VCX4 Select Sensor Connector Tester Connection Specified Condition VCX3 (H14-21) - Body ground Below 1 V VVSX3 (H14-23) - Body ground Below 1 V VCX4 (H14-31) - Body ground Below 1 V VSX4 (H14-30) - Body ground Below 1 V A092028E01 HV (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VCX3 (H14-21) - VCX3 (S4-3) Below 1 Ω VSX3 (H14-23) - VSX3 (S4-5) Below 1 Ω VCX4 (H14-31) - VCX4 (S4-6) Below 1 Ω VSX4 (H14-30) - VSX4 (S4-8) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VCX3 (H14-21) or VCX3 (S4-3) - Body ground 10 kΩ or higher VSX3 (H14-23) or VSX3 (S4-5) - Body ground 10 kΩ or higher VCX4 (H14-31) or VCX4 (S4-6) - Body ground 10 kΩ or higher VSX4 (H14-30) or VSX4 (S4-8) - Body ground 10 kΩ or higher (g) Reconnect the select sensor connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–113 OK 6 INSPECT HYBRID VEHICLE CONTROL ECU (VCX3 AND VCX4 VOLTAGE) (a) Disconnect the S4 select sensor connector. (b) Turn the power switch ON (IG). (c) Measure the voltage between the terminals of the select sensor connector and body ground. Standard voltage Wire Harness Side: S4 VCX4 VCX3 Select Sensor Connector A092028E02 Tester Connection Specified Condition VCX3 (S4-3) - Body ground 9 to 14 V VCX4 (S4-6) - Body ground 9 to 14 V (d) Reconnect the select sensor connector. NG REPLACE HYBRID VEHICLE CONTROL ECU OK 7 REPLACE SELECTOR LEVER GO 8 READ OUTPUT DTC (DTC P0705 IS NOT OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CLEAR CODES. (e) Perform a simulation test. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (g) Read DTCs. Result: DTC P0705 is not output again YES NO REPLACE HYBRID VEHICLE CONTROL ECU SYSTEM IS OK HV HV–114 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0851-579 Park / Neutral Switch Input Circuit Low DTC P0852-580 Park / Neutral Switch Input Circuit High DESCRIPTION Instead of having a parking position as one of the positions of the conventional shift lever, a P position switch is provided independently in the upper area of the selector lever. The switch is based on a momentary type operation mode, in which the button does not lock mechanically. The P position switch contains resistors R1 and R2. When the P position switch is not pressed, the switch provides a combined resistance of R1 and R2; and when the P position switch is pressed, the switch provides only the resistance of R1. The voltage at the P1 terminal of the HV control ECU varies with the changes in the resistance of the switch. The HV control ECU determines the P position switch operation intended by the driver according to this resistance signal. DTC No. INF Code DTC Detection Condition Trouble Area P0851 579 GND short in P position switch circuit • • • Wire harness or connector P position switch HV control ECU P0852 580 Open or +B short in P position switch circuit • • • Wire harness or connector P position switch HV control ECU WIRING DIAGRAM M11 P Position Switch Y J24 J/C A HV 3 W-B 4 R1 A R2 W-B W-B IH HV Control ECU 6 5L 6 5A No. 2 Center Connector No. 2 Center Connector Y 17 H15 P1 9 IA2 L 1 5A 8 5H A092094E01 HV–115 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT P POSITION SWITCH (a) Remove the P position switch. (b) Measure the resistance between the terminals of the P position switch connector. Standard resistance Component Side: M11 E S P Position Switch Tester Connection Condition Specified Condition S (M11-4) - E (M11-3) Keep switch pressed 680 Ω S (M11-4) - E (M11-3) Release switch 4,580 Ω (c) Reinstall the P position switch. A092029E01 NG REPLACE P POSITION SWITCH OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - P POSITION SWITCH) (a) Disconnect the H15 HV control ECU connector. H15 P1 HV Control ECU Connector HV A065744E33 (b) Disconnect the M11 P position switch connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: S M11 P Position Switch Connector A092061E01 Tester Connection Specified Condition P1 (H15-17) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition P1 (H15-17) - S (M11-4) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition P1 (H15-17) or S (M11-4) - Body ground 10 kΩ or higher (g) Reconnect the P position switch connector. (h) Reconnect the HV control ECU connector. HV–116 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HARNESS AND CONNECTOR (P POSITION SWITCH - BODY GROUND) (a) Disconnect the M11 P position switch connector. (b) Measure the resistance between the terminal of the P position switch connector and body ground. Standard resistance (Check for open) Wire Harness Side: E M11 Tester Connection Specified Condition E (M11-3) - Body ground Below 1 Ω (c) Reconnect the P position switch connector. P Position Switch Connector A092061E02 NG OK REPLACE HYBRID VEHICLE CONTROL ECU HV REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A08264 HV–117 DC / DC Converter Status Circuit DESCRIPTION The HV Control ECU monitors the DC / DC converter circuit status via the NODD terminal. If the ECU detects an internal circuit malfunction in the converter and stops converter operation with its fail-safe function, causing the auxiliary battery voltage to drop below 11 V, the ECU outputs DTC P0A08 (INF 264). DTC No. INF Code DTC Detection Condition Trouble Area P0A08 264 All conditions below are detected • DC / DC converter internal circuit malfunction is detected • DC / DC converter enters failsafe mode • Auxiliary battery voltage drops below 11 V • • • • • • • • • • Auxiliary battery Fusible link block assembly Fuse (for 12 V electrical equipment) Engine room relay block Inverter cooling hose Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Wire harness or connector Inverter with converter assembly (DC / DC converter) WIRING DIAGRAM Refer to DTC P0A09 (INF265) (see page HV-125). INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Clear the DTC(s) (see page HV-39). (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG) and turn the intelligent tester ON. (d) Read DTC(s). Result: Result Proceed to One or more of following DTCs is output: P0A94, P0AA1, P0AA4, P0AA6, P0AE0, P0AE6, P0AE7, P0ADB, P0ADF, P3000, P3004, P3110 A P0A08 is output B A GO TO DIAGNOSTIC TROUBLE CODE CHART B 2 CHECK CABLE CONNECTION FROM AUXILIARY BATTERY TERMINAL (a) Turn the power switch OFF. (b) Check the auxiliary battery (12 V) cable connections at places listed below: • The battery positive and negative terminals are not loose. HV HV–118 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM • The body ground of the battery negative cable is not loose. • The FL block nut is not loose. OK: They are not loose. NG CONNECT OR INSTALL SECURELY OK 3 CHECK CONNECTION OF CONNECTORS (FUSIBLE LINK BLOCK ASSEMBLY) (a) Check that the F15 and F16 connectors are securely connected to the fusible link block assembly. OK: Connectors are connected securely. Fusible Link Block Assembly F16 OK Go to step 5 F15 HV A125632E01 NG 4 CHECK CONNECTOR (FUSIBLE LINK BLOCK ASSEMBLY) (a) Check that the F15 and F16 connector terminals do not have burnout. OK: There is no burnout. NG OK REPAIR OR REPLACE CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 5 HV–119 INSPECT FUSIBLE LINK BLOCK ASSEMBLY (a) Measure the resistance between the F15 fusible link block assembly and body ground. Standard resistance Fusible Link Block Assembly Tester Connection Specified Condition F15-1 Body ground Below 1 Ω If the result is not as specified, proceed to NG-A. (b) Measure the resistance between the F16 fusible link block assembly and body ground. Standard resistance F16 Tester Connection Specified Condition F16-1 Body ground Below 1 Ω F16-2 Body ground Below 1 Ω If the result is not as specified, proceed to NG-B. F15 NG-A REPAIR OR REPLACE FUSIBLE LINK BLOCK ASSEMBLY NG-B REPAIR FUSIBLE LINK BLOCK ASSEMBLY AND REPLACE DC / DC FUSE A125427E01 OK 6 CHECK INSTALLATION CONDITION OF DC / DC FUSE (ENGINE ROOM JUNCTION BLOCK) (a) Check the installation condition of the DC / DC fuse. OK: No bolts or nuts are loose. Engine Room Junction Block NG Bolt Nut A125633E01 TIGHTEN BOLT OR NUT HV HV–120 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 7 CHECK FUSIBLE LINK BLOCK ASSEMBLY (100A DC / DC-S) (a) Remove the DC / DC-S fuse from the fusible link block assembly. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSIBLE LINK BLOCK ASSEMBLY OK 8 CHECK CONNECTION OF CONNECTORS (HV CONTROL ECU) H17 H16 H15 H14 (a) Check that the H14, H15, H16 and H17 ECU connectors are securely connected. OK: Connectors are connected securely. NG CONNECT SECURELY HV Control ECU Connector A093719E06 HV OK 9 CHECK CONNECTION OF CONNECTORS (INVERTER WITH CONVERTER ASSEMBLY) CAUTION: Inverter with converter assembly: Be sure to wear insulated gloves. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HV-1). CAUTION: Keep the removed service plug grip in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. (c) Leave the vehicle as is for 5 minutes. HINT: It takes 5 minutes for the high voltage condenser in the inverter to discharge its electricity. (d) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–121 (e) Remove the 5 bolts to disconnect the MG2 power cable. MG2 Power Cable I14 A083600E01 (f) Remove the 5 bolts to disconnect the MG1 power cable. MG1 Power Cable I15 A083601E01 (g) Check the connection condition of the C5 connector. OK: Connector has been connected securely. 1 2 3 4 5 6 NG CONNECT SECURELY C5 HV A125411E01 OK 10 CHECK CONNECTION OF CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY) (a) Check that the C6 connector is connected securely. OK: Connector is connected securely. OK C6 A125412E01 NG Go to step 12 HV–122 11 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK INVERTER WITH CONVERTER ASSEMBLY (a) Disconnect the C6 connector. (b) Check that the C6 connector terminal does not have burnout. OK: There is no burnout. C6 NG REPAIR OR REPLACE CONNECTOR A125412E01 OK 12 CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY BATTERY AND BODY GROUND) (a) Disconnect the C5 and C6 converter inverter connectors. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connectors. Standard voltage Wire Harness Side C5 IGCT S 1 2 3 4 5 6 Tester Connection Condition Specified Condition C5-3 (S) - Body ground Always Some as 12 V battery voltage Inverter with Converter Assembly C6-1 (AMD) - Body ground Always Some as 12 V battery voltage C5-1 (IGCT) - Body ground Power switch ON (IG) 8 to 16 V NODD HV C6 (d) Measure the resistance between the wire harness side connector. Standard resistance 1 AMD Inverter with Converter Assembly A125414E01 OK Tester Connection Condition Specified Condition C5-4 (NODD) - Body ground IG-OFF 100 to 140 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 13 HV–123 CHECK OPERATION OF INVERTER WITH CONVERTER ASSEMBLY C6 C5 C6 A125415E01 (a) Connect the C5 and C6 converter inverter connectors. (b) Set the electrical tester with the AC/DC 400 A probe to the wire harness of the C6 connector. (c) Connect the I14 and I15 connectors (color: orange) to the inverter. (d) Install the inverter cover. (e) Install the service plug grip. (f) Turn the power switch ON (READY). (g) Wait 5 minutes. (h) Operate the electrical devices as listed below: • Set the light control switch to High beam. • Set the heater blower fan to HI. • Turn on the defogger. • Depress the brake pedal. • Press all the switches of the window regulator master switch at the same time. • Turn the steering wheel to the right or left. (i) Measure the amperage and voltage. Standard amperage Item Specified Condition Output current 40 to 100 A Standard voltage Item Specified Condition Battery voltage 13 to 15 V OK Go to step 15 NG 14 INSPECT FUSE (a) Remove the EPS-H, HEAD MAIN-H, H-LP LO LH, H-LP LO RH, H-LP HI LH, and H-LP HI RH fuses from the engine room relay block. (b) Remove the DEF-H, PWR-H, FR-DOOR, STOP M/HTR, A/C (HTR) fuses from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG CHECK FOR SHORT IN ALL HARNESS OR CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE OK 15 CHECK COOLANT LEVEL OF INVERTER WITH CONVERTER ASSEMBLY (a) Check the coolant level in the reservoir tank. HV HV–124 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK: Coolant level in the reservoir tank is between F and L line. NG ADD COOLANT OK 16 CHECK INVERTER COOLANT HOSE (a) Check if the inverter cooling hoses are bent, twisted, damaged or clogged. OK: Hoses are not bent, twisted, damaged, or clogged. NG REPAIR OR REPLACE HOSE OK 17 CHECK CONNECTION CONDITION OF WATER PUMP WITH MOTOR CONNECTOR (LOOSENESS AND POOR CONNECTION) (a) Check the connection condition of the pump and bracket connector. OK: Connector has been connected securely. NG HV CONNECT SECURELY A090415E01 OK 18 CHECK OPERATION OF WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the motor. OK: Coolant surface in reservoir tank has waves. NG OK REPLACE WATER PUMP WITH MOTOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 19 HV–125 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONNECTION) (a) Check the connection condition of the fan connectors. OK: Connectors have been connected securely. NG CONNECT SECURELY A090546E01 OK 20 INSPECT COOLING FAN MOTOR (a) Inspect cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–126 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A09265 DC / DC Converter Status Circuit Low Input DTC P0A10263 DC / DC Converter Status Circuit High Input DESCRIPTION The DC / DC converter converts the DC 201.6 V of the HV battery into DC 12 V in order to supply power to the vehicle's lighting, audio and ECU systems. In addition, it charges the auxiliary battery. A transistor bridge circuit initially converts DC 201.6 V into alternating current, and a transformer lowers its voltage. Then, it is rectified and smoothed (into DC) and converted into DC 12 V. The DC / DC converter controls the output voltage in order to keep a constant voltage at the terminals of the auxiliary battery. Inverter DC 201.6 V DC / DC Converter HV Input Filter AMD GND IG Converter Control Circuit S Auxiliary Battery NODD VLO IDH HV Control ECU A/C ECU A125416E01 HV–127 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The HV control ECU uses the NODD signal line to transmit a stop command to the DC / DC converter and receive signals indicating the normal or abnormal conditions of the 12 V charging system. If the vehicle is being driven with an inoperative DC / DC converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the HV control ECU monitors the operation of the DC / DC converter and alerts the driver if it detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A09 265 Open or GND short in NODD signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly P0A10 263 +B short in NODD signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM DC / DC Converter HV Control ECU 4 NODD C5 V 24 H16 NODD A092298E01 HV INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - DC / DC CONVERTER) (a) Disconnect the H16 HV control ECU connector. H16 NODD HV Control ECU Connector A065745E35 HV–128 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the C5 DC / DC converter connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: C5 NODD DC / DC Converter Connector A092030E01 Tester Connection Specified Condition NODD (H16-24) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition NODD (H16-24) - NODD (C5-4) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition NODD (H16-24) or NODD (C5-4) Body ground 10 kΩ or higher (g) Reconnect the DC / DC converter connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–129 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A09591 DC / DC Converter Status Circuit Low Input DTC P0A10592 DC / DC Converter Status Circuit High Input DESCRIPTION See the description of the DC / DC converter (see page HV-124). The HV control ECU sends the output voltage switch signal to the DC / DC converter via the VLO signal line in order to switch output voltage according to vehicle status. If the vehicle is being driven with an inoperative DC / DC converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the HV control ECU monitors the operation of the DC / DC converter and alerts the driver if it detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A09 591 Open or GND short in VLO signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly P0A10 592 +B short in VLO signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM HV Control ECU DC / DC Converter HV 5 VLO C5 L 31 H16 VLO A092298E02 HV–130 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - DC / DC CONVERTER) (a) Disconnect the H16 HV control ECU connector. H16 VLO HV Control ECU Connector A065745E36 Wire Harness Side: (b) Disconnect the C5 DC / DC converter connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage C5 VLO DC / DC Converter Connector A092030E02 HV Tester Connection Specified Condition VLO (H16-31) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VLO (H16-31) - VLO (C5-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VLO (H16-31) or VLO (C5-5) - Body ground 10 kΩ or higher (g) Reconnect the DC / DC converter connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A0D350 HV–131 High Voltage System Inter-Lock Circuit High DESCRIPTION If the HV control ECU detects the operation of the safety devices (removal of the service plug grip and inverter cover) while the vehicle is stopped (vehicle speed below 3 mph [5 km/h]), it will shut down the system main relays. If the safety devices are correctly reinstalled, it will resume the normal operation after the power source is supplied again. If it does not, there is a possibility of an open circuit, so perform the same inspection as the DTC P0A0D (INF 351). DTC No. INF Code DTC Detection Condition Trouble Area P0A0D 350 Operating safety devices with vehicle stopped (ILK signal is ON) • • Service plug grip installation Inverter cover installation INSPECTION PROCEDURE 1 CHECK SERVICE PLUG GRIP INSTALLATION (a) Check that the service plug grip has been installed properly. OK: The service plug grip has been installed properly NG CORRECTLY REINSTALL OK 2 CHECK INVERTER COVER INSTALLATION (a) Check that the inverter cover has been installed properly. OK: The Inverter cover has been installed properly NG OK GO TO DTC P0A0D-351 CORRECTLY REINSTALL HV HV–132 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A0D351 DTC High Voltage System Inter-Lock Circuit High DESCRIPTION A short pin for the interlock switch is provided on the service plug grip and the inverter cover. Therefore, the interlock signal line circuit opens when the service plug grip or the inverter cover is removed. If the HV control ECU detects an open circuit in the interlock signal line while the vehicle is in motion (vehicle speed above 3 mph [5 km/h]), it stores the information (INF) code 351 in its memory and alerts the driver. While the vehicle is in motion, the HV control ECU will not shut down the high-voltage system even if an open circuit in the interlock system is detected. DTC No. INF Code DTC Detection Condition Trouble Area P0A0D 351 Open in interlock signal circuit while vehicle is running • • • Wire harness or connector Battery plug (No. 2 interlock switch) Inverter with converter assembly (No. 1 interlock switch) WIRING DIAGRAM HV Control ECU L HV 21 IC1 3 IC1 L V 1 H15 ILK V 1 I16 CVSW Inverter with No. 1 Interlock Converter Switch Assembly 2 IRTN No. 2 Interlock Switch 1 ILK I17 Battery Plug A129405E02 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–133 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK INVERTER COVER INSTALLATION (a) Check that the inverter cover has been installed properly. Standard: The inverter cover has been installed properly NG CORRECTLY REINSTALL OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 2 INTERLOCK SWITCH) (a) Disconnect the H15 HV control ECU connector. H15 HV ILK HV Control ECU Connector A065744E20 (b) Disconnect the I17 No. 2 interlock switch connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: No. 2 Interlock Switch Connector I17 Tester Connection Specified Condition ILK (H15-1) - ILK (I17-1) Below 1 Ω Standard resistance (Check for short) A092089E01 Tester Connection Specified Condition ILK (H15-1) or ILK (I17-1) - Body ground 10 kΩ or higher (d) Reconnect the No. 2 interlock switch connector. (e) Reconnect the HV control ECU connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV–134 3 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (NO. 1 INTERLOCK SWITCH - NO. 2 INTERLOCK SWITCH) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the I16 No. 1 interlock switch connector. Wire Harness Side: CVSW I16 No. 1 Interlock Switch Connector A092059E01 (e) Disconnect the I17 No. 2 interlock switch connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: No. 2 Interlock Switch Connector HV I17 IRTN Tester Connection Specified Condition CVSW (I16-1) - IRTN (I17-2) Below 1 Ω Standard resistance (Check for short) A092090E01 Tester Connection Specified Condition CVSW (I16-1) or IRTN (I17-2) - Body ground 10 kΩ or higher (g) Reconnect the No. 1 interlock switch connector. (h) Reconnect the No. 2 interlock switch connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I16 CVSW B A Ground Bolt A092060E01 HV–135 (b) Disconnect the I16 No. 1 interlock switch connector. (c) Check that the ground bolt for the interlock switch is tightened to the specified torque. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (d) Connect terminals A and B as shown in the illustration. (e) Measure the resistance between the I16 No. 1 interlock switch connector and body ground. Standard resistance Tester Connection Specified Condition CVSW (I16-1) - Body ground Below 1 Ω (f) Reconnect the No. 1 interlock switch connector. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR HARNESS OR CONNECTOR, OR REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE BATTERY PLUG HV HV–136 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A0F204 Engine Failed to Start DTC P0A0F205 Engine Failed to Start DTC P0A0F533 Engine Failed to Start DTC P0A0F534 Engine Failed to Start DESCRIPTION The HV control ECU performs the fail-safe control, when the ECM detects an error which will affect THS control. DTC No. INF Code DTC Detection Condition Trouble Area P0A0F 204 Abnormal signal input from ECM (abnormal engine output) • • ECM SFI system P0A0F 205 Abnormal signal input from ECM (engine is unable to start) • • ECM SFI system P0A0F 533 Abnormal signal input from ECM (abnormal engine output by running out of fuel) • • ECM SFI system P0A0F 534 Abnormal signal input from ECM (engine is unable to start by running out of fuel) • • ECM SFI system HV INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output NG OK REPLACE ECM GO TO RELEVANT DTC CHART HV–137 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A0F238 DTC Engine Failed to Start DESCRIPTION The HV control ECU detects this DTC and effects fail-safe control if the engine or transaxle gear has seized up, or foreign objects have been caught in either of them. DTC No. INF Code DTC Detection Condition Trouble Area P0A0F 238 Engine does not start even though cranking it (transaxle input malfunction [engine system]) • • • • • Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU WIRING DIAGRAM HV Control ECU ECM 1 NEO E7 33 NE+ E4 34 NE- E4 12 H16 NEO LG G A A * R 1 G 2 J14 J/C C7 Crankshaft Position Sensor BR A A J12 J/C *: Shielded HV BR EC A092095E01 INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART HV–138 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NO 2 CHECK CRANKSHAFT PULLEY REVOLUTION (a) Turn the power switch OFF. (b) Jack up the vehicle. (c) Manually turn the crankshaft pulley to check if the crankshaft rotates. OK: The crankshaft rotates NG Go to step 11 OK 3 CHECK HARNESS AND CONNECTOR (ECM - CRANKSHAFT POSITION SENSOR) (a) Disconnect the E4 ECM connector. E4 NENE+ ECM Connector A065743E70 HV (b) Disconnect the C7 crankshaft position sensor connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: C7 Crankshaft Position Sensor Connector A092031E01 Tester Connection Specified Condition NE+ (E4-33) - Crankshaft position sensor (C7-1) Below 1 Ω NE- (E4-34) - Crankshaft position sensor (C7-2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition NE+ (E4-33) or Crankshaft position sensor (C7-1) - Body ground 10 kΩ or higher NE- (E4-34) or Crankshaft position sensor (C7-2) - Body ground 10 kΩ or higher (d) Reconnect the crankshaft position sensor connector. (e) Reconnect the ECM connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 4 HV–139 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 NEO HV Control ECU Connector A065745E37 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 Tester Connection Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω NEO ECM Connector A065744E24 Standard resistance (Check for short) Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) -Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK AND CLEAR DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Check and record the DTCs, the freeze frame data, and the information. (f) Clear the DTCs of the HV ECU. GO 6 CHECK READY LIGHT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. HV HV–140 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (e) Read the MG1 REV and ENGINE SPD values. (f) Turn the power switch ON (READY). OK: READY light turns ON HINT: If the READY light does not turn ON, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 7 CHECK ENGINE REV-UP (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 REV and ENGINE SPD values. (f) With the READY light turned ON, depress the accelerator pedal for 10 seconds while the shift position is in P. OK: The engine revs up HINT: If the engine does not rev up, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. HV NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 8 CHECK CREEP MOVEMENT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (READY). Jack up the vehicle. Depress the brake pedal, move the selector lever to the D position, and release the brake pedal. OK: The wheels turn (creep movement) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–141 HINT: If the wheels do not turn, and the reading on the intelligent tester shows DTC P0A90 (INF 602) (HV transaxle output malfunction), replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 9 CHECK ENGINE ACCELERATION SPEED (a) Connect the intelligent tester to the DLC3. (b) While driving at the vehicle speed of more than 6 mph (10 km/h), fully depress the accelerator pedal to raise the engine speed. OK: The engine speed increases smoothly HINT: If the engine over-revs or the reading on the intelligent tester shows DTC P0A90 (INF 241) (HV transaxle input malfunction [torque limiter slipping]), replace the transmission input damper. NG REPLACE TRANSMISSION INPUT DAMPER ASSEMBLY OK 10 CHECK CAUSE OF INCREASE IN REVOLUTION RESISTANCE (a) Investigate what has caused the revolution resistance of the transaxle and engine to become greater. (1) Check the engine lubrication system and transaxle lubrication system. (2) Check the engine coolant and transaxle coolant. (3) Check for any breakdowns in the engine and transaxle. Result: There is no fault NO REPAIR MALFUNCTIONING PARTS AND COMPONENTS YES PERFORM SIMULATION TEST. IF SYMPTOM IS NOT REPRODUCED, REPLACE ENGINE, HV TRANSAXLE AND HV CONTROL ECU 11 CHECK FRONT TIRE REVOLUTION (a) Turn the power switch ON (IG). HV HV–142 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Depress the brake pedal, move the selector lever to the N position. (c) Jack up the vehicle. (d) Manually turn the crankshaft pulley to check if the front tires rotate. OK: The front tires rotate NG REPAIR OR REPLACE ENGINE ASSEMBLY OK REPAIR OR REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D134 Hybrid Powertrain Control Module DTC P0A1D135 Hybrid Powertrain Control Module DTC P0A1D570 Hybrid Powertrain Control Module HV–143 DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 134 135 570 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of vehicle systems. One of these monitors the rationality of internal analog (signal) to digital conversions. The HV control ECU monitors the internal A/D (Analog / Digital Converter) value. If there is an A/D malfunction, the HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 134 / 135 / 570): ADC malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 134 / 135 / 570) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. HV HV–144 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D139 HV–145 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 139 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of vehicle systems. One of these monitors checks the inside of the HV control ECU for a bad integrated circuit which actuates a relay. If the HV control ECU detects a malfunction, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 139): IG malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 139) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV–146 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D140 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 140 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. One of these tests checks for errors after a memory read / write diagnostic test. If the HV control ECU detects this malfunction inside of the ECU, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 140): RAM destruction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS All RAM area Read / write check error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 140) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D141 HV–147 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 141 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. One of these tests checks for errors in the ROM (Read Only Memory) circuits of the HV control ECU. If the HV control ECU detects this malfunction inside of the ECU, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 141): ROM destruction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 141) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV–148 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A1D142 DTC Hybrid Powertrain Control Module DESCRIPTION When the ST turned ON in the ignition switch on the previous model, the ignition switch transmitted the ST signal to the HV control ECU. The new Prius has adopted a push button start system. When the driver pushes on the power switch while depressing the brake pedal, the power source control ECU transmits the ST signal to the HV control ECU. Previous ST Signal: Push Button Start System’s ST Signal: Ignition Switch Stop Light Switch ST2 STSW STP SSW HV Control ECU Auxiliary Battery Auxiliary Battery AM ST2 HV Control ECU Power Switch Power Source Control ECU HV A093723E01 The HV control ECU monitors the ST signal to detect malfunction. If the ST signal is shorted to the +B power supply, the ST will be constantly ON, which will cause the HV system to start by merely turning the power switch ON (IG). The HV control ECU monitors the ST signal to prevent this from occurring. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 142 ST signal of HV control ECU is ON with power switch OFF • • Wire harness or connector Power source control ECU MONITOR DESCRIPTION The HV control ECU monitors an ST signal input from the power source control ECU. If the ST signal is shorted to the +B power supply, the HV control ECU interprets this as the ST signal error, and then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF142): ST malfunction Required sensor / components Power source control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–149 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS ST signal ON COMPONENT OPERATING RANGE ST signal OFF (when the power switch OFF) WIRING DIAGRAM P6 Power Source Control ECU HV Control ECU No. 1 Center Connector STSW 39 Y 10 4J 6 4E Y 5 H14 ST2 A092096E01 HV INSPECTION PROCEDURE 1 INSPECT HYBRID VEHICLE CONTROL ECU (ST2 VOLTAGE) (a) Disconnect the H14 HV control ECU connector. (b) Measure the voltage between the terminal of the HV control ECU connector and body ground with the power switch turned OFF. Standard voltage H14 ST2 HV Control ECU Connector A065748E29 NG Tester Connection Specified Condition ST2 (H14-5) - Body ground Below 1 V (c) Reconnect the HV control ECU connector. OK CHECK FOR INTERMITTENT PROBLEMS HV–150 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - POWER SOURCE CONTROL ECU) (a) Disconnect the H14 HV control ECU connector. H14 ST2 HV Control ECU Connector A065748E29 Wire Harness Side: STSW P6 Power Source Control ECU Connector A092032E01 (b) Disconnect the P6 power source control ECU connector. (c) Measure the voltage between the terminal of the HV control ECU connector or power source control ECU and body ground with the power switch turned OFF. Standard voltage Tester Connection Specified Condition ST2 (H14-5) or STSW (P6-39) - Body ground Below 1 V (d) Reconnect the power source control ECU connector. (e) Reconnect the HV control ECU connector. NG OK HV REPLACE POWER SOURCE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D143 HV–151 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 143 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal ECU systems. One of these monitors compares read and write values at the inside of the HV control ECU memory, which have been indicated by the transponder key or the electronic key. If those two values are inconsistent with each other, the HV control ECU interprets this as an ECU memory failure of the HV control ECU. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 143): EEPROM malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Immobilizer and electronic key area on the EEPROM Read / write check error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 143) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–152 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D144 Hybrid Powertrain Control Module DTC P0A1D145 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 144 145 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. In one of these diagnostics, the HV control ECU performs a self-test. If the HV control ECU detects an internal problem during this self-test, it will conclude that there is an internal malfunction. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 144 / 145): Primary check malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None HV TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions 1 or 2 is met: - 1. Reset signal from engine CPU Not found 2. Communication time between internal ECUs Time out COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 144 / 145) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–153 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–154 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D148 Hybrid Powertrain Control Module DTC P0A1D149 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 148 149 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. In one of these diagnostics, the HV control ECU performs a self-test. If the HV control ECU detects an internal problem during this self-test, it will conclude that there is an internal malfunction. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 148 / 149): HV CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None HV TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 148 / 149) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–155 NEXT COMPLETED HV HV–156 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D150 Hybrid Powertrain Control Module DTC P0A1D151 Hybrid Powertrain Control Module DTC P0A1D152 Hybrid Powertrain Control Module DTC P0A1D155 Hybrid Powertrain Control Module DTC P0A1D156 Hybrid Powertrain Control Module DTC P0A1D158 Hybrid Powertrain Control Module DTC P0A1D564 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. HV DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 150 151 152 155 156 158 564 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU checks the result of the generator CPU self-test. If the HV control ECU detects a "Fail" from the generator CPU self-test, it will conclude that there is an internal malfunction in the generator CPU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 150 / 151 / 152 / 155 / 156 / 158 / 564): Generator CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–157 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 150 / 151 / 152 / 155 / 156 / 158 / 564) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–158 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D159 Hybrid Powertrain Control Module DTC P0A1D160 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 159 160 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these monitors, the HV control ECU checks the motor main CPU serial communication link. If the HV control ECU detects a failure, it will conclude that there is an internal malfunction involving the HV control ECU to motor main CPU communication link. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY HV Related DTCs P0A1D (INF 159 / 160): Motor CPU serial communication error Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 159 / 160) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes is present, replace the HV control ECU. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–159 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–160 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D163 Hybrid Powertrain Control Module DTC P0A1D164 Hybrid Powertrain Control Module DTC P0A1D511 Hybrid Powertrain Control Module DTC P0A1D512 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 163 164 511 512 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In one of these monitors, the HV control ECU monitors the power supply for the motor main CPU. If the HV control ECU detects a failure in the power supply for the motor main CPU, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 163 / 164 / 511 / 512): Motor ECU power malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 163 / 164 / 511 / 512) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–161 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–162 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D165 Hybrid Powertrain Control Module DTC P0A1D168 Hybrid Powertrain Control Module DTC P0A1D198 Hybrid Powertrain Control Module DTC P0A1D199 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 165 168 198 199 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostic monitor, the HV control ECU checks for an R/D (Resolver / Digital Converter) malfunction involving the motor resolver. If the HV control ECU detects an R/D error, it will conclude that there is an internal malfunction involving the motor resolver. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 165 / 168 / 198 / 199): Motor R/D malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 165 / 168 / 198 / 199) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–163 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–164 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D166 Hybrid Powertrain Control Module DTC P0A1D167 Hybrid Powertrain Control Module DTC P0A1D197 Hybrid Powertrain Control Module DTC P0A1D200 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 166 167 197 200 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostic monitor, the HV control ECU checks for an R/D (Resolver / Digital Converter) malfunction involving the generator resolver. If the HV control ECU detects an R/D error, it will conclude that there is an internal malfunction involving the generator resolver. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 166 / 167 / 197 / 200): Generator R/D malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 166 / 167 / 197 / 200) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–165 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–166 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D177 Hybrid Powertrain Control Module DTC P0A1D178 Hybrid Powertrain Control Module DTC P0A1D392 Hybrid Powertrain Control Module DTC P0A1D567 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 177 178 392 567 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU checks the result of the motor main CPU self-test. If the HV control ECU detects a "Fail" from the motor main CPU self-test, it will conclude that there is an internal malfunction in the motor main CPU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 177 / 178 / 392 / 567): Motor main CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 177 / 178 / 392 / 567) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–167 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–168 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D180 Hybrid Powertrain Control Module DTC P0A1D181 Hybrid Powertrain Control Module DTC P0A1D182 Hybrid Powertrain Control Module DTC P0A1D183 Hybrid Powertrain Control Module DTC P0A1D184 Hybrid Powertrain Control Module DTC P0A1D185 Hybrid Powertrain Control Module DTC P0A1D186 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. HV DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 180 181 182 183 184 185 186 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostics monitor, the HV control ECU monitors the output of the rotation angle CPU. If the HV control ECU detects an error in the rotation angle CPU, it will conclude that there is an internal malfunction in the HV control ECU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 180 / 181 / 182 / 183 / 184 / 185 / 186): Rotation angle monitor CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–169 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 180 / 181 / 182 / 183 / 184 / 185 / 186) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–170 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D187 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 187 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU monitors the important RAM circuits of the HV control ECU. If the HV control ECU detects an error in the important RAM circuits, it will conclude that there is an internal malfunction in the HV control ECU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 187): Important RAM error Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Important RAM address Read / write check error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 187) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D188 Hybrid Powertrain Control Module DTC P0A1D189 Hybrid Powertrain Control Module DTC P0A1D192 Hybrid Powertrain Control Module DTC P0A1D193 Hybrid Powertrain Control Module DTC P0A1D195 Hybrid Powertrain Control Module DTC P0A1D196 Hybrid Powertrain Control Module DTC P0A1D565 Hybrid Powertrain Control Module HV–171 DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 188 189 192 193 195 196 565 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU checks the result of the motor CPU selftest. If the HV control ECU detects a "Fail" from the motor CPU self-test, it will conclude that there is an internal malfunction in the motor CPU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 188 / 189 / 192 / 193 / 195 / 196 / 565): Motor CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None HV HV–172 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 188 / 189 / 192 / 193 / 195 / 196 / 565) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D390 HV–173 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 390 Charge control malfunction • HV control ECU INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D (INF 390) and other DTCs are output HINT: If any other codes besides P0A1D (INF 390) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO HV REPLACE HYBRID VEHICLE CONTROL ECU HV–174 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D393 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 393 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. In one of these diagnostics, the HV control ECU performs a self-test. If the HV control ECU detects an internal problem during this self-test, it will conclude that there is an internal malfunction. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 393): HV CPU operation malfunction (routine check) Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 393) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D568 Hybrid Powertrain Control Module DTC P0A1D569 Hybrid Powertrain Control Module HV–175 DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 568 569 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostics monitor, the HV control ECU checks the REF signal from the motor main ECU for errors. If the HV control ECU detects an error in the REF signal, it will conclude that there is a malfunction in the motor main CPU, the REF signal or the HV control ECU. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 568 / 569): Motor REF signal malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS REF signal Abnormal COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 568 / 569) is not detected INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HV HV–176 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A0F (INF 243), P0A40 (INF 500) or P0A41 (INF 245) for the motor resolver is output YES NO REPLACE HYBRID VEHICLE CONTROL ECU HV GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D615 HV–177 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 615 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostics monitor, the HV control ECU checks the communication bus off count and the message register of the CAN (Controller Area Network) controller. If the HV control ECU detects an error in the communication bus off count or message register, it will conclude that there is a malfunction in the HV control ECU. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 615): CAN communication malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Case 1: Message register of the CAN controller Read / write check error Case 2: Communication bus off count Designed number or more COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 615) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). HV HV–178 NEXT COMPLETED HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1F123 HV–179 Battery Energy Control Module DESCRIPTION Based on a malfunction signal received from the battery ECU, the HV control ECU alerts the driver and effects fail-safe control. DTC No. INF Code DTC Detection Condition Trouble Area P0A1F 123 Abnormal signal input from battery ECU (ROM/RAM malfunction) • • HV battery system Battery ECU MONITOR DESCRIPTION Upon receiving an abnormal signal input from the battery ECU, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F (INF 123): Battery ECU / Rationality Required sensor / components Battery ECU, battery current sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Battery ECU Normal INSPECTION PROCEDURE HINT: After repairing the malfunction, restart the system (to turn the READY light ON) and recheck the DTC. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. HV–180 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Result: DTCs are output YES NO REPLACE BATTERY ECU ASSEMBLY HV GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1F129 HV–181 Battery Energy Control Module DESCRIPTION The battery ECU transmits information on the HV battery voltage to the HV control ECU via CAN communication. DTC No. INF Code DTC Detection Condition Trouble Area P0A1F 129 HV battery voltage circuit malfunction • • • • • HV battery voltage circuit Service plug grip High voltage fuse Battery plug Battery ECU MONITOR DESCRIPTION The HV control ECU calculates the differences between the received HV battery voltage, boost converter voltage, and inverter voltage. If any of the differences exceed prescribed values, the HV control ECU determines that there is a malfunction in the battery voltage circuit. When the HV control ECU detects a malfunction, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F (INF 129): Battery ECU / Voltage (VB) sensor deviation Required sensor / components Battery ECU, boost converter, inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None HV TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Battery ECU Normal HV–182 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM Battery ECU (+) Service Plug Grip L-O 17 B12 VBB10 LG-R 7 B12 VBB9 O O High Voltage Fuse (-) A090438E01 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–183 Result: DTCs listed in the table below are output DTC No. INF Code Detection Item See Page P0ADC 226 Hybrid Battery Positive Contactor Control Circuit High HV-439 P0ADB 227 Hybrid Battery Positive Contactor Control Circuit Low HV-439 P0AE0 228 Hybrid Battery Negative Contactor Control Circuit High HV-441 P0ADF 229 Hybrid Battery Negative Contactor Control Circuit Low HV-441 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 3 INSPECT SERVICE PLUG GRIP A081749E01 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Measure the resistance between the terminals of the service plug grip. Standard resistance: Below 1 Ω NG Go to step 5 OK 4 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the battery plug (see page HB-113). (c) Measure the resistance between the terminals of the battery plug. Standard resistance A B D C A093184E01 Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (d) Reinstall the battery plug (see page HB-114). (e) Reinstall the HV battery assembly (see page HB-96). HV HV–184 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPLACE BATTERY PLUG OK REPLACE BATTERY ECU ASSEMBLY 5 INSPECT HIGH VOLTAGE FUSE CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the high voltage fuse (see page HB-154). HINT: The high voltage fuse is enclosed in the service plug grip. (b) Measure the resistance between the terminals of the high voltage fuse. Standard resistance: Below 1 Ω (c) Reinstall the high voltage fuse (see page HB-154). A057824E01 OK REPLACE SERVICE PLUG GRIP HV NG REPLACE HIGH VOLTAGE FUSE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1F593 HV–185 Battery Energy Control Module DESCRIPTION The battery ECU transmits information on the IG2 voltage of the battery ECU to the HV control ECU via CAN communication. DTC No. INF Code DTC Detection Condition Trouble Area P0A1F 593 IG2 signal circuit of battery ECU malfunction • • Wire harness or connector Battery ECU MONITOR DESCRIPTION When the IG2 voltage of the battery ECU, which is transmitted while the power switch is ON (IG), is low, the HV control ECU determines that a wiring malfunction has occurred at the IG2 terminal of the battery ECU. When the HV control ECU detects the malfunction, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F (INF 593): IG2 signal malfunction Required sensor / components Battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Following conditions are met: (a) and (b) (a) IG2 signal status at HV control ECU ON (b) IG2 signal status from battery ECU OFF COMPONENT OPERATING RANGE Battery ECU DTC P0A1F (INF 593) is not detected HV HV–186 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM Driver Side Junction Block B 4 1J B 1 6 4I 6 4G 7.5 A IGN 21 1E 2 A J2 J/C A W V 1 IA3 13 B11 IG2 O 15 1F IA1 W No. 1 Center Connector Battery ECU O 22 ID3 O V W 1 3A 1 3K 2 1 1 B F15 Fusible 1 BE1 Link Block HV 3I B 3 3I Engine Room W W-B Relay Block 4 IA1 1 4J 13 4E 1 4G 5 4K 35 IG2D No. 1 Center Connector HV Control ECU V O 7 H14 IGSW P6 Power Source Control ECU EF 3 4I 5 4J Auxiliary Battery 4 4G 3I W 120 A MAIN 1 4I IG2 2 1 3M 1 2 15 A AM2 60 A P/I 1 4 3I O AM2 No. 1 Center Connector 12 W A092097E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–187 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (BATTERY ECU - IGN FUSE) (a) Disconnect the B11 battery ECU connector. B11 Battery ECU Connector IG2 A092033E01 Driver Side Junction Block: IGN fuse (b) Remove the IGN fuse from the driver side junction block. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition IG2 (B11-13) - IGN fuse (2) Below 1 Ω Standard resistance (Check for short) A092034E01 Tester Connection Specified Condition IG2 (B11-13) or IGN fuse (2) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the IGN fuse. (e) Reconnect the battery ECU connector. NG OK REPLACE BATTERY ECU ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–188 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A2B248 Drive Motor "A" Temperature Sensor Circuit Range / Performance DTC P0A2B250 Drive Motor "A" Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P0A2C (INF 247) (see page HV-187). DTC No. INF Code DTC Detection Condition Trouble Area P0A2B 248 No. 1 motor temperature sensor malfunction • Hybrid vehicle motor P0A2B 250 No. 1 motor temperature sensor performance problem • Hybrid vehicle motor INSPECTION PROCEDURE If the information (INF) code 248 or 250 is present, replace the hybrid vehicle motor. HINT: The No. 1 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. 1 REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NEXT HV COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–189 DTC P0A2C247 Drive Motor "A" Temperature Sensor Circuit Low DTC P0A2D249 Drive Motor "A" Temperature Sensor Circuit High DESCRIPTION Resistance kΩ (50) (59) (68) (77) (86) (95)(104) Temperature °C (°F) A092300E01 The resistance of the thermistor, which is enclosed in the No. 1 motor temperature sensor, changes in accordance with the changes in the temperature of the motor. The lower the motor temperature, the higher the resistance of the thermistor. Conversely, the higher the temperature, the lower the resistance. The No. 1 motor temperature sensor is connected to the HV control ECU. The power voltage of 5 V is supplied from the MMT terminal of the HV control ECU to the No. 1 motor temperature sensor via resistor R. Because resistor R and the No. 1 motor temperature sensor are connected in series, the resistance changes with the changes in temperature of the motor, which causes the MMT terminal voltage to also change. Based on this signal, the HV control ECU limits the load in order to prevent the motor from overheating. Furthermore, the HV control ECU checks the No. 1 motor temperature sensor for a wiring malfunction and the sensor for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A2C 247 GND short in No. 1 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A2D 249 Open or +B short in No. 1 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU HINT: After confirming DTC P0A2C (INF 247) or P0A2D (INF 249), confirm MOTOR 1 TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction 50°C (-58°F) Open or +B short circuit 205°C (401°F) GND short circuit HV HV–190 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU No. 2 Motor Generator MMT 1 M10 B 18 MMT H17 MMTG 4 M10 R 28 MMTG H17 No. 1 Motor Temperature Sensor R A092299E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (MOTOR 1 TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 1 TEMP value. HV Result: Temperature Displayed Proceed 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 an open or +B short circuit, the intelligent tester indicates -50°C (-58°F). • If there is a GND short circuit, the intelligent tester indicates 205°C (401°F). B C A Go to step 5 CHECK FOR INTERMITTENT PROBLEMS HV–191 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY (CHECK FOR OPEN OR +B SHORT) No. 1 Motor Temperature Sensor HV Control ECU (a) Disconnect the M10 No. 1 motor temperature sensor connector. (b) Turn the power switch ON (IG). MMT MMTG A092038E01 (c) Measure the voltage between the terminals of the No. 1 motor temperature sensor connector. Result: Wire Harness Side: M10 MTT (+) MMTG (-) No. 1 Motor Temperature Sensor Connector Tester Connection Voltage Proceed to MMT (M10-1) - MMTG (M10-4) Approximately 5 V A MMT (M10-1) - MMTG (M10-4) 9 to 14 V B MMT (M10-1) - MMTG (M10-4) Approximately 0 V C A092036E01 HINT: The No. 1 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. (d) Reconnect the No. 1 motor temperature sensor connector. A C REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Go to step 4 B 3 CHECK HARNESS AND CONNECTOR (CHECK FOR +B SHORT) (a) Disconnect the H17 HV control ECU connector. H17 HV Control ECU Connector A065743E71 HV HV–192 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the M10 No. 1 motor temperature sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the No. 1 motor temperature sensor connector and body ground. Standard voltage Wire Harness Side: M10 MMT (+) No. 1 Motor Temperature Sensor Connector A092036E02 Tester Connection Specified Condition MMT (M10-1) - Body ground Approximately 0 V (e) Reconnect the HV control ECU connector. (f) Reconnect the No. 1 motor temperature sensor connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HYBRID VEHICLE CONTROL ECU 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN HYBRID VEHICLE CONTROL ECU) No. 1 Motor Temperature Sensor HV Control ECU (a) Disconnect the M10 No. 1 motor temperature sensor connector. MMT HV MMTG A092037E01 H17 MMT MMTG HV Control ECU Connector A093719E07 (b) Connect terminals MMT and MMTG of the H17 HV control ECU connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 1 TEMP value. OK: 205°C (401°F) HINT: If the intelligent tester indicates a temperature of -50°C (58°F), check the connection of the HV control ECU. If it is connected normally, replace the HV control ECU. (f) Reconnect the No. 1 motor temperature sensor connector. NG REPLACE HYBRID VEHICLE CONTROL ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–193 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN WIRE HARNESS) No. 1 Motor Temperature Sensor HV Control ECU MMT MMTG A092038E01 (a) Disconnect the M10 No. 1 motor temperature sensor connector. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 1 TEMP value. OK: -50°C (-58°F) (e) Reconnect the No. 1 motor temperature sensor connector. HINT: The No. 1 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. OK REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NG 6 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H17 HV control ECU connector. H17 HV Control ECU Connector A065743E72 No. 1 Motor Temperature HV Control ECU Sensor MMT MMTG (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 1 TEMP value. OK: -50°C (-58°F) (e) Reconnect the HV control ECU connector. NG A092039E01 REPLACE HYBRID VEHICLE CONTROL ECU HV HV–194 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A37258 HV–195 Generator Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P0A38 (INF 257) (see page HV-195). DTC No. INF Code DTC Detection Condition Trouble Area P0A37 258 No. 2 motor temperature sensor malfunction • Hybrid vehicle motor INSPECTION PROCEDURE If the information (INF) code 258 is present, replace the hybrid vehicle motor. HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. 1 REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NEXT COMPLETED HV HV–196 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A37260 Generator Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P0A38 (INF 257) (see page HV-195). DTC No. INF Code DTC Detection Condition Trouble Area P0A37 260 No. 2 motor temperature sensor performance problem • • • Hybrid vehicle motor Transaxle fluid leakage HV transaxle assembly INSPECTION PROCEDURE 1 CHECK TRANSAXLE FLUID LEVEL (a) Check if the transaxle is filled with fluid to the specified level. OK: The transaxle is filled with fluid to the specified level HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. NG OK HV REPLACE HYBRID VEHICLE MOTOR ASSEMBLY REPAIR OIL LEAKAGE, OR REPLACE HYBRID VEHICLE TRANSAXLE HV–197 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A38257 Generator Temperature Sensor Circuit Low DTC P0A39259 Generator Temperature Sensor Circuit High DESCRIPTION The No. 2 motor temperature sensor detects the temperature of the transaxle fluid. The resistance of the thermistor installed in the No. 2 motor temperature sensor varies with the changes in the transaxle fluid temperature. The construction in the No. 2 motor temperature sensor and how it is connected to the HV control ECU are the same as those of the No. 1 motor temperature sensor (see page HV-187). Based on the signal provided by the No. 2 motor temperature sensor, the HV control ECU limits the load to prevent the motor from overheating. Furthermore, the HV control ECU checks the No. 2 motor temperature sensor for a wiring malfunction and the sensor for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A38 257 GND short in No. 2 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A39 259 Open or +B short in No. 2 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU HINT: After confirming DTC P0A38 (INF 257) or P0A39 (INF 259), confirm MOTOR 2 TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction -50°C (-58°F) Open or +B short circuit 205°C (401°F) GND short circuit HV WIRING DIAGRAM No. 2 Motor Generator HV Control ECU OMT 3 M10 B 30 OMT H17 OMTG 6 M10 G 29 OMTG H17 R No. 2 Motor Temperature Sensor A092299E02 HV–198 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (MOTOR 2 TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 2 TEMP value. Result: Temperature Displayed Proceed 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 an open or +B short circuit, the intelligent tester indicates -50°C (-58°F). • If there is a GND short circuit, the intelligent tester indicates 205°C (401°F). B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS A 2 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY (CHECK FOR OPEN OR +B SHORT) HV No. 2 Motor Temperature Sensor HV Control ECU (a) Disconnect the M10 No. 2 motor temperature sensor connector. (b) Turn the power switch ON (IG). OMT OMTG A092038E02 (c) Measure the voltage between the terminals of the No. 2 motor temperature sensor connector. Result: Wire Harness Side: M10 OMT (+) OMTG (-) No. 2 Motor Temperature Sensor Connector A092036E03 Tester Connection Voltage Proceed to OMT (M10-3) - OMTG (M10-6) Approximately 5 V A OMT (M10-3) - OMTG (M10-6) 9 to 14 V B OMT (M10-3) - OMTG (M10-6) Approximately 0 V C P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–199 HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. (d) Reconnect the No. 2 motor temperature sensor connector. A REPLACE HYBRID VEHICLE MOTOR ASSEMBLY C Go to step 4 B 3 CHECK HARNESS AND CONNECTOR (CHECK FOR +B SHORT) (a) Disconnect the H17 HV control ECU connector. H17 HV Control ECU Connector A065743E71 Wire Harness Side: M10 OMT (+) No. 2 Motor Temperature Sensor Connector A092036E04 (b) Disconnect the M10 No. 2 motor temperature sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the No. 2 motor temperature sensor connector and body ground. Standard voltage Tester Connection Specified Condition OMT (M10-3) - Body ground Approximately 0 V (e) Reconnect the HV control ECU connector. (f) Reconnect the No. 2 motor temperature sensor connector. NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–200 4 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN HYBRID VEHICLE CONTROL ECU) No. 2 Motor Temperature Sensor HV Control ECU (a) Disconnect the M10 No. 2 motor temperature sensor connector. OMT OMTG A092037E02 H17 OMTG OMT HV Control ECU Connector A093719E08 HV (b) Connect terminals OMT and OMTG of the H17 HV control ECU connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 2 TEMP value. OK: 205°C (401°F) HINT: If the intelligent tester indicates a temperature of -50°C (58°F), check the connection of the HV control ECU. If it is connected normally, replace the HV control ECU. (f) Reconnect the No. 2 motor temperature sensor connector. NG REPLACE HYBRID VEHICLE CONTROL ECU OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN WIRE HARNESS) No. 2 Motor Temperature HV Control ECU Sensor OMT OMTG A092038E02 (a) Disconnect the M10 No. 2 motor temperature sensor connector. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 2 TEMP value. OK: -50°C (-58°F) (e) Reconnect the No. 2 motor temperature sensor connector. HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK HV–201 REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NG 6 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H17 HV control ECU connector. (b) Turn the power switch ON (IG). H17 HV Control ECU Connector A065743E72 No. 2 Motor Temperature HV Control ECU Sensor OMT OMTG (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 2 TEMP value. OK: -50°C (-58°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A092039E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–202 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A3F243 Drive Motor "A" Position Sensor Circuit DTC P0A40500 Drive Motor "A" Position Sensor Circuit Range / Performance DTC P0A41245 Drive Motor "A" Position Sensor Circuit Low DESCRIPTION The motor resolver is a type of sensor that detects the position of the magnetic poles, which are indispensable for ensuring the highly efficient control of the MG1 and MG2. The stator of the resolver contains an excitation coil and two detection coils. Because the rotor has an oval shape, the gap between the stator and the rotor changes as the rotor turns. An alternating current with a predetermined frequency flows through the excitation coil, and detection coils S and C output alternating currents in accordance with the position of the sensor rotor. The HV control ECU detects the absolute position of the rotor in accordance with the phases of detection coils S and C and the height of their waveform. Furthermore, the CPU calculates the amount of change in the position within a predetermined length of time, in order to use the resolver as a speed sensor. Rotor -S -C +C +S HV Excitation Waveform +S +C -S S Output C Waveform -C Excitation Coil A093727E01 The HV control ECU monitors the output signals of the motor resolver and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A3F 243 Interphase short in motor resolver circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A40 500 Motor resolver output is out of normal range • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A41 245 Open or short in motor resolver circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the motor resolver output signal. If the HV control ECU detects output signals that are out of the normal range or specification, it will conclude that there is a malfunction of the motor resolver. The HV control ECU will illuminate the MIL and set a DTC. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–203 MONITOR STRATEGY Related DTCs P0A3F (INF 243): Drive motor "A" position sensor circuit malfunction / Short circuit between phases P0A40 (INF 500): Drive motor "A" position sensor circuit malfunction / Range check P0A41(INF 245): Drive motor "A" position sensor circuit malfunction / Circuit discontinuity or short circuit Required sensor / components Motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor resolver Circuit malfunction (interphase shot, open or short), or abnormal output COMPONENT OPERATING RANGE Motor resolver DTCs P0A3F (INF 243), P0A40 (INF 500) and P0A41 (INF 245) are not detected HV HV–204 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU No. 2 Motor Generator MRF MRFG MSN * 1 M9 4 M9 * 2 M9 5 M9 MSNG MCS * 3 M9 6 MCSG M9 *: Shielded B J12 J/C W-B W-B B 8 W-B EB1 B L 34 H17 P 33 H17 MRFG G 20 H17 R 19 H17 MSNG Y 32 H17 BR 31 H17 MCSG MRF MSN MCS W-B EF A092098E01 HV INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MOTOR RESOLVER) (a) Disconnect the H17 HV control ECU connector. H17 MSN MRF MRFG MSNG HV Control ECU MCSG Connector MCS A065743E73 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the M9 motor resolver connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: M9 MRF MSN MRFG MCS MCSG MSNG HV–205 Motor Resolver Connector Tester Connection Specified Condition MRF (H17-34) - Body ground Below 1 V MRFG (H17-33) - Body ground Below 1 V MSN (H17-20) - Body ground Below 1 V MSNG (H17-19) - Body ground Below 1 V MCS (H17-32) - Body ground Below 1 V MCSG (H17-31) - Body ground Below 1 V A092036E05 (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MRF (H17-34) - MRF (M9-1) Below 1 Ω MRFG (H17-33) - MRFG (M9-4) Below 1 Ω MSN (H17-20) - MSN (M9-2) Below 1 Ω MSNG (H17-19) - MSNG (M9-5) Below 1 Ω MCS (H17-32) - MCS (M9-3) Below 1 Ω MCSG (H17-31) - MCSG (M9-6) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MRF (H17-34) or MRF (M9-1) - Body ground 10 kΩ or higher MRFG (H17-33) or MRFG (M9-4) Body ground 10 kΩ or higher MSN (H17-20) or MSN (M9-2) - Body ground 10 kΩ or higher MSNG (H17-19) or MSNG (M9-5) Body ground 10 kΩ or higher MCS (H17-32) or MCS (M9-3) - Body ground 10 kΩ or higher MCSG (H17-31) or MCSG (M9-6) Body ground 10 kΩ or higher (g) Reconnect the motor resolver connector. (h) Reconnect the HV control ECU connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–206 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT MOTOR RESOLVER Motor Resolver MSN MRF MCS MCSG MSNG MRFG A092040E01 (a) Disconnect the M9 motor resolver connector. (b) Measure the resistance between the terminals of the motor resolver. Standard resistance Tester Connection Specified Condition MRF (M9-1) - MRFG (M9-4) 7.65 to 10.2 Ω MSN (M9-2) - MSNG (M9-5) 12.6 to 16.8 Ω MCS (M9-3) - MCSG (M9-6) 12.6 to 16.8 Ω (c) Using a megohmmeter, measure the insulation resistance between the terminals of the motor resolver. Standard resistance Tester Connection Specified Condition MRF (M9-1) - MSN (M9-2) 10 MΩ or higher MRF (M9-1) - MCS (M9-3) 10 MΩ or higher MSN (M9-2) - MCS (M9-3) 10 MΩ or higher MRFG (M9-4) - MSNG (M9-5) 10 MΩ or higher MRFG (M9-4) - MCSG (M9-6) 10 MΩ or higher MSNG (M9-5) - MCSG (M9-6) 10 MΩ or higher Each terminal listed above Transaxle housing 10 MΩ or higher NG HV OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE HYBRID VEHICLE MOTOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–207 DTC P0A4B253 Generator Position Sensor Circuit DTC P0A4C513 Generator Position Sensor Circuit Range / Performance DTC P0A4D255 Generator Position Sensor Circuit Low DESCRIPTION The generator resolver detects the position of the magnetic poles, which are indispensable for ensuring the highly efficient control of the MG1 and MG2. The construction of the generator resolver and how it is connected to the HV control ECU are the same as those of the motor resolver (see page HV-200). DTC No. INF Code DTC Detection Condition Trouble Area P0A4B 253 Interphase short in generator resolver circuit • • • Wire harness or connector Hybrid vehicle generator HV control ECU P0A4C 513 Generator resolver output is out of normal range • • • Wire harness or connector Hybrid vehicle generator HV control ECU P0A4D 255 Open or short in generator resolver circuit • • • Wire harness or connector Hybrid vehicle generator HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the generator resolver output signal. If the HV control ECU detects output signals that are out of the normal range or specification, it will conclude that there is a malfunction of the generator resolver. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A4B (INF 253): Generator position sensor circuit malfunction / Short circuit between phases P0A4C (INF 513): Generator position sensor circuit malfunction / Range check P0A4D (INF 255): Generator position sensor circuit malfunction / Circuit discontinuity or short circuit Required sensor / components Generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV HV–208 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Generator resolver Circuit malfunction (interphase shot, open or short), or abnormal output COMPONENT OPERATING RANGE Generator resolver DTCs P0A4B (INF 253) P0A4C (INF 513) and P0A4D (INF 255) are not detected WIRING DIAGRAM No. 1 Motor Generator GRF GRFG GSN HV Control ECU * 3 M5 6 M5 * 2 M5 5 M5 GSNG GCS * 1 M5 4 GCSG M5 HV *: Shielded J12 J/C B W-B W-B B 8 W-B EB1 B B 27 H17 W 26 H17 GRFG R 22 H17 G 21 H17 GSNG Y 23 H17 BR 24 H17 GCSG GRF GSN GCS W-B EF A092098E02 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–209 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - GENERATOR RESOLVER) (a) Disconnect the H17 HV control ECU connector. H17 GCSG GRF GRFG GSNG HV Control ECU GSN Connector GCS A065743E74 (b) Disconnect the M5 generator resolver connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: M5 GCS GSN GCSG GRF GRFG GSNG Generator Resolver Connector Tester Connection Specified Condition GRF (H17-27) - Body ground Below 1 V GRFG (H17-26) - Body ground Below 1 V GSN (H17-22) - Body ground Below 1 V GSNG (H17-21) - Body ground Below 1 V GCS (H17-23) - Body ground Below 1 V GCSG (H17-24) - Body ground Below 1 V A092036E06 (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GRF (H17-27) - GRF (M5-3) Below 1 Ω GRFG (H17-26) - GRFG (M5-6) Below 1 Ω GSN (H17-22) - GSN (M5-2) Below 1 Ω GSNG (H17-21) - GSNG (M5-5) Below 1 Ω GCS (H17-23) - GCS (M5-1) Below 1 Ω GCSG (H17-24) - GCSG (M5-4) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GRF (H17-27) or GRF (M5-3) - Body ground 10 kΩ or higher GRFG (H17-26) or GRFG (M5-6) Body ground 10 kΩ or higher GSN (H17-22) or GSN (M5-2) - Body ground 10 kΩ or higher GSNG (H17-21) or GSNG (M5-5) Body ground 10 kΩ or higher GCS (H17-23) or GCS (M5-1) - Body ground 10 kΩ or higher HV HV–210 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition GCSG (H17-24) or GCSG (M5-4) Body ground 10 kΩ or higher (g) Reconnect the generator resolver connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 INSPECT GENERATOR RESOLVER Generator Resolver GSN GRF GRFG HV GCS GSNG GCSG A092040E02 (a) Disconnect the M5 generator resolver connector. (b) Measure the resistance between the terminals of the generator resolver. Standard resistance Tester Connection Specified Condition GCS (M5-1) - GCSG (M5-4) 12.6 to 16.8 Ω GSN (M5-2) - GSNG (M5-5) 12.6 to 16.8 Ω GRF (M5-3) - GRFG (M5-6) 7.65 to 10.2 Ω (c) Using a megohmmeter, measure the insulation resistance between the terminals of the generator resolver. Standard resistance Tester Connection Specified Condition GCS (M5-1) - GSN (M5-2) 10 MΩ or higher GCS (M5-1) - GRF (M5-3) 10 MΩ or higher GSN (M5-2) - GRF (M5-3) 10 MΩ or higher GCSG (M5-4) - GSNG (M5-5) 10 MΩ or higher GCSG (M5-4) - GRFG (M5-6) 10 MΩ or higher GSNG (M5-5) - GRFG (M5-6) 10 MΩ or higher Each terminal listed above Transaxle housing 10 MΩ or higher NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A51174 HV–211 Drive Motor "A" Current Sensor Circuit DESCRIPTION The HV control performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A51 174 HV control ECU internal error • HV control ECU INSPECTION PROCEDURE If the information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–212 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A60288 Drive Motor "A" Phase V Current DTC P0A60289 Drive Motor "A" Phase V Current DTC P0A60290 Drive Motor "A" Phase V Current DTC P0A60292 Drive Motor "A" Phase V Current DTC P0A60294 Drive Motor "A" Phase V Current DTC P0A60501 Drive Motor "A" Phase V Current DTC P0A63296 Drive Motor "A" Phase W Current DTC P0A63297 Drive Motor "A" Phase W Current DTC P0A63298 Drive Motor "A" Phase W Current DTC P0A63300 Drive Motor "A" Phase W Current DTC P0A63302 Drive Motor "A" Phase W Current DTC P0A63502 Drive Motor "A" Phase W Current HV DESCRIPTION See the description of the inverter (see page HV-220). The motor inverter current sensors detect the amperage that flows through the V and W phase cables between the inverter and MG1/MG2. The inverter transmits information that is necessary for effecting control, such as the amperage and voltage, to the HV control ECU. The HV control ECU monitors the inverter current sensors to detect a malfunction in the sensor system. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–213 It does not detect malfunctions in the high voltage system. DTC No. INF Code DTC Detection Condition Trouble Area P0A60 288 Phase V current sub sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A60 289 Open in phase V current sub sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A60 290 Phase V current main sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A60 292 Open in phase V current main sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A60 294 Phase V current main and sub sensors of motor inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A60 501 Phase V current main and sub sensors of motor inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly P0A63 296 Phase W current sub sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A63 297 Open in phase W current sub sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A63 298 Phase W current main sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A63 300 Open in phase W current main sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A63 302 Phase W current main and sub sensors of motor inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A63 502 Phase W current main and sub sensors of motor inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor inverter current sensor. If the HV control ECU detects a fault, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A60 (INF 288 / 289 / 290 / 292 / 294 / 501): Motor inverter current sensor / Phase V current sensor malfunction P0A63 (INF 296 / 297 / 298 / 300 / 302 / 502): Motor inverter current sensor / Phase W current sensor malfunction Required sensor / components Motor inverter current sensor, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property HV HV–214 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE P0A60 (INF 288 / 289 / 290 / 292 / 294 / 501): Motor inverter current sensor DTC P0A60 (INF 288 / 289 / 290 / 292 / 294 / 501) is not detected P0A63 (INF 296 / 297 / 298 / 300 / 302 / 502): Motor inverter current sensor DTC P0A63 (INF 296 / 297 / 298 / 300 / 302 / 502) is not detected WIRING DIAGRAM HV Control ECU Inverter 7 MIVA I10 HV * G 30 H15 MIVA 8 MIVB I10 W 21 H15 MIVB 23 MIWA I10 R 29 H15 MIWA 24 MIWB I10 B 20 H15 MIWB 16 GINV I10 Y *: Shielded J5 J/C * A 23 H15 GINV A IK A092099E01 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–215 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 MIWB MIWA MIVA HV Control ECU Connector GINV MIVB A065744E27 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: I10 MIVA MIVB GINV I10 MIWA Inverter Connector MIWB A092041E07 Tester Connection Specified Condition MIVA (H15-30) - Body ground Below 1 V MIVB (H15-21) - Body ground Below 1 V MIWA (H15-29) - Body ground Below 1 V MIWB (H15-20) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MIVA (H15-30) - MIVA (I10-7) Below 1 Ω MIVB (H15-21) - MIVB (I10-8) Below 1 Ω MIWA (H15-29) - MIWA (I10-23) Below 1 Ω MIWB (H15-20) - MIWB (I10-24) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) HV HV–216 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition MIVA (H15-30) or MIVA (I10-7) - Body ground 10 kΩ or higher MIVB (H15-21) or MIVB (I10-8) - Body ground 10 kΩ or higher MIWA (H15-29) or MIWA (I10-23) Body ground 10 kΩ or higher MIWB (H15-20) or MIWB (I10-24) Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A72326 Generator Phase V Current DTC P0A72327 Generator Phase V Current DTC P0A72328 Generator Phase V Current DTC P0A72330 Generator Phase V Current DTC P0A72333 Generator Phase V Current DTC P0A72515 Generator Phase V Current DTC P0A75334 Generator Phase W Current DTC P0A75335 Generator Phase W Current DTC P0A75336 Generator Phase W Current DTC P0A75338 Generator Phase W Current DTC P0A75341 Generator Phase W Current DTC P0A75516 Generator Phase W Current HV–217 HV DESCRIPTION Refer to DTC P0A60 (INF 288) (see page HV-210). DTC No. INF Code DTC Detection Condition Trouble Area P0A72 326 Phase V current sub sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly HV–218 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area P0A72 327 Open in phase V current sub sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A72 328 Phase V current main sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A72 330 Open in phase V current main sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A72 333 Phase V current main and sub sensors of generator inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A72 515 Phase V current main and sub sensors of generator inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly P0A75 334 Phase W current sub sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A75 335 Open in phase W current sub sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A75 336 Phase W current main sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A75 338 Open in phase W current main sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A75 341 Phase W current main and sub sensors of generator inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A75 516 Phase W current main and sub sensors of generator inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly HV MONITOR DESCRIPTION The HV control ECU monitors the generator inverter current sensor. If the HV control ECU detects a fault, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A72 (INF 326 / 327 / 328 / 330 / 333 / 515): Generator inverter current sensor / Phase V current sensor malfunction P0A75 (INF 334 / 335 / 336 / 338 / 341 / 516): Generator inverter current sensor / Phase W current sensor malfunction Required sensor / components Generator inverter current sensor, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–219 TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE P0A72 (INF 326 / 327 / 328 / 330 / 333 / 515): Generator inverter current sensor DTC P0A72 (INF 326 / 327 / 328 / 330 / 333 / 515) is not detected P0A75 (INF 334 / 335 / 336 / 338 / 341 / 516): Generator inverter current sensor DTC P0A75 (INF 334 / 335 / 336 / 338 / 341 / 516) is not detected WIRING DIAGRAM HV Control ECU Inverter 2 I10 * W 3 GIVB I10 B 33 H15 GIVB 18 GIWA I10 R 32 H15 GIWA 19 GIWB I10 G 31 H15 GIWB 16 GINV I10 Y GIVA *: Shielded J5 J/C 34 H15 GIVA * A 23 H15 GINV A HV IK A092099E03 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) NOTICE: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. HV–220 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GIVA GINV GIVB GIWA GIWB HV Control ECU Connector A065744E44 Wire Harness Side I10 Inverter Connector GIVB GIVA GINV I10 HV GIWA GIWB A092041E31 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GIVA (H15-34) - Body ground Below 1 V GIVB (H15-33) - Body ground Below 1 V GIWA (H15-32) - Body ground Below 1 V GIWB (H15-31) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GIVA (H15-34) - GIVA (I10-2) Below 1 Ω GIVB (H15-33) - GIVB (I10-3) Below 1 Ω GIWA (H15-32) - GIWA (I10-18) Below 1 Ω GIWB (H15-31) - GIWB (I10-19) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GIVA (H15-34) or GIVA (I10-2) - Body ground 10 kΩ or higher GIVB (H15-33) or GIVB (I10-3) - Body ground 10 kΩ or higher GIWA (H15-32) or GIWA (I10-18) Body ground 10 kΩ or higher GIWB (H15-31) or GIWB (I10-19) Body ground 10 kΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher HV–221 (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–222 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78266 Drive Motor "A" Inverter Performance DTC P0A78267 Drive Motor "A" Inverter Performance DESCRIPTION The inverter converts the high-voltage direct current of the HV battery and the alternating current for the MG1/MG2. The inverter contains a three-phase bridge circuit, which consists of 6 power transistors each for the MG1 and the MG2, in order to convert the direct current and the three-phase alternating current. The HV control ECU controls the actuation of the power transistors. The inverter transmits information that is necessary for effecting control, such as the amperage and voltage, to the HV control ECU. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MG1 MG2 U V W U V W Amperage Sensor HV–223 Amperage Sensor Power Transistor HV Control ECU IPM for Driving Interlock Switch HV Inverter IPM for Boosting DC / DC Converter Reactor A/C Inverter Boost Converter Inverter with Converter Assembly HV Battery A093740E02 HV–224 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The HV control ECU uses a voltage sensor, which has been built into the inverter, to detect the high voltage after boost control. Output Voltage (V) 5.0 4.0 3.0 2.0 1.0 0 100 200 300 400 500 600 700 High-Voltage (V) A125422E01 The inverter voltage sensor outputs a voltage that varies between 0 and 5 V in accordance with the changes in the high voltage. The higher the high voltage, the higher the output voltage, and the lower the high voltage, the lower the output voltage. The HV control ECU monitors the inverter voltage and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 266 Open or GND short in inverter voltage (VH) sensor circuit • • • P0A78 267 +B short in inverter voltage (VH) sensor circuit • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HV HINT: After confirming DTC P0A78 (INF 266 or 267), confirm VH in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Voltage Displayed Malfunction 765 V +B short circuit 0V Open or GND short circuit MONITOR DESCRIPTION The HV control ECU monitors the inverter voltage (VH) sensor circuit. If the HV control ECU detects an open or short malfunction of the VH sensor circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 266 / 267): Motor inverter / VH malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–225 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Voltage (VH) sensor circuit Open or short COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 266 / 267) is not detected WIRING DIAGRAM (Shielded) Inverter HV Control ECU 12 I10 Y 16 GINV I10 Y VH 26 H15 VH (Shielded) J5 J/C A 23 H15 GINV A IK A092100E03 HV INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D is output HV–226 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES GO TO RELEVANT DTC CHART NO 2 READ VALUE OF INTELLIGENT TESTER (VH) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the VH value. Result: Voltage Displayed Proceed to 765 V A 0V B 1 to 764 V C HINT: • If there is a +B short circuit, the intelligent tester indicates 765 V. • If there is an open or GND short circuit, the intelligent tester indicates 0 V. B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS A HV 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–227 (d) Disconnect the I10 inverter connector. Wire Harness Side I10 VH GINV I10 Inverter Connector A092041E35 Inverter Voltage Sensor HV Control ECU VH GINV A125426E01 (e) 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. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the VH value. Standard voltage: 0V (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H15 HV control ECU connector. H15 HV Control ECU Connector VH GINV A065744E45 HV HV–228 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Inverter Voltage Sensor HV Control ECU VH GINV (b) 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. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the VH value. Standard voltage: 0V (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. HV H15 HV Control ECU Connector VH GINV A065744E45 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side I10 (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection VH Inverter Connector A092041E35 Specified Condition VH (H15-26) - VH (I10-12) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) GINV I10 HV–229 Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 INSPECT HYBRID VEHICLE CONTROL ECU (VH VOLTAGE) (a) Turn the power switch ON (READY). 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. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage H15 VH (+) GINV (-) HV Control ECU Connector A124045E16 Tester Connection Specified Condition VH (H15-26) - GINV (H15-23) 1.6 to 3.8 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–230 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78272 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). The inverter switches the power transistors ON and OFF in accordance with power transistor actuation signals received from the HV control ECU, in order to change the direction of the current that flows through the MG1/MG2. Also, the inverter regulates the duration of the switching time through PWM (Pulse Width Modulation) control, in order to control the voltage that is applied to the MG1/MG2. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 272 Abnormality in motor PWM circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor PWM circuit. If there is an error in the power transistor actuation signals which are transmitted to the inverter, the HV control ECU interprets this as a malfunction of the motor PWM circuit. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 272): Motor PWM malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None HV TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Power transistor actuation signal Abnormal COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 272) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–231 WIRING DIAGRAM Inverter HV Control ECU (Shielded) 11 MWU I10 R 11 H15 MWU 9 MUU I10 B 9 H15 MUU 10 MVU I10 W 10 H15 MVU A J5 J/C IK A092101E04 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D is output YES NO GO TO RELEVANT DTC CHART HV HV–232 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 MUU MVU MWU HV Control ECU Connector A065744E46 Wire Harness Side: I10 HV MUU MVU MWU (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MUU (H15-9) - MUU (I10-9) Below 1 Ω MVU (H15-10) - MVU (I10-10) Below 1 Ω MWU (H15-11) - MWU (I10-11) Below 1 Ω Standard resistance (Check for short) I10 Inverter Connector A092041E36 Tester Connection Specified Condition MUU (H15-9) or MUU (I10-9) - Body ground 10 kΩ or higher MVU (H15-10) or MVU (I10-10) - Body ground 10 kΩ or higher MWU (H15-11) or MWU (I10-11) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78278 Drive Motor "A" Inverter Performance DTC P0A78280 Drive Motor "A" Inverter Performance HV–233 DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter detects a circuit malfunction or over-voltage, the inverter transmits this information to the OVH terminal of the HV control ECU via the motor inverter over-voltage signal line. The HV control ECU monitors the motor inverter over-voltage signal line to detect the malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 278 +B short in motor inverter overvoltage (OVH) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 280 Open or GND short in motor inverter over-voltage (OVH) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor inverter over-voltage (OVH) signal line. If the HV control ECU detects an open or short malfunction of the OVH signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 278 / 280): Motor inverter / Motor inverter Sinv detection Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Over-voltage signal circuit Open or short COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 278 / 280) is not detected HV HV–234 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter 28 I10 OVH 22 H15 OVH BR (Shielded) 16 GINV I10 23 H15 GINV Y A J5 J/C IK A092102E06 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GINV OVH HV Control ECU Connector A065744E47 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 GINV I10 Inverter Connector OVH A092041E37 HV–235 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition OVH (H15-22) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition OVH (H15-22) - OVH (I10-28) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition OVH (H15-22) or OVH (I10-28) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–236 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78279 Drive Motor "A" Inverter Performance DTC P0A78503 Drive Motor "A" Inverter Performance DTC P0A78504 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter detects a circuit malfunction or over-voltage, the inverter transmits this information to the OVH terminal of the HV control ECU via the motor inverter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 279 Motor inverter over-voltage (OVH) signal detection (overvoltage by inverter assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A78 503 Motor inverter over-voltage (OVH) signal detection (overvoltage by HV control ECU malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A78 504 Motor inverter over-voltage (OVH) signal detection (overvoltage by HV transaxle assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly HV MONITOR DESCRIPTION If the motor inverter detects over-voltage, it transmits an over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 279 / 503 / 504): Motor inverter / OVH detection over voltage Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV–237 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Motor inverter Over-voltage COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 279 / 503 / 504) is not detected WIRING DIAGRAM Inverter (Shielded) U V MG1 W U V MG2 W IPM for Driving HV Control ECU 4 GUU I10 B 15 H15 GUU 5 GVU I10 G 14 H15 GVU 6 I10 GWU Y 13 H15 GWU (Shielded) 9 MUU I10 B 9 H15 MUU 10 MVU I10 W 10 H15 MVU 11 MWU I10 R 11 H15 MWU 16 I10 GINV Y 23 H15 GINV A A HV J5 J/C IK A092103E03 HV–238 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CONFIRM INFORMATION (EXCLUSIVE INFO 3) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 279, 503, or 504 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 3. Result: -32 to 32 (during driving without battery power) HINT: If the value is inside the range shown above, DTCs other than P0A78 (INF 279, 503 and 504) have been detected as well. Perform troubleshooting for those DTCs first. HV YES GO TO RELEVANT DTC CHART NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3 HV–239 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E04 OK 4 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both the service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 279, 503, or 504 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result Displayed in Exclusive Information 4 Proceed 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 HV HV–240 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 5 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both the service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output HV DTC No. INF Code Detection Item See Page P0A78 266 Drive Motor "A" Inverter Performance HV-220 P0A94 558 or 560 DC / DC Converter Performance HV-389 P0A94 588 DC / DC Converter Performance HV-409 P0A94 589 DC / DC Converter Performance HV-412 P0ADB 227 Hybrid Battery Positive Contactor Control Circuit Low HV-439 P0ADF 229 Hybrid Battery Negative Contactor Control Circuit Low HV-441 P3000 125 HV Battery Malfunction HV-466 P3004 131 Power Cable Malfunction HV-470 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 6 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Motor: I14 U V W A092045E03 HV–241 (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 7 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. HV HV–242 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Generator: I15 V W U A092046E03 (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance HV Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (f) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–243 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 GUU GVU GWU MUU MVU MWU I10 Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector A093730E07 OK REPLACE HYBRID VEHICLE CONTROL ECU AND INVERTER WITH CONVERTER ASSEMBLY NG 9 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU MUU MVU MWU I10 GINV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) 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. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Inverter Connector A093731E05 Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V HV HV–244 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU HV REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78282 HV–245 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter detects a circuit malfunction or over-voltage, the inverter transmits this information to the OVH terminal of the HV control ECU via the motor inverter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 282 Motor inverter over voltage (OVH) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the motor inverter detects a circuit malfunction, it transmits a motor inverter over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 282): Motor inverter / OVH detection circuit malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor inverter Circuit malfunction COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 282) is not detected HV HV–246 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM B F15 Fusible 1 BE1 Link Block Assembly B 1 120 A MAIN L A W 1 3M Inverter J3 J/C A 1 I9 L 2 I9 GND1 O 1 3A 1 3K 4 3J 2 3J W-B 1 60A P/I 20A HEV HV Control ECU IGCT 2 Auxiliary Battery IGCT Engine Room Relay Block 4 H16 MREL 3 3J W-B EE EF A092104E02 INSPECTION PROCEDURE HV CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in table below is output DTC No. INF Code Detection Item See Page P0A78 278 or 280 Drive Motor "A" Inverter performance HV-231 YES NO GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–247 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. HV HV–248 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) 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. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage I9 Inverter Connector GND1(-) IGCT (+) A093729E03 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78283 Drive Motor "A" Inverter Performance DTC P0A78285 Drive Motor "A" Inverter Performance HV–249 DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits this information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. The HV control ECU monitors the motor inverter fail signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 283 +B short in motor inverter fail (MFIV) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 285 Open or GND short in motor inverter fail (MFIV) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor inverter fail (MFIV) signal line. If the HV control ECU detects an open or short malfunction of the MFIV signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 283 / 285): Motor inverter/Motor inverter Finv detection Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Motor inverter fail signal circuit Open or short COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 283 / 285) is not detected HV HV–250 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter MFIV 27 I10 18 H15 MFIV G (Shielded) 16 GINV I10 23 H15 GINV Y A J5 J/C IK A092102E07 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 HV Control ECU Connector MFIV GINV A065744E48 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 GINV I10 Inverter Connector MFIV A092041E38 HV–251 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition MFIV (H15-18) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MFIV (H15-18) - MFIV (I10-27) Below 1Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MFIV (H15-18) or MFIV (I10-27) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–252 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78284 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 284 Motor inverter fail (MFIV) signal detection (inverter overheating) • • • • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the motor inverter overheats, it transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A78 (INF 284): Motor inverter / MFIV detection over heat Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor inverter Overheated COMPONENT OPERATING RANGE Motor inverter WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). DTC P0A78 (INF 284) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–253 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are 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, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES NO GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART HV HV–254 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 3 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 4 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. HV NG CONNECT SECURELY A090415E04 OK 5 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–255 OK 6 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 7 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 9 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E10 OK CONNECT SECURELY HV HV–256 10 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 11 CONFIRM INFORMATION (EXCLUSIVE INFO 4) HV (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 284 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed 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 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–257 B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 12 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. HV HV–258 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 13 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) HV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 MUU MVU MWU Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. OK I10 REPLACE INVERTER WITH CONVERTER ASSEMBLY GINV Inverter Connector A093730E08 NG 14 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I10 MUU MVU MWU I10 GINV Inverter Connector A093731E06 HV–259 (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: Inverter Connector DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–260 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78286 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 286 Motor inverter fail (MFIV) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the motor inverter detects a circuit malfunction, it transmits a motor inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 286): Motor inverter / MFIV detection circuit malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor inverter Circuit malfunction COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 286) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–261 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A78 283 or 285 Drive Motor "A" Inverter performance HV-247 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HV HV–262 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) 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. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage HV I9 Inverter Connector GND1(-) IGCT (+) A093729E03 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78287 Drive Motor "A" Inverter Performance DTC P0A78505 Drive Motor "A" Inverter Performance DTC P0A78506 Drive Motor "A" Inverter Performance HV–263 DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 287 Motor inverter fail (MFIV) signal detection (over current by inverter assembly malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly P0A78 505 Motor inverter fail (MFIV) signal detection (over current by HV control ECU malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly P0A78 506 Motor inverter fail (MFIV) signal detection (over current by HV transaxle assembly malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If over-amperage flows through the motor inverter due to an internal short, the motor inverter transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 287 / 505 / 506): Motor inverter / MFIV detection over current Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV HV–264 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Motor inverter Over current (internal short) COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 287 / 505 / 506) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output HV 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 P0A4 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, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–265 DTC No. Relevant Diagnosis P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG Inverter Connector A092044E05 OK CONNECT SECURELY HV HV–266 4 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HYBRID VEHICLE MOTOR ASSEMBLY A090458E01 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Check if the three-phase alternating current cable installation bolts on the hybrid vehicle motor are tightened to the specified torque. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Reinstall the inverter cover (see page HV-538). (d) Reinstall the service plug grip (see page HB-154). NG TIGHTEN THEM TO SPECIFIED TORQUE OK 5 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 287, 505, or 506 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. HV Result: Displayed in Exclusive Information 4 Proceed 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 C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–267 A 6 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {(1 + 0.00393 x (T - 20)} Rt: Resistance between measured lines (mΩ) R20: Resistance converted to 20°C (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher HV HV–268 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 7 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 HV MUU MVU MWU Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. OK I10 REPLACE INVERTER WITH CONVERTER ASSEMBLY GINV Inverter Connector A093730E08 NG 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I10 MUU MVU MWU I10 GINV Inverter Connector (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) 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. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection A093731E06 HV–269 Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–270 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78304 Drive Motor "A" Inverter Performance DTC P0A78305 Drive Motor "A" Inverter Performance DTC P0A78507 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a motor gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG2 by turning OFF the power transistors that are actuating the MG2. The HV control ECU monitors the motor gate shutdown signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 304 Open or +B short in motor gate shutdown (MSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 305 GND short in motor gate shutdown (MSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 507 Open in motor gate shutdown (MSDN) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION HV The HV control ECU monitors the motor gate shutdown (MSDN) signal line. If the HV control ECU detects an open or short malfunction of the MSDN signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 304 / 305 / 507): Motor inverter / Motor gate shutdown signal malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Motor gate shutdown signal circuit Open or short P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–271 COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 304 / 305 / 507) is not detected WIRING DIAGRAM HV Control ECU Inverter (Shielded) 25 MSDN I10 G A 8 H15 MSDN J5 J/C IK A092105E04 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. HV HV–272 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). (e) Disconnect the I10 inverter connector. H15 MSDN HV Control ECU Connector Wire Harness Side A065744E28 (f) 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. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage I10 I10 Inverter Connector MSDN Tester Connection Specified Condition MSDN (H15-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) A092041E39 Tester Connection Specified Condition MSDN (H15-8) - MSDN (I10-25) Below 1 Ω Standard resistance (Check for short) HV Tester Connection Specified Condition MSDN (H15-8) or MSDN (I10-25) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78306 HV–273 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). The HV control ECU controls MG2 torque in accordance with the driving condition. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 306 Failure in monitoring MG2 torque performance • • Hybrid vehicle motor Inverter with converter assembly MONITOR DESCRIPTION If the difference between the requested MG2 torque and the actual MG2 torque exceeds a predetermined value, the HV control ECU determines that there is malfunction in the execution or monitoring of the MG2 torque. Then, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 306): Discrepancy between motor monitored torque and commanded torque Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Difference between demanded and actual MG2 torque Exceeds the standard level COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 306) is not detected INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV HV–274 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 306) and other DTCs are output HINT: If any other codes besides P0A78 (INF 306) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY HV Hybrid Vehicle Motor: I14 U V W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–275 T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance (f) Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–276 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78308 Drive Motor "A" Inverter Performance DESCRIPTION The HV control ECU receives a collision signal from the center airbag sensor and the No. 1 circuit breaker sensor to determine that the vehicle has been damaged. Then, it cuts off the high-voltage system to ensure safety. If the HV control ECU receives the collision signal only from the center airbag sensor, it turns OFF the system main relay and the power switch. If the HV control ECU receives the collision signal only from the No. 1circuit breaker sensor, it turns only the system main relay OFF. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 308 Collision signal input from center airbag sensor or No. 1 circuit breaker sensor • • Supplemental restraint system No. 1 circuit breaker sensor INSPECTION PROCEDURE 1 CHECK VEHICLE FOR ANY DAMAGE (a) Check the vehicle for any damage. Result: The vehicle is damaged. YES REPAIR VEHICLE NO 2 HV GO TO SUPPLEMENTAL RESTRAINT SYSTEM (a) Troubleshoot the airbag system. Result: There is malfunction in the airbag system. NO REPLACE NO. 1 CIRCUIT BREAKER SENSOR YES REPAIR MALFUNCTIONING PARTS AND COMPONENTS P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78508 HV–277 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a motor gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG2 by turning OFF the power transistors that are actuating the MG2. The HV control ECU monitors the motor gate shutdown signal and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 508 Motor gate shutdown (MSDN) signal malfunction • • Wire harness or connector HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the motor gate shutdown (MSDN) signal. If the HV control ECU detects a fault in the MSDN signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 508): Motor inverter shutdown signal line malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Actual status of shutdown command signal and its monitoring result Inconsistent COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 508) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 304) (see page HV-269). INSPECTION PROCEDURE CAUTION: • 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. HV HV–278 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 508) and other DTCs are output HINT: If any other codes besides P0A78 (INF 508) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H15 MSDN HV Control ECU Connector A065744E28 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side (e) Disconnect the I10 inverter connector. 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. (f) Turn the power switch ON (IG). (g) Measure the voltage between the terminal of the H15 HV control ECU connector and body ground. Standard voltage I10 I10 Inverter Connector HV–279 MSDN A092041E39 Tester Connection Specified Condition MSDN (H15-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MSDN (H15-8) - MSDN (I10-25) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MSDN (H15-8) or MSDN (I10-25) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–280 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78510 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a motor gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG2 by turning OFF the power transistors that are actuating the MG2. The HV control ECU monitors the motor gate shutdown signal and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 510 Motor inverter gate malfunction • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM Refer to DTC P0A78 (INF 304) (see page HV-269). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 MSDN HV Control ECU Connector A065744E28 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminal of the H15 HV control ECU connector and body ground. Standard voltage I10 I10 Inverter Connector HV–281 MSDN A092041E39 Tester Connection Specified Condition MSDN (H15-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MSDN (H15-8) - MSDN (I10-25) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MSDN (H15-8) or MSDN (I10-25) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–282 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78523 Drive Motor "A" Inverter Performance DESCRIPTION Refer to DTC P0A78 (INF 266) (see page HV-220). DTC No. INF Code DTC Detection Condition Trouble Area P0A78 523 Inverter voltage (VH) sensor offset malfunction • • System main relay Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the inverter voltage (VH) sensor signal. If the HV control ECU detects a fault in the sensor signal, the HV control ECU interprets this as a VH sensor failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 523): Voltage (VH) malfunction Required sensor / components Motor inverter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 523) is not detected INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–283 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 523) and other DTCs are output HINT: If any other codes besides P0A78 (INF 523) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect all the high-voltage terminals of the system main relays. (d) Measure the resistance at the switch side of the system main relays. Standard resistance: 10 kΩ or higher (e) Connect the high-voltage terminals of the system main relays. (f) Reinstall the service plug grip (see page HB-154). A087664E02 NG REPLACE STUCK SYSTEM MAIN RELAY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–284 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78586 Drive Motor "A" Inverter Performance DESCRIPTION Refer to DTC P0A78 (INF 266) (see page HV-220). DTC No. INF Code DTC Detection Condition Trouble Area P0A78 586 Inverter voltage (VH) sensor performance problem • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the inverter voltage (VH) sensor signal. If the HV control ECU detects a fault in the sensor signal, the HV control ECU interprets this as a VH sensor failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 586): Voltage (VH) sensor deviation Required sensor / components Motor inverter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 586) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 266) (see page HV-223). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–285 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 586) and other DTCs are output HINT: If any other codes besides P0A78 (INF 586) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 VH GINV HV Control ECU Connector A065744E22 HV HV–286 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side I10 VH GINV I10 Inverter Connector A092041E40 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition VH (H15-26) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VH (H15-26) - VH (I10-12) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). HV NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A309 HV–287 Generator Inverter Performance DESCRIPTION Refer to DTC P0A78 (INF 272) (see page HV-228). DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 309 Abnormality in generator PWM circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the generator PWM circuit. If there is an error in the power transistor actuation signals which are transmitted to the inverter, the HV control ECU interprets this as a malfunction of the generator PWM circuit. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 309): Generator PWM malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Power transistor actuation signal Abnormal COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 309) is not detected HV HV–288 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU (Shielded) Inverter 6 GWU I10 Y 13 H15 GWU 5 GVU I10 G 14 H15 GVU 4 GUU I10 B 15 H15 GUU A J5 J/C IK A092101E03 INSPECTION PROCEDURE HV CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D is output YES NO GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–289 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. H15 GUU GVU GWU HV Control ECU Connector A065744E30 Wire Harness Side GUU GVU (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) I10 Tester Connection Specified Condition GUU (H15-15) - GUU (I10-4) Below 1 Ω GVU (H15-14) - GVU (I10-5) Below 1 Ω GWU (H15-13) - GWU (I10-6) Below 1 Ω GWU Standard resistance (Check for short) I10 Inverter Connector A092041E41 Tester Connection Specified Condition GUU (H15-15) or GUU (I10-4) - Body ground 10 kΩ or higher GVU (H15-14) or GVU (I10-5) - Body ground 10 kΩ or higher GWU (H15-13) or GWU (I10-6) - Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–290 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A321 Generator Inverter Performance DTC P0A7A323 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of the HV control ECU via the generator inverter fail signal line. The HV control ECU monitors the generator inverter fail signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 321 +B short in generator inverter fail (GFIV) signal circuit • • Wire harness or connector Inverter with converter assembly P0A7A 323 Open or GND short in generator inverter fail (GFIV) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the generator inverter fail (GFIV) signal line. If the HV control ECU detects an open or short malfunction of the GFIV signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A7A (INF 321 / 323): Generator inverter Finv detection Required sensor / components Generator Inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Generator inverter fail signal circuit Open or short COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 321 / 323) is not detected HV–291 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter GFIV 22 I10 35 H15 GFIV GR (Shielded) 16 GI NV I10 23 H15 GINV Y A J5 J/C IK A092102E08 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GFIV GINV HV Control ECU Connector A065744E31 HV HV–292 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage I10 GINV I10 GFIV Inverter Connector A092041E42 Tester Connection Specified Condition GFIV (H15-35) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GFIV (H15-35) - GFIV (I10-22) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GFIV (H15-35) or GFIV (I10-22) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). HV NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A322 HV–293 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of HV control ECU via the generator inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 322 Generator inverter fail (GFIV) signal detection (inverter overheating) • • • • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the generator inverter overheats, it transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 322): Generator inverter / GFIV detection over heat Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Generator inverter Overheated COMPONENT OPERATING RANGE Generator inverter WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). DTC P0A7A (INF 322) is not detected HV HV–294 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output DTC No. HV 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 P0A4 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, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES NO GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–295 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 3 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 4 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E03 OK 5 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–296 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 6 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 7 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 INSPECT NO. 2 COOLING FAN MOTOR HV (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 9 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 10 HV–297 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 11 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A7A to display its freeze frame data. (f) Select the item that has INF code 322 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed 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 HV HV–298 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 12 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 HV V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–299 (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 13 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 Tester Connection GUU GVU GWU GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. NG I10 Inverter Connector Specified Condition GINV A093730E09 Go to step 14 HV HV–300 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE INVERTER WITH CONVERTER ASSEMBLY 14 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU I10 GINV Inverter Connector A093731E07 HV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) 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. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A324 HV–301 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of HV control ECU via the generator inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 324 Generator inverter fail (GFIV) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the generator inverter detects a circuit malfunction, it transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 324): Generator inverter / GFIV detection circuit malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Generator inverter Circuit malfunction COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 324) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • 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. HV HV–302 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A7A 321 or 323 Generator Inverter Performance HV-288 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) HV I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK : Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–303 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) 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. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage I9 Inverter Connector GND1(-) IGCT (+) A093729E02 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–304 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A325 Generator Inverter Performance DTC P0A7A517 Generator Inverter Performance DTC P0A7A518 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of HV control ECU via the generator inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 325 Generator inverter fail (GFIV) signal detection (over current by inverter assembly malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A7A 517 Generator inverter fail (GFIV) signal detection (over current by HV control ECU malfunction) • • • • HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly Wire harness or connector P0A7A 518 Generator inverter fail (GFIV) signal detection (over current by HV transaxle assembly malfunction) • HV • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If over-amperage flows through the generator inverter due to an internal short, the generator inverter transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 325 / 517 / 518): Generator inverter / GFIV detection over current Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–305 TYPICAL MALFUNCTION THRESHOLDS Generator inverter Over current (internal short) COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 325 / 517 / 518) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are 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 P0A4 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, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction HV HV–306 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Relevant Diagnosis P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) HV CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG Inverter Connector A092044E02 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 4 HV–307 CHECK HYBRID VEHICLE GENERATOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Check if the three-phase alternating current cable installation bolts on the hybrid vehicle generator are tightened to the specified torque. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Reinstall the inverter cover (see page HV-538). (d) Reinstall the service plug grip (see page HB-154). NG TIGHTEN THEM TO SPECIFIED TORQUE A090459E01 OK 5 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A7A to display its freeze frame data. (f) Select the item that has INF code 325, 517, or 518 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed 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 C REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–308 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 6 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 HV CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher HV–309 (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 7 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 GUU GVU GWU Tester Connection Specified Condition GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. NG I10 Inverter Connector GINV A093730E09 OK REPLACE INVERTER WITH CONVERTER ASSEMBLY Go to step 8 HV HV–310 8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU I10 Inverter Connector GINV A093730E09 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) 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. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) HV Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A342 Generator Inverter Performance DTC P0A7A343 Generator Inverter Performance DTC P0A7A519 Generator Inverter Performance HV–311 DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a generator gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG1 by turning OFF the power transistors that are actuating the MG1. The HV control ECU monitors the generator gate shutdown signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 342 Open or +B short in generator gate shutdown (GSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A7A 343 GND short in generator gate shutdown (GSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A7A 519 Open in generator gate shutdown (GSDN) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the generator gate shutdown (GSDN) signal line. If the HV control ECU detects an open or short malfunction of the GSDN signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 342 / 343 / 519): Generator inverter / Generator gate shutdown signal malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Generator gate shutdown signal circuit Open or short HV HV–312 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 342 / 343 / 519) is not detected WIRING DIAGRAM (Shielded) Inverter 20 I10 GSDN R A HV Control ECU 16 H15 GSDN J5 J/C IK A092105E05 INSPECTION PROCEDURE HV CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–313 (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GSDN HV Control ECU Connector A065744E34 Wire Harness Side: I10 I10 GSDN Inverter Connector A092041E22 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GSDN (H15-16) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GSDN (H15-16) - GSDN (I10-20) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GSDN (H15-16) or GSDN (I10-20) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–314 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A7A344 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). The HV control ECU controls MG1 torque in accordance with the driving condition. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 344 Failure in monitoring MG1 torque performance • • Hybrid vehicle generator Inverter with converter assembly MONITOR DESCRIPTION If the difference between the requested MG1 torque and the actual MG1 torque exceeds a predetermined value, the HV control ECU determines that there is a malfunction in the execution or monitoring of the MG1 torque. Then, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A7A (INF 344): Generator inverter / Discrepancy between generator monitored torque and commanded torque Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Difference between demanded and actual MG1 torque Exceeds the standard level COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 344) is not detected INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–315 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A7A (INF 344) and other DTCs are output HINT: If any other codes besides P0A7A (INF 344) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) HV HV–316 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance (f) Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A520 HV–317 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a generator gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG1 by turning OFF the power transistors that are actuating the MG1. The HV control ECU monitors the generator gate shutdown signal and detects a malfunction. DTC No. INF Code. DTC Detection Condition Trouble Area P0A7A 520 Generator gate shutdown (GSDN) signal malfunction • • Wire harness or connector HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the generator gate shutdown (GSDN) signal. If the HV control ECU detects a fault in the GSDN signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 520): Generator inverter shutdown signal line malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Actual status of shutdown command signal and its monitoring result Inconsistent COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 520) is not detected WIRING DIAGRAM Refer to DTC P0A7A (INF 342) (see page HV-310). INSPECTION PROCEDURE CAUTION: • 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. HV HV–318 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO CURRENT CODES. (e) Read DTCs. Result: DTC P0A7A (INF 520) and other DTCs are output HINT: If any other codes besides P0A7A (INF 520) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H15 GSDN HV Control ECU Connector A065744E34 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 I10 GSDN Inverter Connector A092041E22 HV–319 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GSDN (H15-16) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GSDN (H15-16) - GSDN (I10-20) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GSDN (H15-16) or GSDN (I10-20) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–320 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A7A522 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a generator gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG1 by turning OFF the power transistors that are actuating the MG1. The HV control ECU monitors the generator inverter gate and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 522 Generator inverter gate malfunction • • Wire harness or connector Inverter with converter assembly MONITOR STRATEGY Related DTCs P0A7A (INF 522): Malfunction of Inverter gate shutdown circuit Required sensors / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the DTCs listed are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 522) is not detected WIRING DIAGRAM Refer to DTC P0A7A (INF 342) (see page HV-310). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–321 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GSDN HV Control ECU Connector A065744E34 Wire Harness Side: I10 I10 GSDN Inverter Connector A092041E22 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GSDN (H15-16) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GSDN (H15-16) - GSDN (I10-20) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GSDN (H15-16) or GSDN (I10-20) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–322 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90239 Drive Motor "A" Performance DTC P0A90241 Drive Motor "A" Performance DTC P0A90602 Drive Motor "A" Performance HV–323 DESCRIPTION The HV transaxle consists of a planetary gear unit, MG1 and MG2. A gear unit uses the planetary gear to split engine output in accordance with a driving request during driving the vehicle or charging its internal HV battery. The MG2 provides assistance to the engine output while increasing the drive force of the vehicle. Furthermore, the MG2 effects regenerative braking by converting the energy (which is consumed in the form of heat during normal braking) into electrical energy and recovering it into the HV battery. Through regenerative braking, as well as decelerating the vehicle, the MG2 generates high-voltage electrical power which is used for the purpose of charging the HV battery. The MG1 supplies electrical power, which is used for charging the HV battery or for driving the MG2. It also has a stepless transmission function to control the transaxle by regulating the amount of generation of electrical energy, which effectively varies the MG1 speed. In addition, the MG1 is used as a starter motor to start the engine. The transmission input damper absorbs the shock that accompanies transmission of the drive force from the engine. HV HV–324 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Planetary Gear Unit MG2 MG1 Drive force from the engine Oil Pump Transmission Input Damper Counter Gears Final Gears Different Gear Unit HV A092301E02 DTC No. INF Code DTC Detection Condition Trouble Area P0A90 239 HV transaxle input malfunction (shaft damaged) • • • • • P0A90 241 HV transaxle input malfunction (torque limiter slipping) • • • • • P0A90 602 HV transaxle output malfunction • • • • • WIRING DIAGRAM Refer to DTC P0A0F (INF 238) (see page HV-135). Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–325 INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 CHECK CRANKSHAFT PULLEY REVOLUTION (a) Turn the power switch OFF. (b) Jack up the vehicle. (c) Manually turn the crankshaft pulley to check if the crankshaft rotates. OK: The crankshaft rotates NG Go to step 10 OK 3 CHECK HARNESS AND CONNECTOR (ECM - CRANKSHAFT POSITION SENSOR) (a) Disconnect the E4 ECM connector. E4 NENE+ ECM Connector A065743E70 (b) Disconnect the C7 crankshaft position sensor connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: C7 Crankshaft Position Sensor Connector A092031E01 Tester Connection Specified Condition NE+ (E4-33) - Crankshaft position sensor (C7-1) Below 1 Ω NE- (E4-34) - Crankshaft position sensor (C7-2) Below 1 Ω HV HV–326 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance (Check for short) Tester Connection Specified Condition NE+ (E4-33) or Crankshaft position sensor (C7-1) - Body ground 10 kΩ or higher NE- (E4-34) or Crankshaft position sensor (C7-2) - Body ground 10 kΩ or higher (d) Reconnect the crankshaft position sensor connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 NEO HV Control ECU Connector A065745E37 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 HV Tester Connection Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω NEO ECM Connector A065744E24 Standard resistance (Check for short) Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) - Body ground 10 Ω or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK AND CLEAR DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–327 (e) Check and record the DTCs, the freeze frame data, and the information. (f) Clear the DTCs of the HV ECU. GO 6 CHECK READY LIGHT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 REV and ENGINE SPD values. (f) Turn the power switch ON (READY). OK: READY light turns ON HINT: If the READY light does not turn ON, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 7 CHECK ENGINE REV-UP (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 REV and ENGINE SPD values. (f) With the READY light turned ON, depress the accelerator pedal for 10 seconds while the shift position is in P. OK: The engine revs up HINT: If the engine does not rev up, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. NG OK REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY HV HV–328 8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CREEP MOVEMENT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (READY). Jack up the vehicle. Depress the brake pedal, move the selector lever to the D position, and release the brake pedal. OK: The wheels turn (creep movement) HINT: If the wheels do not turn, and the reading on the intelligent tester shows DTC P0A90 (INF 602) (HV transaxle output malfunction), replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 9 CHECK ENGINE ACCELERATION SPEED (a) Connect the intelligent tester to the DLC3. (b) While driving at the vehicle speed of more than 6 mph (10 km/h), fully depress the accelerator pedal to raise the engine speed. OK: The engine speed increases smoothly HINT: If the engine over-revs or the reading on the intelligent tester shows DTC P0A90 (INF 241) (HV transaxle input malfunction [torque limiter slipping]), replace the transmission input damper. HV NG REPLACE TRANSMISSION INPUT DAMPER ASSEMBLY OK PERFORM SIMULATION TEST. IF SYMPTOM IS NOT REPRODUCED, REPLACE HV TRANSAXLE AND HV CONTROL ECU 10 CHECK FRONT TIRE REVOLUTION (a) Turn the power switch ON (IG). (b) Depress the brake pedal, move the selector lever to the N position. (c) Jack up the vehicle. (d) Manually turn the crankshaft pulley to check if the front tires rotate. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–329 OK: The front tires rotate NG REPAIR OR REPLACE ENGINE ASSEMBLY OK REPAIR OR REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY HV HV–330 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90240 Drive Motor "A" Performance DESCRIPTION Refer to DTC P0A90 (INF 239) (see page HV-321). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 240 Generator locked • INSPECTION PROCEDURE If the information (INF) code is present, replace the hybrid vehicle generator. 1 REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY NEXT COMPLETED HV Hybrid vehicle generator P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90242 HV–331 Drive Motor "A" Performance DESCRIPTION Refer to DTC P0A90 (INF 239) (see page HV-321). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 242 Planetary gear locked • HV transaxle assembly INSPECTION PROCEDURE If the information (INF) code is present, replace the HV transaxle assembly. 1 REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Replace the hybrid vehicle transaxle assembly (see page HX-69). NEXT COMPLETED HV HV–332 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A90251 Drive Motor "A" Performance DESCRIPTION When three-phase alternating current flows through the three-phase windings of the stator coil, a rotating magnetic field is generated in the motor. The system controls the rotating magnetic field in accordance with the rotating position and speed of the rotor. As a result, the permanent magnets provided on the rotor are pulled in the rotating direction, which cause the generation of torque. The generated torque is practically proportionate to the amount of current. Therefore, the system controls the speed of the motor by regulating the frequency of the alternating current. Furthermore, the system properly controls the rotating magnetic field and the angle of the rotor magnets in order to generate high torque in an efficient manner, even at high speeds. U Phase # Stator Coil Rotor Rotating Magnetic Field Reaction N S # HV W Phase V Phase : from inverter # Attraction # : wired in motor A093725E04 DTC No. INF Code DTC Detection Condition Trouble Area P0A90 251 MG2 magnetic force deterioration or same phase short circuit • Hybrid vehicle motor MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle motor (MG2). If the HV control ECU detects a reduction in the magnetic force of the MG2 or an in-phase short, it interprets this as a MG2 failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A90 (INF 251): Magnetic force deterioration/same phase short circuit Required sensor / components Hybrid vehicle motor, inverter, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–333 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle motor DTC P0A90 (INF 251) is not detected INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A90 (INF 251) and other DTCs are output HINT: If any other codes besides P0A90 (INF 251) are output, perform troubleshooting for those DTCs first. YES NO REPLACE HYBRID VEHICLE MOTOR ASSEMBLY GO TO RELEVANT DTC CHART HV HV–334 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90509 Drive Motor "A" Performance DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 509 MG2 system malfunction • • Hybrid vehicle motor Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle motor (MG2) system. If the HV control ECU detects a malfunction in the MG2 system, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A90 (INF 509): Motor system malfunction Required sensor / components Hybrid vehicle motor, inverter, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following TOYOTA's intellectual property DTCs are not present No other condition - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle motor DTC P0A90 (INF 509) is not detected INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–335 (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A90 (INF 509) and other DTCs are output HINT: If any other codes besides P0A90 (INF 509) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E02 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. HV HV–336 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90604 Drive Motor "A" Performance DTC P0A90605 Drive Motor "A" Performance HV–337 DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 604 MG2 power balance malfunction (small power balance) • • Battery current sensor Hybrid vehicle motor P0A90 605 MG2 power balance malfunction (large power balance) • • Battery current sensor Hybrid vehicle motor MONITOR DESCRIPTION The HV control ECU monitors the energy balance of the hybrid vehicle motor (MG2) system. If the HV control ECU detects a malfunction in the amount of electrical energy while the MG2 charges or discharges electricity, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A90 (INF 604 / 605): Hybrid vehicle motor / Power balance malfunction Required sensor / components Hybrid vehicle motor, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle motor (power balance) Small or large COMPONENT OPERATING RANGE Hybrid vehicle motor DTC P0A90 (INF 604 / 605) is not detected DTC P0A90 (INF 604 / 605) is not detected INSPECTION PROCEDURE CAUTION: • 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. HV HV–338 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A90 (INF 604 or 605) and other DTCs are output HINT: If any other codes besides P0A90 (INF 604 or 605) are output, perform troubleshooting for those DTCs first. HV YES GO TO RELEVANT DTC CHART NO 3 INSPECT BATTERY CURRENT SENSOR Component Side: GIB IB VIB Battery Current Sensor A077580E03 (a) Remove the battery current sensor (see page HB-142). (b) Measure the resistance between terminals 1 (VIB) and 2 (GIB). Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (c) Measure the resistance between terminals 1 (VIB) and 3 (IB). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–339 Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 3.5 to 4.5 kΩ Positive probe to terminal 3 (IB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (d) Measure the resistance between terminals 2 (GIB) and 3 (IB). Standard resistance: 0.2 kΩ or less NOTICE: Even if the probes are changed around, the resistance will not vary. (e) Reinstall the battery current sensor (see page HB-143). NG REPLACE BATTERY CURRENT SENSOR OK REPLACE HYBRID VEHICLE MOTOR ASSEMBLY HV HV–340 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A92261 Hybrid Generator Performance DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A92 261 MG1 magnetic force deterioration or same phase short circuit • Hybrid vehicle generator MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle generator (MG1). If the HV control ECU detects a reduction in the magnetic force of the MG1 or an in-phase short, it interprets this as a MG1 failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A92 (INF 261): Magnetic force deterioration/same phase short circuit Required sensor / components Hybrid vehicle generator, inverter, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle generator DTC P0A92 (INF 261) is not detected INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A92 (INF 261) and other DTCs are output P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–341 HINT: If any other codes besides P0A92 (INF 261) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY HV HV–342 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A92521 Hybrid Generator Performance DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A92 521 MG1 system malfunction • • Hybrid vehicle generator Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle generator (MG1) system. If the HV control ECU detects a malfunction in the MG1 system, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A92 (INF 521): Generator system malfunction Required sensor / components Hybrid vehicle generator, inverter, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle generator DTC P0A92 (INF 521) is not detected INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–343 (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A92 (INF 521) and other DTCs are output HINT: If any other codes besides P0A92 (INF 521) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. HV HV–344 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A92606 Hybrid Generator Performance DTC P0A92607 Hybrid Generator Performance HV–345 DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A92 606 MG1 power balance malfunction (small power balance) • • Battery current sensor Hybrid vehicle generator P0A92 607 MG1 power balance malfunction (large power balance) • • Battery current sensor Hybrid vehicle generator MONITOR DESCRIPTION The HV control ECU monitors the energy balance of the hybrid vehicle generator (MG1) system. If the HV control ECU detects a malfunction in the amount of electrical energy while the MG1 charges or discharges electricity, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A92 (INF 606 / 607): Hybrid vehicle generator / Power balance malfunction Required sensor / components Hybrid vehicle generator, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle generator (power balance) Small or large COMPONENT OPERATING RANGE Hybrid vehicle generator DTC P0A92 (INF 606 / 607) is not detected INSPECTION PROCEDURE CAUTION: • 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. HV HV–346 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A92 (INF 606 or 607) and other DTCs are output HINT: If any other codes besides P0A92 (INF 606 or 607) are output, perform troubleshooting for those DTCs first. HV YES GO TO RELEVANT DTC CHART NO 3 INSPECT BATTERY CURRENT SENSOR Component Side: GIB IB VIB Battery Current Sensor A077580E03 (a) Remove the battery current sensor (see page HB-142). (b) Measure the resistance between terminals 1 (VIB) and 2 (GIB). Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (c) Measure the resistance between terminals 1 (VIB) and 3 (IB). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–347 Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 3.5 to 4.5 kΩ Positive probe to terminal 3 (IB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (d) Measure the resistance between terminals 2 (GIB) and 3 (IB). Standard resistance: 0.2 kΩ or less NOTICE: Even if the probes are changed around, the resistance will not vary. (e) Reinstall the battery current sensor (see page HB-143). NG REPLACE BATTERY CURRENT SENSOR OK REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY HV HV–348 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A93346 Inverter Cooling System Performance DTC P0A93347 Inverter Cooling System Performance DESCRIPTION The inverter converts the high-voltage direct current of the HV battery into the alternating current for the MG1 and the MG2. The inverter generates heat during the conversion process, and this heat could damage the inverter if a cooling system is unavailable. Therefore, similar to the MG1 and the MG2, the inverter is cooled by a dedicated cooling system, which consists of an electric water pump, cooling fan, and radiator. This cooling system is independent of the engine cooling system. Reservoir Tank Water Pump HV Radiator A092091E01 The HV control ECU monitors the electric water pump, cooling fan and cooling system, and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A93 346 Inverter cooling system malfunction (water pump system malfunction) • • • • • • P0A93 347 Inverter cooling system malfunction (electric cooling fan system malfunction) • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–349 MONITOR DESCRIPTION If the HV control ECU detects a malfunction in the electric water pump, fan, or radiator, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A93 (INF 346 / 347): Inverter cooling system performance / Inverter cooling system Required sensor / components Water pump, radiator fan, inverter, boost converter, DC / DC converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Water pump Radiator fan DTC P0A93 (INF 346 / 347) is not detected INSPECTION PROCEDURE HV 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 2 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION HV–350 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E01 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY OK HV 5 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 6 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–351 OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–352 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94442 DC / DC Converter Performance DESCRIPTION The boost converter contains a booster IPM (Intelligent Power Module), which includes an IGBT (Insulated Gate Bipolar Transistor) and a reactor. The HV control ECU actuates the IGBT, which controls the current in the reactor. The boost converter boosts the high-voltage direct current rated at 201.6 V to an approximate direct current voltage of 500 V. The inverter converts the voltage that has been boosted by the boost converter into alternating current, which is used for driving the MG1/MG2. When the MG1/MG2 operates as a generator, the alternating current of approximately 500 V from the MG1/MG2 is converted into direct current by the inverter. Then, the boost converter drops this voltage to a direct current voltage rated at 201.6 V in order to charge the HV battery. Boost Converter Inverter Assembly Inverter Booster IPM HV Battery MG1/ MG2 Reactor HV Voltage Conversion Before boosting direct current After boosting direct current After converting alternating current A093726E02 The HV control ECU uses a voltage sensor that is built into the boost converter to detect the high voltage (VL) before it is boosted. Also, it uses a voltage sensor that is built into the inverter to detect the high voltage (VH) after it has been boosted. Based on the voltage before and after it has been boosted, the HV control ECU boosts it to a target voltage by controlling the operation of the boost converter. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 442 Abnormal voltage execution value • Inverter with converter assembly P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–353 INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A94 (INF 442) and other DTCs are output HINT: If any other codes besides P0A94 (INF 442) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–354 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94545 DC / DC Converter Performance DTC P0A94546 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter detects a circuit malfunction or over-voltage, the boost converter transmits this information to the OVL terminal of the HV control ECU via the boost converter over-voltage signal line. The HV control ECU monitors the boost converter over-voltage signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 545 Open or GND short in boost converter over-voltage (OVL) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 546 +B short in boost converter overvoltage (OVL) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter over-voltage (OVL) signal line. If the HV control ECU detects an open or short malfunction of the OVL signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 545 / 546): Boost converter / Converter OVL detection Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter over-voltage (OVL) signal circuit Open or short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 545 / 546) is not detected HV–355 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter 31 I10 OVL 22 H16 OVL B (Shielded) 32 GCNV I10 8 H16 GCNV G A J5 J/C IK A092102E09 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 GCNV CPWM HV Control ECU Connector A065745E41 HV HV–356 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 GCNV I10 Inverter Connector OVL A092041E44 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition OVL (H16-22) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition OVL (H16-22) - OVL (I10-31) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition OVL (H16-22) or OVL (I10-31) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). HV NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94547 DC / DC Converter Performance DTC P0A94548 DC / DC Converter Performance DTC P0A94549 DC / DC Converter Performance HV–357 DESCRIPTION See the description of the booster converter (see page HV-350). If the boost converter detects a circuit malfunction or over-voltage, the boost converter transmits that information to the OVL terminal of the HV control ECU via the boost converter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 547 Boost converter over-voltage (OVL) signal detection (overvoltage by HV control ECU malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 548 Boost converter over-voltage (OVL) signal detection (overvoltage by inverter assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 549 Boost converter over-voltage (OVL) signal detection (overvoltage by HV transaxle assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the boost converter detects over-voltage, it transmits a boost converter over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 547 / 548 / 549): OVL detection over-voltage Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV HV–358 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Boost converter Over-voltage COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 547 / 548 / 549) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CONFIRM INFORMATION (EXCLUSIVE INFO 3) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 547, 548, or 549 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 3. Result: -32 to 32 (during driving without battery power) HINT: If the value is inside the range shown above, DTCs other than P0A78 (INF 547, 548 and 549) have been detected as well. Perform troubleshooting for those DTCs first. HV YES NO GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–359 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 NG I9 CONNECT SECURELY Inverter Connector A092044E02 OK 4 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. HV HV–360 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 547, 548, or 549 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed 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 C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 5 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. HV DTC No. INF Code Detection Item See Page P0A78 266 Drive Motor "A" Inverter Performance HV-220 P0A94 558 or 560 DC / DC Converter Performance HV-389 P0A94 588 DC / DC Converter Performance HV-409 P0A94 589 DC / DC Converter Performance HV-412 P0ADB 227 Hybrid Battery Positive Contactor Control Circuit Low HV-439 P0ADF 229 Hybrid Battery Negative Contactor Control Circuit Low HV-441 P3000 125 HV Battery Malfunction HV-466 P3004 131 Power Cable Malfunction HV-470 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–361 NO 6 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E02 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher HV HV–362 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 7 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection HV Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C ) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (f) HV–363 Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 Tester Connection GUU GVU GWU MUU MVU MWU I10 Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector A093730E07 OK REPLACE HYBRID VEHICLE CONTROL ECU AND INVERTER WITH CONVERTER ASSEMBLY NG 9 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. HV HV–364 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I10 GUU GVU GWU MUU MVU MWU I10 GINV Inverter Connector A093731E05 (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) 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. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK HV REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94550 HV–365 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter detects a circuit malfunction or over-voltage, the boost converter transmits that information to the OVL terminal of the HV control ECU via the boost converter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 550 Boost converter over-voltage (OVL) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the boost converter detects a circuit malfunction, it transmits a boost converter over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 550): OVL detection circuit malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter Circuit malfunction COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 550) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV HV–366 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A94 545 or 546 DC / DC Converter Malfunction HV-352 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) HV I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–367 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 CHECK INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) 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. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage I9 Inverter Connector GND1(-) IGCT (+) A093729E02 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–368 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94551 DC / DC Converter Performance DTC P0A94552 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter has a circuit malfunction, or internal short, or overheats, the boost converter transmits this information to the FCV terminal of the HV control ECU via the boost converter fail signal line. The HV control ECU monitors the boost converter fail signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 551 Open or GND short in boost converter fail (FCV) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 552 +B short in boost converter fail (FCV) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter fail (FCV) signal line. If the HV control ECU detects an open or short malfunction of the FCV signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 551 / 552): Boost converter / Converter Finv detection Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter fail signal circuit Open or short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 551 / 552) is not detected HV–369 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter 30 I10 FCV 20 H16 FCV W (Shielded) 32 GCNV I10 8 H16 GCNV G A J5 J/C IK A092102E10 INSPECTION PROCEDURE CAUTION: • 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: HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 GCNV FCV HV Control ECU Connector A065745E50 HV HV–370 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side I10 FCV (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection I10 Inverter Connector GINV A092041E45 Specified Condition FCV (H16-20) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition FCV (H16-20) - FCV (I10-30) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition FCV (H16-20) or FCV (I10-30) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). HV NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94553 HV–371 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter has a circuit malfunction, internal short, or overheats, the boost converter transmits that information to the FCV terminal of the HV control ECU via the boost converter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 553 Boost converter fail (FCV) signal detection (boost converter overheating) • • • • • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the boost converter is overheated, it transmits a boost converter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 553): FCV detection over heat Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter Overheated COMPONENT OPERATING RANGE Boost converter WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). DTC P0A94 (INF 553) is not detected HV HV–372 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output DTC No. HV 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 P0A4 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, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES NO GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–373 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 3 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 4 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E02 OK 5 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–374 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 6 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 7 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 INSPECT NO. 2 COOLING FAN MOTOR HV (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 9 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 10 HV–375 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 11 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 553 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed 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 HV HV–376 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 12 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V HV W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1+ 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–377 (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩor higher V (I14-2) - Body ground 10 MΩor higher W (I14-3) - Body ground 10 MΩor higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 13 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 Ω HV HV–378 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (f) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK 14 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage HV I10 GUU GVU GWU MUU MVU MWU I10 Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector A093730E07 NG OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 15 HV–379 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU MUU MVU MWU I10 GINV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) 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. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Inverter Connector A093731E05 Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–380 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94554 DC / DC Converter Performance DTC P0A94555 DC / DC Converter Performance DTC P0A94556 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter has a circuit malfunction, internal short, or overheats, the boost converter transmits that information to the FCV terminal of the HV control ECU via the boost converter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 554 Boost converter fail (FCV) signal detection (over current by HV control ECU malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 555 Boost converter fail (FCV) signal detection (over current by inverter assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 556 Boost converter fail (FCV) signal detection (over current by HV transaxle assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly HV MONITOR DESCRIPTION If over-amperage flows through the boost converter due to an internal short, the boost converter transmits a boost converter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 554 / 555 / 556): FCV detection over current Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Other conditions belong to TOYOTA's intellectual property HV–381 - TYPICAL MALFUNCTION THRESHOLDS Boost converter Over current (internal short) COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 554 / 555 / 556) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are 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 P0A4 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, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction HV HV–382 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Relevant Diagnosis P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART. NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK HV 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG Inverter Connector A092044E02 CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–383 OK 4 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 554, 555, or 556 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed 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 C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 5 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). HV HV–384 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Motor: I14 U V W A092045E03 (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor 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. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance HV Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 6 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Generator: I15 V W U A092046E03 HV–385 (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: 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. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩor higher V (I15-2) - Body ground 10 MΩor higher W (I15-3) - Body ground 10 MΩor higher (f) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 7 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. HV HV–386 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) 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. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 GUU GVU GWU MUU MVU MWU I10 Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector OK REPLACE INVERTER WITH CONVERTER ASSEMBLY A093730E07 NG 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) HV I10 GUU GVU GWU MUU MVU MWU I10 GINV Inverter Connector A093731E05 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) 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. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) HV–387 Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–388 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A94557 DC / DC Converter Performance DESCRIPTION See the description of the booster converter (see page HV-350). If the boost converter has a circuit malfunction, internal short, or overheats, the boost converter transmits that information to the FCV terminal of the HV control ECU via the boost converter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 557 Boost converter fail (FCV) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the boost converter detects a circuit malfunction, it transmits a boost converter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 557): FCV detection circuit malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter Circuit malfunction COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 557) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • 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. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–389 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A94 551 or 552 DC / DC Converter Malfunction HV-366 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HV HV–390 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 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. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) 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. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage HV I9 Inverter Connector GND1(-) IGCT (+) A093729E02 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94558 DC / DC Converter Performance DTC P0A94559 DC / DC Converter Performance DTC P0A94560 DC / DC Converter Performance HV–391 DESCRIPTION See the description of the boost converter (see page HV-350). Upon receiving a boost converter gate shutdown signal from the HV control ECU, the boost converter forcefully stops the operation of the boost converter by turning OFF the power transistors that are actuating the boost converter. The HV control ECU monitors the boost converter gate shutdown signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 558 GND short in boost converter gate shutdown (CSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 559 Open or +B short in boost converter gate shutdown (CSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 560 Open in boost converter gate shutdown (CSDN) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter gate shutdown (CSDN) signal line. If the HV control ECU detects an open or short malfunction of the CSDN signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 558 / 559 / 560): Boost converter / Converter gate shutdown signal malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter gate shutdown signal circuit Open or short HV HV–392 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 558 / 559 / 560) is not detected WIRING DIAGRAM (Shielded) Inverter 29 CSDN I10 W A HV Control ECU 9 H16 CSDN J5 J/C IK A092105E06 INSPECTION PROCEDURE HV CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–393 (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 CSDN HV Control ECU Connector A065745E38 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: I10 I10 Inverter Connector CSDN A092041E46 Tester Connection Specified Condition CSDN (H16-9) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CSDN (H16-9) - CSDN (I10-29) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CSDN (H16-9) or CSDN (I10-29) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–394 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A94561 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). Upon receiving a boost converter gate shutdown signal from the HV control ECU, the boost converter forcefully stops the operation of the boost converter by turning OFF the power transistors that are actuating the boost converter. The HV control ECU monitors the boost converter gate shutdown signal and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 561 Abnormal boost converter gate shutdown (CSDN) signal • • Wire harness or connector HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the boost converter gate shutdown (CSDN) signal. If the HV control ECU detects an abnormality in the CSDN signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 561): Boost converter / Converter shutdown signal line malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Actual status of shutdown command signal and its monitoring result Inconsistent COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 561) is not detected WIRING DIAGRAM Refer to DTC P0A94 (INF 558) (see page HV-390). INSPECTION PROCEDURE CAUTION: • 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. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–395 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A94 (INF 561) and other DTCs are output HINT: If any other codes besides P0A94 (INF 561) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 CSDN HV Control ECU Connector A065745E38 HV HV–396 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: I10 I10 Inverter Connector CSDN A092041E46 Tester Connection Specified Condition CSDN (H16-9) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CSDN (H16-9) - CSDN (I10-29) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CSDN (H16-9) or CSDN (I10-29) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG HV OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94583 DC / DC Converter Performance DTC P0A94584 DC / DC Converter Performance HV–397 DESCRIPTION Output Voltage V 5.0 4.0 3.0 2.0 1.0 0 0 25 50 75 100 125 150 (32) (77)(122)(167)(212)(257)(302) Temperature °C (°F) A093728E02 See the description of the boost converter (see page HV-350). The HV control ECU uses a temperature sensor, which is built into the boost converter, to detect the temperature of the boost converter. The boost converter temperature sensor outputs a voltage, which varies between 0 and 5 V in accordance with the changes in the temperature. The higher the boost converter temperature, the lower the output voltage. Conversely, the lower the temperature, the higher the output voltage. The HV control ECU limits the load based on the signals transmitted by the boost converter temperature sensor, in order to prevent the boost converter from overheating. Furthermore, the HV control ECU detects a malfunction in the wiring of the boost converter temperature sensor, as well as in the sensor itself. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 583 Open or GND short in boost converter temperature sensor circuit • • P0A94 584 +B short in boost converter temperature sensor circuit • • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P0A94 (INF 583 or 584), confirm CONVERTER TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction -50°C (-58°F) +B short circuit 205°C (401°F) Open or GND short circuit HV HV–398 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MONITOR DESCRIPTION The HV control ECU monitors the boost converter temperature sensor circuit. If the HV control ECU detects an open or short malfunction of the sensor circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 583 / 584): Boost converter / Converter temperature sensor malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter temperature sensor circuit Open or short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 583 / 584) is not detected WIRING DIAGRAM HV Inverter HV Control ECU (Shielded) 14 CT I10 R 21 H16 CT 32 GCNV I10 G 8 H16 GCNV J5 J/C A IK A092106E05 INSPECTION PROCEDURE CAUTION: • 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. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–399 • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ VALUE OF INTELLIGENT TESTER (CONVERTER TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the CONVERTER TEMP value. Result: Temperature Displayed Proceed 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 intelligent tester indicates -50°C (-58°F). • If there is an open or GND short circuit, the intelligent tester indicates 205°C (401°F). B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 HV READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). HV–400 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 CT I10 Inverter Connector GCNV A092041E25 Converter Temperature Sensor HV Control ECU CT GCNV HV A125426E02 (e) 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. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the CONVERTER TEMP value. OK: 205°C (401°F) (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H16 HV control ECU connector. H16 GCNV CT HV Control ECU Connector A065745E39 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Converter Temperature Sensor HV Control ECU CT GCNV HV–401 (b) 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. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the CONVERTER TEMP value on the intelligent tester. OK: 205°C (401°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E01 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. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H16 HV control ECU connector. H16 GCNV CT HV Control ECU Connector A065745E39 HV HV–402 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) I10 Tester Connection CT I10 Inverter Connector GCNV A092041E25 Specified Condition CT (H16-21) - CT (I10-14) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CT (H16-21) or CT (I10-14) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 INSPECT HYBRID VEHICLE CONTROL ECU (CT VOLTAGE) (a) 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. (b) Measure the voltage between the terminals of the H16 HV control ECU connector. Standard voltage HV H16 CT (+) Tester Connection Specified Condition CT (H16-21) - GCNV (H16-8) 2.0 to 4.5 V NG GCNV (-) HV Control ECU Connector A093719E01 OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94585 HV–403 DC / DC Converter Performance DESCRIPTION Refer to DTC P0A94 (INF 589) (see page HV-412). DTC No. INF Code DTC Detection Condition Trouble Area P0A94 585 Boost converter voltage (VL) sensor performance problem • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter voltage sensor signal. If the HV control ECU detects an abnormality in the sensor signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 585): Boost converter / Voltage (VL) sensor deviation Required sensor / components Boost converter, inverter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 585) is not detected WIRING DIAGRAM Refer to DTC P0A94 (INF 589) (see page HV-413). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV–404 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A94 (INF 585) and other DTCs are output HINT: If any other codes besides P0A94 (INF 585) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H16 GCNV VL HV Control ECU Connector A065745E40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage I10 Inverter Connector VL I10 Front View HV–405 GCNV A092041E26 Tester Connection Specified Condition VL (H16-30) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VL (H16-30) - VL (I10-15) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VL (H16-30) or VL (I10-15) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–406 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A94587 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). The HV control ECU uses two voltage sensors, VL and VB, to detect voltage levels. The VL sensor that has been built into the boost converter is used to detect the high voltage before it is boosted. The VB sensor that has been built into the battery ECU is used to detect voltage of the HV battery. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 587 Difference between voltages from HV battery voltage (VB) sensor and boost converter voltage (VL) sensor is large • • • • • Wire harness or connector Inverter with converter assembly Service plug grip High voltage fuse Battery ECU MONITOR DESCRIPTION The HV control ECU monitors signals of HV battery voltage (VB) and boost converter voltage (VL) sensors. When a large difference occurs between the voltages from the VB and VL sensors, the HV control ECU interprets this as a failure of either of the sensors. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 587): Voltage (VB or VL) sensor deviation Required sensor / components Boost converter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Difference between the voltages of HV battery and boost converter voltage sensors Exceeds the standard level COMPONENT OPERATING RANGE Boost converter Battery ECU WIRING DIAGRAM Refer to DTC P0A94 (INF 589) (see page HV-413). DTC P0A94 (INF 587) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–407 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: Display (DTC Output) Proceed to Only DTC P0A94 (INF 587) A DTCs P0A94 (INF 587), and P0A1F (INF 129) (HV battery voltage circuit malfunction) B DTCs P0A94 (INF 587), and P0A94 (INF 442) (Abnormal voltage execution value) C DTCs P0A94 (INF 587), and P0A94 (INF 585) (Boost converter voltage (VL) sensor performance problem) D DTCs other than above E B C GO TO DTC P0A1F-129 Go to step 4 D GO TO DTC P0A94-585 E AFTER PERFORMING "CHECK HARNESS AND CONNECTOR" PROCEDURE, GO TO RELEVANT DTC CHART A 2 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output HV HV–408 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES GO TO RELEVANT DTC CHART NO 3 INSPECT SERVICE PLUG GRIP A081749E02 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Measure the resistance between the terminals of the service plug grip. Standard resistance: Below 1 Ω (d) Reinstall the service plug grip (see page HB-154). NG Go to step 6 OK 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H16 GCNV VL HV Control ECU Connector A065745E40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage I10 VL I10 Inverter Connector HV–409 GCNV A092041E27 Tester Connection Specified Condition VL (H16-30) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VL (H16-30) - VL (I10-15) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VL (H16-30) or VL (I10-15) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK OUTPUT DTC (a) Proceed to A if only DTC P0A94 (INF 587) is output as a result of DTC reading in the "READ OUTPUT DTC" procedure. (b) Proceed to B if DTCs P0A94 (INF 587) and P0A94 (INF 442) are output as a result of DTC reading in the "READ OUTPUT DTC" procedure. B REPLACE INVERTER WITH CONVERTER ASSEMBLY A REPLACE INVERTER WITH CONVERTER ASSEMBLY AND BATTERY ECU ASSEMBLY HV HV–410 6 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT HIGH VOLTAGE FUSE CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the high voltage fuse (see page HB-154). HINT: The high voltage fuse is enclosed in the service plug grip. (b) Measure the resistance between the terminals of the high voltage fuse. Standard resistance: Below 1 Ω (c) Reinstall the high voltage fuse (see page HB-154). A057824E02 OK REPLACE SERVICE PLUG GRIP HV NG REPLACE HIGH VOLTAGE FUSE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94588 HV–411 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). The boost converter switches the power transistors ON and OFF in accordance with the power transistor actuation signals received from the HV control ECU, in order to change the current that flows into the reactor. Also, the boost converter regulates the duration of the switching time through PWM (Pulse Width Modulation) control, in order to control the boosting voltage. The HV control ECU monitors the boost converter PWM circuit and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 588 Abnormality in boost converter PWM circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter PWM circuit. If there is an error in the power transistor actuation signals which are transmitted to the boost converter, the HV control ECU interprets this as a malfunction of the boost converter PWM circuit. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 588): Boost converter / Converter PWM malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Power transistor actuation signal Abnormal COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 588) is not detected HV HV–412 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU (Shielded) Inverter 13 CPWM I10 B 10 H16 CPWM 32 GCNV I10 G 8 H16 GCNV J5 J/C A IK A092106E06 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 GCNV CPWM HV Control ECU Connector A065745E41 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage I10 CPWM I10 Inverter Connector HV–413 GCNV A092041E28 Tester Connection Specified Condition CPWM (H16-10) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CPWM (H16-10) - CPWM (I10-13) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CPWM (H16-10) or CPWM (I10-13) Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–414 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94589 DC / DC Converter Performance DTC P0A94590 DC / DC Converter Performance DESCRIPTION Output Voltage (V) 5.0 4.0 3.0 2.0 1.0 0 100 200 300 400 500 600 700 High-Voltage (V) A125422E01 HV See the description of the boost converter (see page HV-350). The HV control ECU uses a voltage sensor, which has been built into the boost converter, to detect the high voltage before it is boosted and for boost control. The boost converter voltage sensor outputs a voltage that varies between 0 and 5 V in accordance with the changes in the high voltage. The higher the high voltage, the higher the output voltage, and the lower the high voltage, the lower the output voltage. The HV control ECU monitors a signal line of the boost converter voltage sensor and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 589 Open or GND short in boost converter voltage (VL) sensor circuit • • • P0A94 590 +B short in boost converter voltage (VL) sensor circuit • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P0A94 (INF 589 or 590), confirm VL in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Voltage Displayed Malfunction 510 V +B short circuit 0V Open or GND short circuit MONITOR DESCRIPTION The HV control ECU monitors the boost converter voltage (VL) sensor circuit. If the HV control ECU detects an open or short malfunction of the VL sensor circuit, the HV control ECU illuminates the MIL and sets a DTC. HV–415 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MONITOR STRATEGY Related DTCs P0A94 (INF 589 / 590): Boost converter / VL malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter voltage sensor circuit Short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 589 / 590) is not detected WIRING DIAGRAM Inverter HV Control ECU (Shielded) 15 VL I10 Y 32 GCNV I10 G J5 J/C 30 H16 VL HV 8 H16 GCNV A IK A092106E07 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. HV–416 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ VALUE OF INTELLIGENT TESTER (VL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the VL value. Result: Voltage Displayed Proceed to 510 V A 0V B 1 to 509 V C HINT: • If there is a +B short circuit, the intelligent tester indicates 510 V. • If there is an open or GND short circuit, the intelligent tester indicates 0 V. B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 HV READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–417 (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 VL I10 GCNV Inverter Connector A092041E29 Boost Converter Voltage Sensor HV Control ECU VL GCNV A125426E03 (e) 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. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the VL value. Standard voltage: 0V (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H16 HV control ECU connector. H16 GCNV VL HV Control ECU Connector A065745E40 HV HV–418 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Boost Converter Voltage Sensor HV Control ECU VL GCNV (b) 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. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the VL value. Standard voltage: 0V (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E02 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. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H16 HV control ECU connector. HV H16 GCNV VL HV Control ECU Connector A065745E40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) I10 Tester Connection VL I10 Inverter Connector HV–419 GCNV A092041E29 Specified Condition VL (H16-30) - VL (I10-15) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VL (H16-30) or VL (I10-15) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK HYBRID VEHICLE CONTROL ECU (VL VOLTAGE) (a) Turn the power switch ON (READY). 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. (b) Measure the voltage between the terminals of the H16 HV control ECU connector. Standard voltage H16 VL (+) GCNV (-) HV Control ECU Connector A093719E19 Tester Connection Specified Condition VL (H16-30) - GCNV (H16-8) 1.9 to 3.4 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–420 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AA1231 Hybrid Battery Positive Contactor Circuit Stuck Closed DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). Because it might be impossible to shut off the high-voltage system if either of the No. 1 and No. 2 system main relays becomes stuck, the HV control ECU monitors the two relays and stops the system if malfunction is found in either relay. DTC No. INF Code DTC Detection Condition Trouble Area P0AA1 231 System main relay terminal of HV battery positive side stuck closed • • No. 1 system main relay No. 2 system main relay INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). HV NG OK REPLACE NO. 2 SYSTEM MAIN RELAY REPLACE NO. 1 SYSTEM MAIN RELAY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AA1233 HV–421 Hybrid Battery Positive Contactor Circuit Stuck Closed DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). Because it might be impossible to shut off the high-voltage system if any one of the No. 1 to No. 3 system main relays becomes stuck, the HV control ECU monitors the 3 relays and stops the system if malfunction is found in either relay. DTC No. INF Code DTC Detection Condition Trouble Area P0AA1 233 System main relay terminals of HV battery positive and negative sides stuck closed • • • No. 1 system main relay No. 2 system main relay No. 3 system main relay INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG REPLACE NO. 1 SYSTEM MAIN RELAY OK 2 INSPECT NO. 2 SYSTEM MAIN RELAY (a) Inspect the No. 2 system main relay (see page HB-126). NG OK REPLACE NO. 3 SYSTEM MAIN RELAY REPLACE NO. 2 SYSTEM MAIN RELAY HV HV–422 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AA4232 Hybrid Battery Negative Contactor Circuit Stuck Closed DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). DTC No. INF Code DTC Detection Condition Trouble Area P0AA4 232 System main relay terminal of HV battery negative side stuck closed • No. 3 system main relay MONITOR DESCRIPTION The HV control ECU monitors the No. 3 system main relay, because shutting off the high-voltage system might be impossible if the relay terminal becomes stuck. If the HV control ECU detects that the relay terminal has stuck closed, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0AA4 (INF 232): SMR circuit / "-" side stuck Required sensor / components No. 3 system main relay Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE No. 3 system main relay DTC P0AA4 (INF 232) is not detected INSPECTION PROCEDURE If the information (INF) code is present, replace the No. 3 system main relay. 1 REPLACE NO. 3 SYSTEM MAIN RELAY (a) Replace the No. 3 system main relay (see page HB124). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–423 DTC P0AA6526 Hybrid Battery Voltage System Isolation Fault DTC P0AA6611 Hybrid Battery Voltage System Isolation Fault DTC P0AA6612 Hybrid Battery Voltage System Isolation Fault DTC P0AA6613 Hybrid Battery Voltage System Isolation Fault DTC P0AA6614 Hybrid Battery Voltage System Isolation Fault DESCRIPTION DTC No. INF Code DTC Detection Condition Trouble Area P0AA6 526*1 Insulation resistance of high voltage circuit and body is low • • • • • • • • • • • • • Frame wire System main relay System main resistor HV battery assembly Electric inverter compressor Battery ECU HV transaxle assembly Inverter with converter assembly Main battery cable No. 2 main battery cable Battery plug No. 2 frame wire Junction block P0AA6 611*2 Insulation resistance of A/C compressor motor or A/C inverter is low • • Electric inverter compressor Inverter with converter assembly P0AA6 612*2 Insulation resistance of HV battery, battery ECU, system main relay, or system main resistor is low • • • • • • • • • HV battery assembly Battery ECU System main relay System main resistor Main battery cable No. 2 main battery cable Battery plug No. 2 frame wire Junction block P0AA6 613*2 Insulation resistance of HV transaxle or motor and generator inverters is low • • HV transaxle assembly Inverter with converter assembly P0AA6 614*2 Insulation resistance of motor and generator inverters, A/C inverter, system main relay, system main resistor, or frame wire is low • • • • • Frame wire System main relay System main resistor HV battery assembly Inverter with converter assembly Main battery cable No. 2 main battery cable Battery plug No. 2 frame wire Junction block • • • • • HV HV–424 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: *1: Stored simultaneously when DTC P0AA6 is set. *2: Stored when a malfunction has been isolated after INF code 526 was set. INF code 611 to 614 are set next trip. HV HV–425 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM Outline of High-Voltage Circuit and Areas: INF Code 526 Vehicle Insulation Resistance Reduction INF Code 612 INF Code 614 HV Battery Area High Voltage Direct Current Area HV Battery Resistor SMR1 Frame Wire INF Code 613 Inverter Assembly SMR2 MG1 Boost Converter Battery ECU Transaxle Area Inverter MG2 SMR3 Service Plug Grip HV A/C Inverter A/C Motor INF Code 611 A/C Area A125425E01 HV–426 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: Display (DTC Output) Proceed to DTC P0AA6 A DTCs P0AA6 and P0A1D (HV control ECU malfunction) B DTCs P0AA6 and P0A1F (Battery ECU malfunction) C HV B GO TO DTC CHART. FIND DTC P0A1D TO PROCEED TO ITS TROUBLE SHOOTING FLOWCHART C GO TO DTC CHART. FIND DTC P0A1F TO PROCEED TO ITS TROUBLESHOOTING FLOWCHART A 2 READ OUTPUT INF CODE (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Display the freeze frame data for DTC P0AA6 and check its information (INF) code. NOTICE: If only INF code 526 is present, recheck INF code after waiting for 30 seconds with the power switch OFF. Result: Display (INF Code Output) Proceed to Only 526 (Insulation resistance of high voltage circuit and body is low) A 526 and 611 (Insulation resistance of A/C area is low) AC-134 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Display (INF Code Output) Proceed to 526 and 612 (Insulation resistance of HV battery area is low) B 526 and 613 (Insulation resistance of transaxle area is low) C 526 and 614 (Insulation resistance of high voltage direct current area is low) D B Go to step 5 C Go to step 18 D Go to step 19 HV–427 A 3 CHECK ELECTRIC INVERTER COMPRESSOR Electric Inverter Compressor Connector C4 A087661E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the C4 electric inverter compressor connector. (d) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the electric inverter compressor connector and the body ground. Standard resistance Tester Connection Specified Condition C4-1 - Body ground 3.0 MΩ or higher C4-2 - Body ground 3.0 MΩ or higher C4-3 - Body ground 3.0 MΩ or higher NG REPLACE ELECTRIC INVERTER COMPRESSOR OK 4 CHECK INSULATION RESISTANCE (INVERTER, TRANSAXLE AND FRAME WIRE) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. HV HV–428 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM A/C Inverter Connector C4 (b) Check that the electric inverter compressor connector has been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the A/C inverter connector and the body ground. Standard resistance Tester Connection Specified Condition C4-1 - Body ground 2.0 MΩ or higher C4-2 - Body ground 2.0 MΩ or higher C4-3 - Body ground 2.0 MΩ or higher A087662E02 NG Go to step 15 OK 5 CHECK HV BATTERY AREA CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Check that the service plug grip has been detached. If not, remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the B12 and B13 battery ECU connectors. HV B13 B12 Battery ECU Connector A093736E03 A087663E02 (d) Disconnect the main battery cables from the system main relays. (e) Using a megohmmeter, measure the insulation resistance between the positive terminal on the HV battery side of the system main relay and the body ground. Standard resistance: 10 MΩ or higher (f) Using a megohmmeter, measure the insulation resistance between the negative terminal on the HV battery side of the system main relay and the body ground. Standard resistance: 10 MΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK HV–429 REPLACE BATTERY ECU ASSEMBLY NG 6 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect all the high-voltage terminals of the system main relays. (c) Measure the resistance at the switch side of the system main relays. Standard resistance: Below 1 Ω NG A087664E02 GO TO "CHECK INSULATION RESISTANCE" PROCEDURE AFTER REPLACING STUCK SYSTEM MAIN RELAY OK 7 CHECK SYSTEM MAIN RELAYS FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Check that all the high-voltage terminals of the system main relays have been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the system main relays and the body ground. Standard resistance: 10 MΩ or higher NG A087665E01 REPLACE SYSTEM MAIN RELAY WITH REDUCED INSULATION RESISTANCE OK 8 CHECK SYSTEM MAIN RESISTOR FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. HV HV–430 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Check that both terminals of the system main resistor have been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminal of the system main resistor and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE SYSTEM MAIN RESISTOR A087666E01 OK 9 INSPECT MAIN BATTERY CABLE Shielded A A093737E01 HV CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the battery cover (see page HB-93). (c) Check if the main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (d) Remove the terminal (A in the illustration) on the battery module side of the main battery cable only. (e) Using a megohmmeter, measure the insulation resistance between each terminal of the main battery cable and the shielded ground. Standard resistance: 10 MΩ or higher NG REPLACE MAIN BATTERY CABLE OK 10 INSPECT NO. 2 MAIN BATTERY CABLE A A093738E01 CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, check if the No. 2 main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (b) Remove the terminal (A in illustration) on the battery module side of the No. 2 main battery cable only. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 main battery cable and the shielded ground. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–431 Standard resistance: 10 MΩ or higher NG REPLACE NO. 2 MAIN BATTERY CABLE OK 11 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, disconnect only the connecting terminal of the battery plug. NOTICE: Do not reinstall the service plug grip. (b) Using a megohmmeter, measure the insulation resistance between each terminal of the battery plug wire harness and body ground. Standard resistance: 10 MΩ or higher A090474E01 NG REPLACE BATTERY PLUG OK 12 INSPECT NO. 2 FRAME WIRE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, check if the No. 2 frame wire cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body. (b) Remove all the terminals on the battery module side of the No. 2 frame wire. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 frame wire connector and the battery case. Standard resistance: 10 MΩor higher NG A090471E01 OK REPLACE NO. 2 FRAME WIRE HV HV–432 13 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT JUNCTION BLOCK CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, remove the junction block. (b) Visually check the junction block for any damage. OK: No cracks or damage NG REPLACE JUNCTION BLOCK A090472E01 OK 14 INSPECT HV BATTERY ASSEMBLY CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, measure the insulation resistance between each terminal (positive and negative side) of each battery module of the HV battery assembly and the battery case using a megohmmeter. Standard resistance: Some of the battery modules have continuity of below 10 MΩ HV NG REPLACE BATTERY ECU ASSEMBLY A090470E01 OK REPLACE HV SUPPLY BATTERY ASSEMBLY 15 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–433 (b) Disconnect all the high-voltage terminals of the system main relays. (c) Measure the resistance at the switch side of the system main relays. Standard resistance: Below 1 Ω NG A087664E02 GO TO "CHECK INSULATION RESISTANCE" PROCEDURE AFTER REPLACING STUCK SYSTEM MAIN RELAY OK 16 CHECK FRAME WIRE FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect the frame wire from the inverter. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground. Standard resistance: 10 MΩor higher NG REPLACE FRAME WIRE A087667E01 HV OK 17 CHECK HV TRANSAXLE ASSEMBLY FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Remove the inverter cover (see page HV-531). HV–434 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) Disconnect the three-phase alternating current cables for the motor and generator from the inverter. (d) Using a megohmmeter, measure the insulation resistance between the 6 terminals of the three-phase alternating current cables on the transaxle side and the body ground. Standard resistance Hybrid Vehicle Motor: I14 U W V Hybrid Vehicle Generator: I15 Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher NG V W REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY U A127509E01 OK REPLACE INVERTER WITH CONVERTER ASSEMBLY 18 HV CHECK HV TRANSAXLE AREA FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (d) Disconnect the three-phase alternating current cables for the motor and generator from the inverter. (e) Using a megohmmeter, measure the insulation resistance between the 6 terminals of the three-phase alternating current cables on transaxle side and the body ground. Standard resistance Hybrid Vehicle Motor: U I14 V W Hybrid Vehicle Generator: W V HV–435 I15 Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher OK U REPLACE INVERTER WITH CONVERTER ASSEMBLY A125413E01 NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 19 CHECK HIGH VOLTAGE DIRECT CURRENT AREA FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the frame wire from the inverter. (d) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground. Standard resistance: 10 MΩ or higher OK A087667E01 NG REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–436 20 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK FRAME WIRE FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect the frame wire from the system main relays. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE FRAME WIRE A087670E01 OK 21 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect all the high-voltage terminals of the system main relays. (c) Measure the resistance at the switch side of the system main relays. Standard resistance: Below 1 Ω HV NG A087664E02 GO TO "CHECK INSULATION RESISTANCE" PROCEDURE AFTER REPLACING STUCK SYSTEM MAIN RELAY OK 22 CHECK SYSTEM MAIN RELAYS FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Check that all the high-voltage terminals of the system main relays have been disconnected. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–437 (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the system main relays and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE SYSTEM MAIN RELAY WITH REDUCED INSULATION RESISTANCE A087665E01 OK 23 CHECK SYSTEM MAIN RESISTOR FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Check that both terminals of the system main resistor have been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminal of the system main resistor and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE SYSTEM MAIN RESISTOR A087666E01 HV OK 24 INSPECT MAIN BATTERY CABLE Shielded A A093737E01 CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the battery cover (see page HB-93). (c) Check if the main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (d) Remove the terminal (A in the illustration) on the battery module side of the main battery cable only. (e) Using a megohmmeter, measure the insulation resistance between each terminal of the main battery cable and the shielded ground. Standard resistance: 10 MΩ or higher HV–438 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPLACE MAIN BATTERY CABLE OK 25 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, check if the No. 2 main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (b) Remove the terminal (A in illustration) on the battery module side of the No. 2 main battery cable only. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 main battery cable and the shielded ground. Standard resistance: 10 MΩ or higher A NG REPLACE NO. 2 MAIN BATTERY CABLE A093738E01 OK HV 26 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, disconnect only the connecting terminal of the battery plug. NOTICE: Do not reinstall the service plug grip. (b) Using a megohmmeter, measure the insulation resistance between each terminal of the battery plug wire harness and the body ground. Standard resistance: 10 MΩ or higher A090474E01 NG REPLACE BATTERY PLUG OK 27 INSPECT NO. 2 FRAME WIRE CAUTION: Wear insulated gloves and goggles before performing the following operation. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–439 (a) Following the previous step, check if the No. 2 frame wire cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body. (b) Remove all the terminals on the battery module side of the No. 2 frame wire. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 frame wire connector and the battery case. Standard resistance: 10 MΩ or higher NG REPLACE NO. 2 FRAME WIRE A090471E01 OK 28 INSPECT JUNCTION BLOCK CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, remove the junction block. (b) Visually check the junction block for any damage. OK: No cracks or damage NG REPLACE JUNCTION BLOCK HV A090472E01 OK 29 INSPECT HV BATTERY ASSEMBLY CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, measure the insulation resistance between each terminal (positive and negative side) of each battery module of the HV battery assembly and the battery case using a megohmmeter. Standard resistance: Some of the battery modules have continuity of below 10 MΩ NG A090470E01 REPLACE BATTERY ECU ASSEMBLY HV–440 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE HV SUPPLY BATTERY ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–441 DTC P0ADC226 Hybrid Battery Positive Contactor Control Circuit High DTC P0ADB227 Hybrid Battery Positive Contactor Control Circuit Low DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). The HV control ECU monitors the proper operation of the No. 2 system main relay (CON2) to check for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0ADC 226 Open or +B short in No. 2 system main relay circuit • • • Wire harness or connector No. 2 system main relay HV control ECU P0ADB 227 GND short in No. 2 system main relay circuit • • • Wire harness or connector No. 2 system main relay HV control ECU WIRING DIAGRAM Refer to DTC P0AE7 (INF 224) (see page HV-445). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 2 SYSTEM MAIN RELAY (a) Inspect the No. 2 system main relay (see page HB-126). NG REPLACE NO. 2 SYSTEM MAIN RELAY OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 2 SYSTEM MAIN RELAY) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see pageHB-154 ). HV HV–442 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. H16 CON2 HV Control ECU Connector A065745E43 Wire Harness Side: No. 2 System Main Relay Connector S22 CON2 A093716E04 (d) Disconnect the S22 No. 2 system main relay connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CON2 (H16-2) - Body ground Below 1 V (g) Turn the power switch OFF. (h) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) HV Tester Connection Specified Condition CON2 (H16-2) - CON2 (S22-2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CON2 (H16-2) or CON2 (S22-2) - Body ground 10 kΩ or higher (i) Reconnect the No. 2 system main relay connector. (j) Reconnect the HV control ECU connector. (k) Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–443 DTC P0AE0228 Hybrid Battery Negative Contactor Control Circuit High DTC P0ADF229 Hybrid Battery Negative Contactor Control Circuit Low DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). The HV control ECU monitors the proper operation of the No. 3 system main relay (CON3) to check for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0AE0 228 Open or +B short in No. 3 system main relay circuit • • • Wire harness or connector No. 3 system main relay HV control ECU P0ADF 229 GND short in No. 3 system main relay circuit • • • Wire harness or connector No. 3 system main relay HV control ECU MONITOR DESCRIPTION DTC P0AE0 (INF 228): The HV control ECU monitors the proper operation of the No. 3 system main relay (CON3). If the HV control ECU detects an open or short malfunction of the relay circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0AE0 (INF 228): Rationality (cont3 malfunction) Required sensor / components No. 3 system main relay Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS No. 3 system main relay circuit Short COMPONENT OPERATING RANGE No. 3 system main relay WIRING DIAGRAM Refer to DTC P0AE7 (INF 224) (see page HV-445). DTC P0AE0 (INF 228) is not detected HV HV–444 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 3 SYSTEM MAIN RELAY (a) Inspect the No. 3 system main relay (see page HB-126). NG REPLACE NO. 3 SYSTEM MAIN RELAY OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 3 SYSTEM MAIN RELAY) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. HV H16 CON3 HV Control ECU Connector A065745E44 Wire Harness Side: No. 3 System Main Relay Connector S22 CON3 A093717E04 (d) Disconnect the S22 No. 3 system main relay connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CON3 (H16-3) - Body ground Below 1 V P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–445 (g) Turn the power switch OFF. (h) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CON3 (H16-3) - CON3 (S22-3) Below 1 Ω Standard resistance (Check for short) Specified Connection Specified Condition CON3 (H16-3) or CON3 (S22-3) - Body ground 10 kΩ or higher (i) Reconnect the No. 3 system main relay connector. (j) Reconnect the HV control ECU connector. (k) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–446 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AE7224 Hybrid Battery Precharge Contactor Control Circuit High DTC P0AE6225 Hybrid Battery Precharge Contactor Control Circuit Low DESCRIPTION SMR2 SMR1 Resistor Service Plug Grip SMR3 A093714E01 HV The SMRs (System Main Relays) connect and disconnect the high-voltage power supply circuit in accordance with requests from the HV control ECU. To ensure a reliable operation, they consists of a total of 3 relays (1 for the negative side and 2 for the positive side). To connect, SMR1 and SMR3 turn ON initially. Then, SMR2 turns ON and SMR1 turns OFF. This process protects the circuit from the high-voltage surge current by allowing the limit current to flow via the resistor. To disconnect, SMR2 and SMR3 turn OFF in that order. The HV control ECU checks that the relays have turned OFF properly. The HV control ECU monitors the proper operation of the SMRs (CON1, CON2 and CON3) to check for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0AE7 224 Open or +B short in No. 1 system main relay circuit • • • Wire harness or connector No. 1 system main relay HV control ECU P0AE6 225 GND short in No. 1 system main relay circuit • • • Wire harness or connector No. 1 system main relay HV control ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–447 WIRING DIAGRAM HV Control ECU HV Battery Assembly No. 2 System Main Relay (+) 2 S22 G 1 IC1 G 2 H16 CON2 1 S22 R 2 IC1 R 1 H16 CON1 22 IC1 Y 3 H16 CON3 System Main Resistor Service Plug Grip No. 1 System Main Relay (-) 3 S22 No. 3 System Main Relay Y A092107E04 INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG OK REPLACE NO. 1 SYSTEM MAIN RELAY HV HV–448 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 SYSTEM MAIN RELAY) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Disconnect the H16 HV control ECU connector. H16 CON1 HV Control ECU Connector A065745E42 Wire Harness Side: No. 1 System Main Relay Connector S22 HV CON1 A093715E04 (d) Disconnect the S22 No. 1 system main relay connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CON1 (H16-1) - Body ground Below 1 V (g) Turn the power switch OFF. (h) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CON1 (H16-1) - CON1 (S22-1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CON1 (H16-1) or CON1 (S22-1) - Body ground 10 kΩ or higher (i) Reconnect the No. 1 system main relay connector. (j) Reconnect the HV control ECU connector. (k) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–449 OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–450 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AEE276 Motor Inverter Temperature Sensor "A" Circuit Range / Performance DTC P0AEE277 Motor Inverter Temperature Sensor "A" Circuit Range / Performance DESCRIPTION Refer to DTC P0AEF (INF 275) (see page HV-453). DTC No. INF Code DTC Detection Condition Trouble Area P0AEE 276 Sudden change in motor inverter temperature sensor output • • • • • • P0AEE 277 Motor inverter temperature sensor output deviation • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly WIRING DIAGRAM Refer to DTC P0AEF (INF 275) (see page HV-453). INSPECTION PROCEDURE HV CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG OK ADD HV COOLANT P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–451 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV453]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E02 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG OK REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–452 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 6 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). HV NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 9 HV–453 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG CONNECT SECURELY Inverter Connector A092044E05 OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the H15 HV control ECU connector. H15 GINV MIVT HV Control ECU Connector A065744E29 HV HV–454 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 I9 GINV I10 Inverter Connector MIVT A092063E05 (c) Disconnect the I9 and I10 inverter connectors. (d) 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. (e) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition MIVT (H15-19) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MIVT (H15-19) - MIVT (I10-26) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MIVT (H15-19) or MIVT (I10-26) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (h) (i) (j) (k) HV Reconnect the inverter connectors. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV–455 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AEF275 Drive Motor Inverter Temperature Sensor "A" Circuit Low DTC P0AF0274 Drive Motor Inverter Temperature Sensor "A" Circuit High DESCRIPTION The HV control ECU uses a temperature sensor, which is built into the inverter, to detect the temperature of the motor inverter. The same cooling system that is routed to the MG1 and MG2 cools the inverter. This cooling system is independent from the engine cooling system. The characteristic of the motor inverter temperature sensor is the same as the boost converter temperature sensor (see page HV-395). The HV control ECU limits the load based on the signals transmitted by the motor inverter temperature sensor, in order to check the effectiveness of the inverter cooling system and prevent the inverter from overheating. Furthermore, the HV control ECU detects a malfunction in the wiring of the motor inverter temperature sensor, as well as in the sensor itself. DTC No. INF Code DTC Detection Condition Trouble Area P0AEF 275 Open or GND short in motor inverter temperature sensor circuit • • P0AF0 274 +B short in motor inverter temperature sensor circuit • • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P0AEF (INF 275) or P0AF0 (INF 274), confirm MG2 INVERT TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction -50°C (-58°F) +B short circuit 205°C (401°F) Open or GND short circuit HV WIRING DIAGRAM Inverter HV Control ECU (Shielded) 26 MIVT I10 L 19 H15 MIVT 16 GINV I10 Y 23 H15 GINV J5 J/C A IK A092106E08 HV–456 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ VALUE OF INTELLIGENT TESTER (MG2 INVERT TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG2 INVERT TEMP value. Result: Temperature Displayed Proceed 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 intelligent tester indicates -50°C (-58°F). • If there is an open or GND short circuit, the intelligent tester indicates 205°C (401°F). HV B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–457 (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 GINV I10 Inverter Connector MIVT A092041E30 Motor Inverter Temperature Sensor HV Control ECU MIVT GINV A125426E04 (e) 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. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the MG2 INVERT TEMP value. OK: 205°C (401°F) (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H15 HV control ECU connector. H15 GINV MIVT HV Control ECU Connector A065744E29 HV HV–458 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Motor Inverter Temperature Sensor HV Control ECU MIVT GINV (b) 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. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MG2 INVERT TEMP value. OK: 205°C (401°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E03 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. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. HV H15 GINV MIVT HV Control ECU Connector A065744E29 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–459 (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: I10 Tester Connection Specified Condition MIVT (H15-19) - MIVT (I10-26) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) GINV I10 Inverter Connector MIVT A092041E30 Tester Connection Specified Condition MIVT (H15-19) or MIVT (I10-26) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 INSPECT HYBRID VEHICLE CONTROL ECU (MIVT VOLTAGE) H15 GINV (-) MIVT (+) HV Control ECU Connector A093719E20 (a) 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. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage Tester Connection Specified Condition MIVT (H15-19) - GINV (H15-23) 2.0 to 4.5 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–460 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P2120-111 Throttle / Pedal Position Sensor / Switch "D" Circuit DTC P2121-106 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance DTC P2121-114 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance DTC P2125-112 Throttle / Pedal Position Sensor / Switch "E" Circuit DTC P2126-109 Throttle / Pedal Position Sensor / Switch "E" Circuit Range / Performance DTC P2138-110 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation DESCRIPTION Refer to DTC P2122 (INF 104) (see page HV-460). HV DTC No. INF Code DTC Detection Condition Trouble Area P2120 111 Accelerator pedal position main sensor value does not change while its sub sensor value changes • Accelerator pedal rod P2121 106 Internal error of accelerator pedal position main sensor • Accelerator pedal rod P2121 114 Accelerator pedal not smoothly returning to its original position • Accelerator pedal rod P2125 112 Accelerator pedal position sub sensor value does not change while its main sensor value changes • Accelerator pedal rod P2126 109 Internal error of accelerator pedal position sub sensor • Accelerator pedal rod P2138 110 Difference between main sensor value and sub sensor value is large • Accelerator pedal rod INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the Accelerator pedal rod. 1 REPLACE ACCELERATOR PEDAL ROD (a) Replace the Accelerator pedal rod (see page HV-567). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–461 NEXT COMPLETED HV HV–462 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P2122-104 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input DTC P2123-105 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input DTC P2127-107 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input DTC P2128-108 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input DESCRIPTION HV HINT: • This is the repair procedure for the accelerator pedal position sensor. • This electrical throttle system does not use a throttle cable. • This accelerator pedal position sensor is a non-contact type. The accelerator pedal position sensor is mounted on the accelerator pedal to detect how much it is depressed. It has 2 sensor terminals (VPA and VPA2) to detect the accelerator pedal position and a malfunction of the accelerator pedal position sensor itself. Since this sensor is electronically controlled with hall elements, accurate control and reliability can be obtained. In the accelerator pedal position sensor, the voltage applied to terminals VPA and VPA2 of the HV control ECU changes between 0 V and 5 V in proportion to the degree of depressing the accelerator pedal. The VPA is a signal to indicate the actual accelerator pedal position angle which is used for the HV system control, and the VPA2 is a signal to indicate the actual accelerator pedal position angle which is used for detecting a malfunction of the sensor itself (terminal VPA). The HV control ECU judges how much the accelerator pedal is being depressed from the VPA and VPA2 signals, and controls the HV system based on the signals. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–463 Sensor Voltage (V) 5 Hall Element Magnet 4 VPA 3.2 EPA 5V VPA 1.6 VCPA 0.8 VPA2 EPA2 5V VCP2 Full-Close Full-Open Accelerator Pedal Position Magnet Accelerator Pedal Position Sensor VPA2 HV Control ECU HV A019803E25 DTC No. INF Code DTC Detection Condition Trouble Area P2122 104 Open or GND short in accelerator pedal position main sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU P2123 105 +B short in accelerator pedal position main sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU P2127 107 Open or GND short in accelerator pedal position sub sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU P2128 108 +B short in accelerator pedal position sub sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU HV–464 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM A13 Accelerator Pedal Position Sensor VPA EPA VCPA VPA2 EP2 VCP2 (Shielded) HV Control ECU 6 L 26 VPA1 H16 5 B 27 H16 4 Y EP1 25 VCP1 H16 3 W 34 VPA2 H16 2 R 35 H16 1 EP2 33 VCP2 H16 G J5 J/C A IK A092108E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND #2) (a) (b) (c) (d) HV Depressed Released FI07052E10 NG Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the ACCEL POS #1 and #2 values on the intelligent tester with the engine stopped. OK: Changes with accelerator pedal pressure OK Go to step 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–465 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ACCELERATOR PEDAL POSITION SENSOR) (a) Disconnect the H16 HV control ECU connector. H16 VPA1 EP1 VCP1 EP2 VCP2 VPA2 HV Control ECU Connector A065745E48 Wire Harness Side: Accelerator Pedal Position Sensor Connector A13 (b) Disconnect the A13 accelerator pedal position sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection VCP2 EP2 VPA2 VCPA EPA VPA Specified Condition VPA1 (H16-26) - Body ground Below 1 V VCP1 (H16-25) - Body ground Below 1 V A092050E02 EP1 (H16-27) - Body ground Below 1 V VPA2 (H16-34) - Body ground Below 1 V VCP2 (H16-33) - Body ground Below 1 V EP2 (H16-35) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VPA1 (H16-26) - VPA (A13-6) Below 1 Ω VCP1 (H16-25) - VCPA (A13-4) Below 1 Ω EP1 (H16-27) - EPA (A13-5) Below 1 Ω VPA2 (H16-34) - VPA2 (A13-3) Below 1 Ω VCP2 (H16-33) - VCP2 (A13-1) Below 1 Ω EP2 (H16-35) - EP2 (A13-2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VPA1 (H16-26) or VPA (A13-6) - Body ground 10 kΩor higher VCP1 (H16-25) or VCPA (A13-4) Body ground 10 kΩor higher EP1 (H16-27) or EPA (A13-5) - Body ground 10 kΩor higher VPA2 (H16-34) or VPA2 (A13-3) Body ground 10 kΩor higher VCP2 (H16-33) or VCP2 (A13-1) Body ground 10 kΩor higher HV HV–466 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition EP2 (H16-35) or EP2 (A13-2) - Body ground 10 kΩor higher (g) Reconnect the accelerator pedal position sensor connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT HYBRID VEHICLE CONTROL ECU (VCP1 OR VCP2 VOLTAGE) (a) Disconnect the A13 accelerator pedal position sensor connector. (b) Turn the power switch ON (IG). Accelerator Pedal Position Sensor Connector A092051E01 EP1 H16 (c) Measure the voltage between the terminals of the HV control ECU connector. Standard voltage VCP1 HV VCP2 EP2 HV Control ECU Connector Tester Connection Specified Condition VCP1 (H16-25) - EP1 (H16-27) 4.5 to 5.5 V VCP2 (H16-33) - EP2 (H16-35) 4.5 to 5.5 V (d) Reconnect the accelerator pedal position sensor connector. A093719E14 NG REPLACE HYBRID VEHICLE CONTROL ECU OK 4 REPLACE ACCELERATOR PEDAL ROD (a) Replace the Accelerator pedal rod (see page HV-567). GO 5 CHECK IF DTC OUTPUT RECURS (DTC P2122, P2123, P2127 OR P2128) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Perform a simulation test. (f) Read DTCs. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–467 Result: DTC P2122, P2123, P2127 or P2128 is not output again YES SYSTEM IS OK NO REPLACE HYBRID VEHICLE CONTROL ECU HV HV–468 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3000-123 HV Battery Malfunction DTC P3000-125 HV Battery Malfunction DTC P3000-603 HV Battery Malfunction DESCRIPTION The HV control ECU gives warning to the driver and performs the fail-safe control, according to the abnormal signal received from the battery ECU. DTC No. INF Code DTC Detection Condition Trouble Area P3000 123 Abnormal signal input from battery ECU (HV battery system malfunction) • • HV battery system Battery ECU P3000 125 Abnormal signal input from battery ECU (High voltage fuse blown out) • • HV battery system Battery ECU P3000 603 Abnormal signal input from battery ECU (HV battery cooling system malfunction) • • HV battery system Battery ECU INSPECTION PROCEDURE HINT: After repairing the malfunction, restart the system (to turn the READY light ON) and recheck the DTCs. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output HV YES NO REPLACE BATTERY ECU ASSEMBLY GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–469 P3000-388 HV Battery Malfunction DESCRIPTION Based on the malfunction signal received from the battery ECU, the system alerts the driver and effects fail-safe control. This DTC is output when the SOC (state of charge) of the HV battery decreases as a result of leaving the vehicle in the N position, running out of fuel, or malfunction in the HV control system. DTC No. INF Code DTC Detection Condition Trouble Area P3000 388 Abnormal signal input from battery ECU (discharge inhibition control malfunction) • • • HV control system Fuel shortage HV battery assembly INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P3000 (INF 388) and other DTCs are output HINT: If any other codes besides P3000 (INF 388) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK AMOUNT OF GASOLINE (a) Turn the power switch ON (IG). (b) Check the amount of gasoline with the fuel gauge in the meter. OK: Appropriate amount of gasoline NG REFUEL GASOLINE OK 3 CHECK IF ENGINE STARTS (a) Turn the power switch ON (READY). (b) Check if the engine starts. OK: The engine starts NO REPLACE HV SUPPLY BATTERY ASSEMBLY HV HV–470 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES LEAVE VEHICLE IN P POSITION, AND CHARGE HV BATTERY IN IDLE STATUS UNTIL IDLING STOPS HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–471 P3000-389 HV Battery Malfunction DESCRIPTION Based on the malfunction signal received from the battery ECU, the system alerts the driver and effects fail-safe control. This DTC is output if the HV battery is depleted or the HV control system has malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P3000 389 Abnormal signal input from battery ECU (drop of high voltage) • • HV control system HV battery assembly INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P3000 (INF 389) and other DTCs are output HINT: If any other codes besides P3000 (INF 389) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART HV NO 2 CHECK IF ENGINE STARTS (a) Turn the power switch ON (READY). (b) Check if the engine starts. OK: The engine starts NG REPLACE HV SUPPLY BATTERY ASSEMBLY OK LEAVE VEHICLE IN P POSITION, AND CHARGE HV BATTERY IN IDLE STATUS UNTIL IDLING STOPS HV–472 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P3004-131 Power Cable Malfunction DESCRIPTION DTC No. INF Code DTC Detection Condition Trouble Area P3004 131 High voltage fuse has blown out, service plug grip is disconnected or limiter resistance is cut off • • • • • • • • • • HV battery system System main resistor No. 1 system main relay No. 2 system main relay No. 3 system main relay Main battery cable No. 2 main battery cable Frame wire Inverter with converter assembly HV control ECU WIRING DIAGRAM Refer to DTC P0A78 (INF 266) (see page HV-223). HV Battery Assembly HV Control ECU No. 2 System Main Relay (+) 2 S22 G 1 IC1 G 2 H16 CON2 1 S22 R 2 IC1 R 1 H16 CON1 22 IC1 Y 3 H16 CON3 System Main Resistor HV Service Plug Grip No. 1 System Main Relay (-) No. 3 System Main Relay 3 S22 Y A092107E03 INSPECTION PROCEDURE CAUTION: • 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. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–473 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTC P0A95 is output YES GO TO DTC P0A95 NO 2 INSPECT SYSTEM MAIN RESISTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the system main resistor (see page HB-136). (b) Measure the resistance between the terminals. Standard resistance: 18 to 22 Ω (c) Reinstall the system main resistor (see page HB-136). NG REPLACE SYSTEM MAIN RESISTOR A090485E01 OK 3 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG REPLACE NO. 1 SYSTEM MAIN RELAY OK 4 INSPECT NO. 2 SYSTEM MAIN RELAY (a) Inspect the No. 2 system main relay (see page HB-126). NG OK REPLACE NO. 2 SYSTEM MAIN RELAY HV HV–474 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT NO. 3 SYSTEM MAIN RELAY (a) Inspect the No. 3 system main relay (see page HB-126). NG REPLACE NO. 3 SYSTEM MAIN RELAY OK 6 INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the main battery cable (see page HB-103). (c) Measure the resistance between the terminals of the main battery cable. Standard resistance: Below 1 Ω NG REPLACE MAIN BATTERY CABLE A090469E01 OK 7 HV INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Check the cover and terminals of the main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the main cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. NG OK REPLACE MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 8 HV–475 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the No. 2 main battery cable with the HV battery assembly removed (see page HB-103). (b) Measure the resistance between the terminals of the No. 2 main battery cable. Standard resistance: Below 1 Ω NG REPLACE NO. 2 MAIN BATTERY CABLE A090468E01 OK 9 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Check the cover and terminals of the No. 2 main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the No. 2 main battery cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. NG REPLACE NO. 2 MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY OK 10 INSPECT FRAME WIRE CAUTION: Wear insulated gloves before performing the following operation. HV HV–476 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (a) Disconnect the frame wire from the inverter with converter. A B A087667E02 (b) Check that the frame wire has been disconnected from the system main relay. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and body ground. Standard resistance D C Tester Connection Specified Condition A - Body ground 10 MΩ or higher B - Body ground 10 MΩ or higher A093739E01 (d) Measure the resistance between the terminals of the frame wire. Standard resistance Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (e) Reinstall the HV battery assembly (see page HB-96). (f) Reconnect the frame wire. HV NG REPLACE FRAME WIRE OK 11 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–477 (d) Disconnect the H15 HV control ECU connector. H15 GINV VH HV Control ECU Connector A065744E40 (e) Disconnect the I10 inverter connector. Standard resistance (Check for open) Wire Harness Side: I10 Tester Connection Specified Condition VH (H15-26) - VH (I10-12) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for short) VH GINV I10 Inverter Connector Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 MΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 MΩ or higher A092041E32 (h) (i) (j) (k) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 12 INSPECT HYBRID VEHICLE CONTROL ECU (HV VOLTAGE) (a) Turn the power switch ON (READY). 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. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage H15 GINV (-) VH (+) HV Control ECU Connector A093719E15 Tester Connection Specified Condition VH (H15-26) - GINV (H15-23) 0.3 to 0.7 V NG REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–478 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE HYBRID VEHICLE CONTROL ECU HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–479 P3004-132 Power Cable Malfunction DESCRIPTION DTC No. INF Code DTC Detection Condition Trouble Area P3004 132 Inverter voltage sensor malfunction, or limiter resistance increases • • • • • • • • • HV control system System main resistor No. 1 system main relay No. 3 system main relay Main battery cable No. 2 main battery cable Frame wire Inverter with converter assembly HV control ECU WIRING DIAGRAM Refer to DTC P3004 (INF 131) (see page HV-470). INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) HV (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P3004 (INF 132) and other DTCs are output HINT: If any other codes besides P3004 (INF 132) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT SYSTEM MAIN RESISTOR CAUTION: Wear insulated gloves and goggles before performing the following operation. HV–480 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (a) Remove the system main resistor (see page HB-136). (b) Measure the resistance between the terminals. Standard resistance: 18 to 22 Ω (c) Reinstall the system main resistor (see page HB-136). NG REPLACE SYSTEM MAIN RESISTOR A090485E01 OK 3 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG REPLACE NO. 1 SYSTEM MAIN RELAY OK 4 INSPECT NO. 3 SYSTEM MAIN RELAY (a) Inspect the No. 3 system main relay (see page HB-126). NG REPLACE NO. 3 SYSTEM MAIN RELAY OK HV 5 INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the main battery cable (see page HB-103). (c) Measure the resistance between the terminals of the main battery cable. Standard resistance: Below 1 Ω NG REPLACE MAIN BATTERY CABLE A090469E01 OK 6 INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–481 (a) Check the cover and terminals of the main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the main cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. NG REPLACE MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY OK 7 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the No. 2 main battery cable with the HV battery assembly removed (see page HB-103). (b) Measure the resistance between the terminals of the No. 2 main battery cable. Standard resistance: Below 1 Ω NG REPLACE NO. 2 MAIN BATTERY CABLE A090468E01 OK 8 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Check the cover and terminals of the No. 2 main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the No. 2 main battery cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. HV HV–482 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPLACE NO. 2 MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY OK 9 INSPECT FRAME WIRE CAUTION: Wear insulated gloves before performing the following operation. (a) Disconnect the frame wire from the inverter with converter. A B A087667E02 (b) Check that the frame wire has been disconnected from the system main relay. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and body ground. Standard resistance HV D C Tester Connection Specified Condition A - Body ground 10 MΩ or higher B - Body ground 10 MΩ or higher A093739E01 (d) Measure the resistance between the terminals of the frame wire. Standard resistance Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (e) Reinstall the HV battery assembly (see page HB-96). (f) Reconnect the frame wire. NG REPLACE FRAME WIRE OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–483 NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. H15 VH GINV HV Control ECU Connector A065744E40 (e) Disconnect the I10 inverter connector. (f) 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. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage (Check for open) Wire Harness Side: I10 VH GINV I10 Inverter Connector A092041E32 Tester Connection Specified Condition VH (H15-26) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for short) Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) Reconnect the inverter connector. (k) Reconnect the HV control ECU connector. (l) Reinstall the inverter cover (see page HV-538). (m) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 11 CHECK HYBRID VEHICLE CONTROL ECU (VH VOLTAGE) (a) Turn the power switch ON (READY). HV HV–484 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 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. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage H15 GINV (-) VH (+) HV Control ECU Connector Tester Connection Specified Condition VH (H15-26) - GINV (H15-23) 1.6 to 3.8 V NG A093719E12 OK REPLACE HYBRID VEHICLE CONTROL ECU HV REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–485 P3004-133 Power Cable Malfunction DESCRIPTION The HV control ECU gives warning to the driver and performs the fail-safe control, according to the abnormal signal received from the battery ECU. DTC No. INF Code DTC Detection Condition Trouble Area P3004 133 Abnormal signal input from battery ECU • • HV battery system Battery ECU INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO REPLACE BATTERY ECU ASSEMBLY HV HV–486 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3102-524 Transmission Control ECU Malfunction DTC P3102-525 Transmission Control ECU Malfunction DTC P3102-581 Transmission Control ECU Malfunction DTC P3102-582 Transmission Control ECU Malfunction DTC P3102-597 Transmission Control ECU Malfunction DTC P3102-598 Transmission Control ECU Malfunction DTC P3102-599 Transmission Control ECU Malfunction DESCRIPTION When a signal is input from the P position switch or selector lever, the HV control ECU transmits a P position control (PCON) signal to the transmission control ECU assembly. Based on this signal, the transmission control ECU assembly actuates the shift control actuator in order to mechanically lock or unlock the counter drive gear in the HV transaxle assembly. If the shift control actuator is in the P position, the transmission control ECU assembly transmits a P position (PPOS) signal to the HV control ECU. Transmission Control ECU Assembly P Position Switch HV Control ECU PCON Signal HV PPOS Signal Selector Lever HV Transaxle Assembly P Switch Signal Actuator Position Signal Shift Control Actuator A090456E02 DTC No. INF Code DTC Detection Condition Trouble Area P3102 524 BEAN communication problem of transmission control ECU assembly • • • • P3102 525 Transmission control ECU IG OFF command malfunction • • • • P3102 581 Transmission control ECU malfunction • • • • Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area P3102 582 P position (PPOS) signal is logically inconsistent • • • • P3102 597 GND short in P position (PPOS) signal circuit • • • • P3102 598 +B short in P position (PPOS) signal circuit • • • • P3102 599 P position (PPOS) signal malfunction (output pulse is abnormal) • • • • HV–487 Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU WIRING DIAGRAM HV Control ECU T4 Transmission Control ECU Assembly PCON PPOS 7 9 H17 PCON LG J14 J/C 8 W B B B P6 Power Source Control ECU W 10 H17 PPOS HV W 12 II1 P 5 W 4 4J 2 4I W No. 1 Center Connector A093258E02 HV–488 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU TRANSMISSION CONTROL ECU ASSEMBLY AND POWER SOURCE CONTROL ECU) (a) Disconnect the H17 HV control ECU connector. H17 PCON PPOS HV Control ECU Connector A065743E82 (b) Disconnect the T4 transmission control ECU assembly connector. Wire Harness Side: PCON PPOS T4 Transmission Control ECU Assembly Connector A092055E02 Wire Harness Side: Power Source Control ECU Connector HV P P6 B079748E02 (c) Disconnect the P6 power source control ECU connector. (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition PCON (H17-9) - Body ground Below 1 V PPOS (H17-10) - Body ground Below 1 V (e) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition PCON (H17-9) - PCON (T4-7) Below 1 Ω PPOS (H17-10) - PPOS (T4-8) Below 1 Ω PPOS (H17-10) - P (P6-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition PCON (H17-9) or PCON (T4-7) - Body ground 10 kΩ or higher PPOS (H17-10) or PPOS (T4-8) - Body ground 10 kΩ or higher PPOS (H17-10) or P (P6-5) - Body ground 10 kΩ or higher (f) Reconnect the power source control ECU connector. (g) Reconnect the transmission control ECU assembly connector. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–489 (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 CHECK HARNESS AND CONNECTOR (CHECK FOR +B SHORT IN WIRE HARNESS) H17 H14 (a) Inspect the HV control ECU using an oscilloscope. (b) Turn the power switch ON (IG). GND1 PPOS PCON HV Control ECU Connector A093719E13 5 V / Division CH1 GND CH2 GND (c) Check the waveforms of the voltages between the terminals PCON (H17-9) and GND1 (H14-1), and terminals PPOS (H17-10) and GND1 (H14-1), of the HV control ECU connectors, in order to check for +B short in the signal lines PCON and PPOS. OK: No +B short in either PCON or PPOS signal lines. HINT: • If there is +B short in the signal line, the output voltage is constantly between 9 V and 14 V. • If the signal lines are normal, the waveforms are displayed as shown in the diagram. NG 20 ms / Division REPAIR OR REPLACE HARNESS OR CONNECTOR CH1: PCON Signal Waveform CH2: PPOS Signal Waveform A125641E01 OK 3 READ OUTPUT DTC (T/M CONTROL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / T/M CONTROL / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output HV HV–490 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES GO TO RELEVANT DTC CHART NO REPLACE HV CONTROL ECU, TRANSMISSION ECU AND POWER SOURCE CONTROL ECU HV HV–491 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3107-213 Airbag ECU Communication Circuit Malfunction DTC P3107-214 Airbag ECU Communication Circuit Malfunction DTC P3107-215 Airbag ECU Communication Circuit Malfunction DESCRIPTION The HV control ECU detects a malfunction of the collision signal circuit from the center airbag sensor and gives warning to the driver. DTC No. INF Code DTC Detection Condition Trouble Area P3107 213 GND short in communication circuit between center airbag sensor and HV control ECU • • Wire harness or connector Center airbag sensor P3107 214 Open or +B short in communication circuit between center airbag sensor and HV control ECU • • Wire harness or connector Center airbag sensor P3107 215 Abnormal communication signals between center airbag sensor and HV control ECU • • Wire harness or connector Center airbag sensor WIRING DIAGRAM Center Airbag Sensor HV Control ECU Driver Side Junction Block 22 GSW2 A18 B 15 1E 3 1E No. 2 Center Connector L 14 5L 2 5F L 20 H14 ABFS A092110E04 HV HV–492 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - CENTER AIRBAG SENSOR) (a) Disconnect the H14 HV control ECU connector. H14 HV Control ECU Connector ABFS A065748E37 Center Airbag Sensor Connector (b) Disconnect the A18 center airbag sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage A18 GSW2 A092062E02 HV Tester Connection Specified Condition ABFS (H14-20) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition ABFS (H14-20) - GSW2 (A18-22) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition ABFS (H14-20) or GSW2 (A18-22) Body ground 10 kΩ higher (g) Reconnect the center airbag sensor connector. (h) Reconnect the HV control ECU connector. NG OK REPLACE CENTER AIRBAG SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR HV–493 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3108-535 A/C Amplifier Communication Circuit Malfunction DTC P3108-536 A/C Amplifier Communication Circuit Malfunction DTC P3108-538 A/C Amplifier Communication Circuit Malfunction DESCRIPTION The HV control ECU detects a wiring malfunction in the serial communication line of the A/C inverter. DTC No. INF Code DTC Detection Condition Trouble Area P3108 535 Serial communication malfunction • • Wire harness or connector Inverter with converter assembly P3108 536 A/C inverter malfunction • • Wire harness or connector Inverter with converter assembly P3108 538 Open in STB signal circuit • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM A/C Inverter HV Control ECU HV 4 CLK I11 G 17 H16 CLK 2 TOECU I11 Y 14 H16 ITE 3 TOINV I11 R 24 H16 ETI 5 STB I11 W 25 H16 STB A014137E01 HV–494 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - A/C INVERTER) (a) Disconnect the H15 and H16 HV control ECU connectors. H16 H15 CLK ETI ITE STB HV Control ECU Connector A090418E01 Wire Harness Side: TOECU TOINV CLK STB I11 A/C Inverter Connector (b) Disconnect the I11 A/C inverter connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CLK (H16-17) - Body ground Below 1 V ITE (H16-14) - Body ground Below 1 V ETI (H15-24) - Body ground Below 1 V STB (H15-25) - Body ground Below 1 V A092056E02 HV (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CLK (H16-17) - CLK (I11-4) Below 1 Ω ITE (H16-14) - TOECU (I11-2) Below 1 Ω ETI (H15-24) - TOINV (I11-3) Below 1 Ω STB (H15-25) - STB (I11-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CLK (H16-17) or CLK (I11-4) - Body ground 10 kΩ or higher ITE (H16-14) or TOECU (I11-2) - Body ground 10 kΩ or higher ETI (H15-24) or TOINV (I11-3) - Body ground 10 kΩ or higher STB (H15-25) or STB (I11-5) - Body ground 10 kΩ or higher (g) Reconnect the A/C inverter connector. (h) Reconnect the HV control ECU connectors. NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–495 OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–496 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3108-537 A/C Amplifier Communication Circuit Malfunction DESCRIPTION Refer to DTC 3108 (INF 535) (see page HV-491). DTC No. INF Code DTC Detection Condition Trouble Area P3108 537 Air conditioning amplifier malfunction • INSPECTION PROCEDURE If the information (INF) code is present, replace the air conditioning amplifier. 1 REPLACE AIR CONDITIONING AMPLIFIER NEXT COMPLETED HV Air conditioning amplifier P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3108-594 HV–497 A/C Amplifier Communication Circuit Malfunction DESCRIPTION HINT: DTC P3108 (INF 594) is one of the DTCs that indicate CAN communication malfunction. Since the air conditioning amplifier is connected to BEAN (Body Electronics Area Network), the HV control ECU communicates with it using CAN (Controller Area Network) communication via the gateway ECU. DTC No. INF Code DTC Detection Condition Trouble Area P3108 594 CAN communication malfunction • CAN communication INSPECTION PROCEDURE 1 READ OUTPUT DTC (CODES ALL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (All). (e) Read and record CAN communication malfunction DTCs. HINT: When DTCs other than CAN communication malfunction DTCs are output simultaneously, first correct the CAN communication problem, and then perform troubleshooting for other DTCs. GO GO TO CAN COMMUNICATION SYSTEM HV HV–498 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3110-223 IGCT Relay Malfunction DTC P3110-527 HV Main Relay Malfunction DESCRIPTION The HV control ECU monitors the IGCT relay and IG2 relay to detect malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P3110 223 IGCT relay is always closed • • Wire harness or connector Integration relay (IGCT relay) P3110 527 IG2 logical inconsistency • • Wire harness or connector Integration relay (IG2 relay) WIRING DIAGRAM Refer to the wiring diagram for the IG2 relay (see page HV-184). B L A 1 BE1 1 B 1 3M 120 A MAIN HV O W F15 Fusible Link Block 1 20 A HEV 60 A P/I 2 A L 7 H16 +B1 L 6 H16 +B2 A 4 3J 2 3J 1 3A 1 3K 1 HV Control ECU J3 J/C IGCT 2 3 3J 4 H16 MREL Engine Room Relay Block W-B Auxiliary Battery EE A092111E02 INSPECTION PROCEDURE HINT: If there is a battery voltage at the +B, MREL or IGSW terminal of the HV control ECU even though the power switch is turned OFF, the circuit is shorted to the +B power supply. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–499 INSPECT INTEGRATION RELAY (IGCT RELAY AND IG2 RELAY) (a) Remove the integration relay from the engine room relay block. (b) Inspect the IGCT relay. (1) Measure the resistance between the terminals of the integration relay. Standard resistance Integration Relay A1 IGCT HORN IG2 EFI A4 A3 A2 B1 B4 B3 B2 A2 A3 A4 B2 B3 B4 Tester Connection Specified Condition A4 - C1 10 kΩ or higher A4 - C1 Below 1 Ω (Apply battery voltage to terminals A2 and A3) (c) Inspect the IG2 relay. (1) Measure the resistance between the terminals of the integration relay. Standard resistance C1 C1 Tester Connection Specified Condition B4 - C1 10 kΩ or higher B4 - C1 Below 1 Ω (Apply battery voltage to terminals B2 and B3) A093724E02 NG REPLACE INTEGRATION RELAY (IGCT RELAY OR IG2 RELAY) OK REPAIR OR REPLACE HARNESS AND CONNECTOR AFTER INSPECTION (HV CONTROL ECU INTEGRATION RELAY) HV HV–500 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3137-348 Collision Sensor Low Input DTC P3138-349 Collision Sensor High Input DESCRIPTION The HV control ECU checks the line connection of the circuit breaker sensor (collision sensor) signal and gives warning to the driver if malfunction is detected. DTC No. INF Code DTC Detection Condition Trouble Area P3137 348 GND short in No. 1 circuit breaker sensor circuit • • Wire harness or connector No. 1 circuit breaker sensor P3138 349 Open or +B short in No. 1 circuit breaker sensor circuit • • Wire harness or connector No. 1 circuit breaker sensor WIRING DIAGRAM HV Control ECU W 1 16 H16 AS1G SIFC3 No. 1 Circuit Breaker Sensor SIF+ 2 Y 15 H16 AS1 HV A092112E03 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 CIRCUIT BREAKER SENSOR) (a) Disconnect the H16 HV control ECU connector. H16 AS1G AS1 HV Control ECU Connector A065745E49 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the C3 No. 1 circuit breaker sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: C3 SIF- HV–501 SIF+ No. 1 Circuit Breaker Sensor Connector Tester Connection Specified Condition AS1 (H16-15) - Body ground Below 1 V AS1G (H16-16) - Body ground Below 1 V A092057E02 (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition AS1 (H16-15) - SIF+ (C3-2) Below 1 Ω AS1G (H16-16) - SIF- (C3-1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition AS1 (H16-15) or SIF+ (C3-2) - Body ground 10 kΩ or higher AS1G (H16-16) or SIF- (C3-1) - Body ground 10 kΩ or higher (g) Reconnect the No. 1 circuit breaker sensor connector. (h) Reconnect the HV control ECU connector. NG OK REPLACE NO. 1 CIRCUIT BREAKER SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–502 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3221-314 Generator Inverter Temperature Sensor Circuit Range / Performance DTC P3221-315 Generator Inverter Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P3222 (INF 313) (see page HV-505). DTC No. INF Code DTC Detection Condition Trouble Area P3221 314 Sudden change in generator inverter temperature sensor output • • • • • • P3221 315 Generator inverter temperature sensor output deviation • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly WIRING DIAGRAM Refer to DTC P3222 (INF 313) (see page HV-505). INSPECTION PROCEDURE HV CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG OK ADD HV COOLANT P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–503 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E01 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG OK REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–504 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 6 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). HV NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 9 HV–505 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG CONNECT SECURELY Inverter Connector A092044E02 OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the H15 HV control ECU connector. H15 GIVT GINV HV Control ECU Connector A065744E41 HV HV–506 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 I9 GINV I10 GIVT Inverter Connector A092063E06 (c) Disconnect the I9 and I10 inverter connectors. (d) 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. (e) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GIVT (H15-27) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GIVT (H15-27) - GIVT (I10-21) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) 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 (h) (i) (j) (k) HV Reconnect the inverter connectors. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–507 DTC P3222-313 Generator Inverter Temperature Sensor Circuit High / Low DTC P3223-312 Generator Inverter Temperature Sensor Circuit High DESCRIPTION The HV control ECU uses a temperature sensor, which is built into the inverter, to detect the temperature of the generator inverter. The same cooling system that is routed to the MG1 and MG2 cools the inverter. This cooling system is independent from the engine cooling system. The characteristic of the generator inverter temperature sensor is the same as the boost converter temperature sensor (see page HV-350). The HV control ECU limits the load based on the signals transmitted by the generator inverter temperature sensor, in order to check the effectiveness of the inverter cooling system and prevent the inverter from overheating. Furthermore, the HV control ECU detects a malfunction in the wiring of the generator inverter temperature sensor, as well as in the sensor itself. DTC No. INF Code DTC Detection Condition Trouble Area P3222 313 Open or GND short in generator inverter temperature sensor circuit • • P3223 312 +B short in generator inverter temperature sensor circuit • • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P3222 (INF 313) or P3223 (INF 312), confirm MG1 INVERT TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. HV Temperature Displayed Malfunction -50°C (-58°F) +B short circuit 205°C (401°F) Open or GND short circuit WIRING DIAGRAM Inverter HV Control ECU (Shielded) 21 GIVT I10 27 H15 GIVT W (Shielded) 16 GINV I10 23 H15 GINV Y J5 J/C A A IK A092100E04 HV–508 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 READ VALUE OF INTELLIGENT TESTER (MG1 INVERT TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 INVERT TEMP value. Result Temperature Displayed Proceed 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 intelligent tester indicates -50°C (-58°F). • If there is an open or GND short circuit, the intelligent tester indicates 205°C (401°F). HV B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–509 (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 GINV I10 GIVT Inverter Connector A092041E33 Generator Inverter Temperature Sensor HV Control ECU GIVT GINV A125426E05 (e) 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. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the MG1 INVERT TEMP value. OK: 205°C (401°F) (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H15 HV control ECU connector. H15 GIVT GINV HV Control ECU Connector A065744E41 HV HV–510 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Generator Inverter Temperature Sensor HV Control ECU GIVT GINV (b) 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. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MG1 INVERT TEMP value. OK: 205°C (401°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E04 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. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. HV H15 GIVT GINV HV Control ECU Connector A065744E41 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–511 (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: I10 Tester Connection Specified Condition GIVT (H15-27) - GIVT (I10-21) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) GINV I10 GIVT Inverter Connector A092041E33 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 (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK HYBRID VEHICLE CONTROL ECU (GIVT VOLTAGE) H15 GINV (-) GIVT (+) HV Control ECU Connector A093719E05 (a) 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. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage Tester Connection Specified Condition GIVT (H15-27) - GINV (H15-23) 2.0 to 4.5 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–512 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3226-562 DC/DC Boost Converter Temperature Sensor DTC P3226-563 DC/DC Boost Converter Temperature Sensor DESCRIPTION Refer to DTC P0A94 (INF 583) (see page HV-395). DTC No. INF Code DTC Detection Condition Trouble Area P3226 562 Sudden change in boost converter temperature sensor output • • • • • • Wire harness or connector Inverter cooling system Water pump with assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly P3226 563 Boost converter temperature sensor output deviation • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly • • • WIRING DIAGRAM Refer to DTC P0A94 (INF 583) (see page HV-396). INSPECTION PROCEDURE HV CAUTION: • 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 are required to discharge the high-voltage condenser inside the inverter. 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 2 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–513 OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E01 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY OK 5 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG A090546E01 OK CONNECT SECURELY HV HV–514 6 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV CONNECT SECURELY HV Control ECU Connector A093719E09 OK 9 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: 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. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–515 (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG CONNECT SECURELY Inverter Connector A092044E02 OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the H16 HV control ECU connector. H16 GCNV CT HV Control ECU Connector A065745E51 Wire Harness Side: I10 I9 CT I10 Inverter Connector GCNV A092063E07 (c) Disconnect the I9 and I10 inverter connectors. (d) 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. (e) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CT (H16-21) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CT (H16-21) - CT (I10-14) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard (Check for short) HV HV–516 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition CT (H16-21) or CT (I10-14) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (h) (i) (j) (k) Reconnect the inverter connectors. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–517 DTC U0100-211 Lost Communication with ECM / PCM "A" DTC U0100-212 Lost Communication with ECM / PCM "A" DTC U0100-530 Lost Communication with ECM / PCM "A" DTC U0111-208 Lost Communication with Battery Energy Control Module "A" DTC U0111-531 Lost Communication with Battery Energy Control Module "A" DTC U0129-220 Lost Communication with Brake System Control Module DTC U0129-222 Lost Communication with Brake System Control Module DTC U0129-528 Lost Communication with Brake System Control Module DTC U0129-529 Lost Communication with Brake System Control Module DTC U0131-433 Lost Communication with Power Steering Control Module DTC U0131-434 Lost Communication with Power Steering Control Module DTC U0146-435 Lost Communication with Gateway "A" DESCRIPTION The HV control ECU transmits and receives signals to and from the ECM, battery ECU, skid control ECU, power steering ECU, and the gateway ECU via CAN (Controller Area Network) communication. DTC No. INF Code DTC Detection Condition Trouble Area U0100 211 CAN communication problem between ECM and HV control ECU (no signal input) • CAN communication system U0100 212 CAN communication problem between ECM and HV control ECU (transmission error) • CAN communication system HV HV–518 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area U0100 530 CAN communication problem between ECM and HV control ECU (CAN communication system malfunction) • CAN communication system U0111 208 CAN communication problem between battery ECU and HV control ECU (no signal input) • CAN communication system U0111 531 CAN communication problem between battery ECU and HV control ECU (CAN communication system malfunction) • CAN communication system U0129 220 CAN communication problem between skid control ECU and HV control ECU (no signal input) • CAN communication system U0129 222 CAN communication problem between skid control ECU and HV control ECU (CAN communication system malfunction) • CAN communication system U0129 528 CAN communication problem between skid control ECU and HV control ECU (transmission error) • CAN communication system U0129 529 CAN communication problem between skid control ECU and HV control ECU (regenerative torque malfunction) • CAN communication system U0131 433 CAN communication problem between power steering ECU and HV control ECU (no signal input) • CAN communication system U0131 434 CAN communication problem between power steering ECU and HV control ECU (CAN communication system malfunction) • CAN communication system U0146 435 CAN communication problem between gateway ECU and HV control ECU (no signal input) • CAN communication system HV MONITOR DESCRIPTION If the HV control ECU detects a malfunction in the CAN communication with the ECM or battery ECU, it illuminates the MIL and sets a DTC. MONITOR STRATEGY U0100: Related DTCs U0100 (INF 211): Receiving check for the specific frame U0100 (INF 212): Sending data check U0100 (INF 530): Receiving check for the all frame Required sensor / components Main: ECM Sub: CAN bus line Frequency of operation Continuous Duration U0100 (INF 211, 212): 0.1 second or more U0100 (INF 530): 1.91 seconds or more MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–519 U0111: Related DTCs U0111 (INF 208): Receiving check for the specific frame U0111 (INF 531): Receiving check for the all frame Required sensor / components Main: Battery ECU Sub: CAN bus line Frequency of operation Continuous Duration U0111 (INF 208): 0.1 second or more U0111 (INF 531): 1.6 seconds or more MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS CAN communication Communication failure COMPONENT OPERATING RANGE ECM DTC U0100 (INF 211 / 212 / 530) is not detected Battery ECU DTC U0111 (INF 208 / 531) is not detected INSPECTION PROCEDURE 1 HV READ OUTPUT DTC (CODES ALL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (All). (e) Read and record CAN communication malfunction DTCs. Result: Display (DTC Output) Proceed to U0100 (INF 211) or U0129 (INF 220) A U0100 (INF 211) and CAN communication malfunction DTCs B U0129 (INF 220) and CAN communication malfunction DTCs B P3108 (INF 594) and CAN communication malfunction DTCs B HINT: • When DTCs other than CAN communication malfunction DTCs are output simultaneously, first correct the CAN communication problem, and then perform troubleshooting for other DTCs. • DTC P3108 (INF 594) is one of the DTCs that indicates a CAN communication malfunction. HV–520 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B GO TO CAN COMMUNICATION SYSTEM A 2 CHECK TERMINAL OF ECM AND ECUS (+B1, +B2, CANH AND CANL TERMINALS) H14 H16 +B1 +B2 CANL CANH HV Control ECU Connector E6 (a) Check connection condition of each connector of the HV control ECU, ECM and battery ECU, as well as contact condition of each terminal shown in the table. Type of ECU Terminal No. Symbols HV control ECU H16-7 +B1 HV control ECU H16-6 +B2 HV control ECU H14-8 CANH HV control ECU H14-9 CANL ECM E6-31 CANH ECM E6-30 CANL Battery ECU B11-18 CANH Battery ECU B11-19 CANL OK: Connectors have been connected securely and there is no poor contact on each terminal. CANH CANL ECM Connector B11 HV CANL CANH Battery ECU Connector A126988E01 OK CHECK FOR INTERMITTENT PROBLEMS NG CONNECT SECURELY HV–520 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER (d) Do not carry any metal objects such as a mechanical pencil or a measuring tape that could fall and cause a short circuit. (e) After removing any high voltage wires, insulate them immediately with insulation tape. (f) Always tighten the high voltage screw terminals to the specified torque. Insufficient or excessive torque will cause malfunctions. (g) After finishing work on the high voltage systems and before reinstalling the service plug, reconfirm that you have not left any parts or tools lying around, that the high voltage terminals are tightened and that the connectors are connected. HV P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–521 COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HV 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY TERMINAL SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E01 HV–522 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER FRONT WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 HV WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) ENGINE ROOM NO. 2 RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E01 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER x 12 HV–523 11 (112, 8.1) INVERTER COVER 11 (112, 8.1) NO. 2 INVERTER COOLING HOSE ENGINE ROOM MAIN WIRE HARNESS HV NO. 1 CIRCUIT BREAKER SENSOR CONNECTOR NO. 1 INVERTER COOLING HOSE NO. 6 INVERTER COOLING HOSE x6 HOOD TO COWL TOP SEAL N*m (kgf*cm, ft.*lbf) : Specified torque A124445E01 HV–524 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER 21 (214, 16) 21 (214, 16) 8.0 (82, 71 in.*lbf) 21 (214, 16) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) HV MG2 POWER CABLE 8.0 (82, 71 in.*lbf) INVERTER WITH CONVERTER ASSEMBLY MG1 POWER CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124446E01 HV–525 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER NO. 1 INVERTER BRACKET 8.0 (82, 71 in.*lbf) 25 (255, 18) HV 8.0 (82, 71 in.*lbf) NO. 1 CIRCUIT BREAKER SENSOR BRACKET 25 (255, 18) NO. 2 INVERTER BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque A124447E01 HV–526 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER ON-VEHICLE INSPECTION 1. INSPECT INVERTER CAUTION: Wear insulating gloves. HINT: Check DTCs before performing the inspections on the converter and inverter, and perform the appropriate troubleshooting. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). (c) Remove the inverter cover. (1) Using a T30 "torx" socket, remove the screw. (2) Remove the 12 bolts and inverter cover. Torx Screw A083598E01 Connector A Connector C HV Connector B A092562E01 (d) Disconnect connectors A and B shown in the illustration. (e) Turn the power switch ON (IG). If turning the power switch ON (IG) with the service plug grip removed, the DTC of the interlock switch system will be output. (f) Using a voltmeter, measure the voltage. Also, using an ohmmeter, measure the resistance. NOTICE: The inspection should be performed on the wire harness side, not on the terminal side. HV–527 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER MIVB MUU MVU MWU MIVA GWU GVU GUU VH GIVB CPWM GSDN VL GIVA GINV GCNV GIWA GIWB CT FCV GIVT CSDN GFIV OVH MIWA MFIV MIWB MIVT MSDN OVL GND ILK Connector B IGCT Connector C Connector A A133543E01 Standard condition Tester Connection Measuring Condition Specified Condition A-2 (GIVA) - A-16 (GINV) - Approximately 0 V A-3 (GIVB) - A-16 (GINV) - Approximately 0 V A-4 (GUU) - A-16 (GINV) - Approximately 14 to 16 V A-5 (GVU) - A-16 (GINV) - Approximately 14 to 16 V A-6 (GWU) - A-16 (GINV) - Approximately14 to 16 V A-7 (MIVA) - A-16 (GINV) - Approximately 0 V A-8 (MIVB) - A-16 (GINV) - Approximately 0 V A-9 (MUU) - A-16 (GINV) - Approximately 14 to 16 V A-10 (MVU) - A-16 (GINV) - Approximately 14 to 16 V A-11 (MWU) - A-16 (GINV) - Approximately 14 to 16 V A-12 (VH) - A-16 (GINV) - Approximately 0.5 V A-13 (CPWM) - A-32 (GCNV) - Approximately 0 V A-14 (GSDN) - A-32 (GCNV) - Approximately 2 to 4.5 V A-15 (VL) - A-32 (GCNV) - Approximately 0.5 V A-16 (GINV) - C-2 (GND) - Approximately 0 V A-18 (GIWA) - A-16 (GINV) - Approximately 0 V A-19 (GIWB) - A-16 (GINV) - Approximately 0 V A-20 (CT) - A-16 (GINV) - Approximately 0 V A-21 (GIVT) - A-16 (GINV) - Approximately 2 to 4.5 V A-22 (GFIV) - A-16 (GINV) - Approximately 5 to 8 V A-23 (MIWA) - A-16 (GINV) - Approximately 0 V A-24 (MIWB) - A-16 (GINV) - Approximately 0 V A-25 (MSDN) - A-16 (GINV) - Approximately 0 V HV HV–528 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER Tester Connection Measuring Condition A-26 (MIVT) - A-16 (GINV) - Specified Condition Approximately 2 to 4.5 V A-27 (MFIV) - A-16 (GINV) - Approximately 5 to 8 V A-28 (OVH) - A-16 (GINV) - Approximately 5 to 8 V A-29 (CSDN) - A-32 (GCNV) - Approximately 0 V A-30 (FCV) - A-32 (GCNV) - Approximately 13.5 to 16.5 V A-31 (OVL) - A-32 (GCNV) - Approximately 13.5 to 16.5 V A-32 (GCNV) - C-2 (GND) - Approximately 0 V B-1 (ILK) - Body ground After installing the probe to the terminal, temporarily install the inverter cover. It does not have to be tightened with the bolts at this point. Below 1 Ω C-1 (IGCT) - C-2 (GND) - Approximately 8 to 16 V C-2 (GND) - Body ground - Below 1 Ω If the standards are not met, replace the inverter with converter assembly. 2. Combination Meter INSPECT CONVERTER CAUTION: Wear insulating gloves. HINT: If the HV system warning, master warning light and charge warning come on at the same time, check the DTCs and perform the appropriate troubleshooting. Master Warning Light Multi Information Display HV HV System Warning Charge Warning A133181E01 (a) Check the operation. (1) Using a voltmeter, measure the voltage of the auxiliary battery terminal when the "READY" light is OFF and ON. Standard voltage “READY” Light "READY" Light A077557E01 Specified Condition ON 14 V OFF 12 V HINT: When the "READY" light is ON, the converter outputs the voltage. When it is OFF, the auxiliary battery outputs the voltage. P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–529 (b) Inspect the output current. (1) Remove the 5 bolts, and disconnect the MG1 power cables from the inverter. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083601E02 (2) Remove the 5 bolts, and disconnect the MG2 power cable. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083600E02 A077564E01 (3) Install a voltmeter and the AC/DC 400 A probe to the locations shown in the illustration. (4) Connect the MG1 power cable to the MG1 power cable terminal with the 5 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. (5) Connect the MG2 power cable to the MG2 power cable terminal with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. (6) With the "READY" light ON, operate the 12 V electrical devices one by one, and then measure the output current. Standard ampere: Approximately 80 A or less HINT: If the output current is 0 A or greater than 80 A, check the input/output signal. (c) Check the input/output signal. (1) Disconnect the connectors shown in the illustration. (2) Using a voltmeter, measure the voltage between the body ground and the terminal of the vehicle side wire harness connector. Standard condition: Equal to the auxiliary battery terminal voltage A077564E01 HV HV–530 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER (3) Disconnect the connectors shown in the illustration. A077563E01 IGCT (4) Turn the power switch ON (IG). Using a voltmeter and ohmmeter, measure the voltage and resistance between the connector terminals on the vehicle harness side. Standard condition S 1 2 3 4 5 6 Tester Connection NODD G100865E02 Specified Condition 1 (IGCT) - Body ground 8 to 16 V 3 (S) - Body ground Equal to the auxiliary battery voltage 4 (NODD) - Body ground 120 to 140 kΩ (when power switch is OFF) If the standards are not met, replace the inverter with converter assembly. HV P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–531 REMOVAL CAUTION: • When working on high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HV-1). 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN HV COOLANT (See page HX-58) 5. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 6. REMOVE REAR DECK FLOOR BOX (See page CH-4) 7. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 9. REMOVE SERVICE PLUG GRIP (See page HB-154) 10. REMOVE FRONT WIPER ARM COVER 11. REMOVE FRONT WIPER ARM RH (See page WW-13) 12. REMOVE FRONT WIPER ARM LH (See page WW-13) 13. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 14. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 15. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 16. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-13) HV HV–532 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER 17. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 18. REMOVE RADIATOR SUPPORT OPENING COVER 19. REMOVE INVERTER COVER (a) Using a T30 "torx" socket, remove the screw. (b) Remove the 12 bolts and inverter cover. Torx Screw A083598E01 20. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V CAUTION: Wear insulating gloves. (a) Using a voltmeter, measure the voltage of the high voltage DC line. Standard voltage: 0V HINT: Use a measuring range of DC 400 V or more on the voltmeter. A092565E01 HV (b) Using the voltmeter, measure the voltage between the terminals of the three phase connector (U - V, V - W, U - W). Standard voltage: 0V HINT: Use a measuring range of DC 400 V or more on the voltmeter. A077532E01 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–533 21. DISCONNECT NO. 2 INVERTER COOLING HOSE A083552E01 22. DISCONNECT NO. 1 INVERTER COOLING HOSE A083602E01 23. DISCONNECT NO. 6 INVERTER COOLING HOSE HV A083557E01 24. DISCONNECT NO. 1 CIRCUIT BREAKER SENSOR (a) Move the outer section to the wire harness side as illustrated, and then disconnect the circuit breaker sensor. Outer Section A083556E01 A083553E01 25. DISCONNECT FRAME WIRE CAUTION: • Wear insulating gloves. • After removing the service plug grip, be sure to wait for at least 5 minutes before performing any work. • Insulate the electrode and connector parts with insulating tape. (a) Remove the 2 frame wire connectors from the inverter with converter assembly. HV–534 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER Lock Pin 26. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Using a small screwdriver, lift up the lock pin (green) as illustrated to unlock it. CAUTION: Wear insulating gloves. (b) Disconnect the connector for the air conditioning inverter. CAUTION: Wear insulating gloves. A083603E01 (c) Disconnect the 3 connectors shown in the illustration. A083554E01 (d) Disconnect the 3 connectors shown in the illustration and the engine main wire harness. HV A083555E01 (e) Remove the 5 bolts, then disconnect the MG2 power cable. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083600E02 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER (f) HV–535 Remove the 5 bolts, then disconnect the MG1 power cable. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083601E02 (g) Remove the 3 bolts and the inverter with converter assembly. A083599E01 (h) Disconnect the connector for the air conditioning inverter from the bracket. (i) Remove the bolt and connector bracket for the air conditioning inverter. HV A083573E01 27. REMOVE NO. 1 INVERTER BRACKET (a) Remove the 2 bolts and inverter bracket. A083578E01 28. REMOVE NO. 2 INVERTER BRACKET (a) Remove the 2 bolts and inverter bracket. A083577E01 HV–536 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER 29. REMOVE NO. 1 CIRCUIT BREAKER SENSOR (a) Remove the 2 bolts and circuit breaker sensor. A083574E01 INSTALLATION 1. INSTALL NO. 1 CIRCUIT BREAKER SENSOR (a) Install the circuit breaker sensor with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 2. INSTALL NO. 2 INVERTER BRACKET (a) Install the inverter bracket with the 2 bolts. Torque: 25 N*m (255 kgf*cm, 18 in.*lbf) 3. INSTALL NO. 1 INVERTER BRACKET (a) Install the inverter bracket with the 2 bolts. Torque: 25 N*m (255 kgf*cm, 18 in.*lbf) 4. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the connector bracket for the air conditioning inverter with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Install the connector for the air conditioning inverter on the bracket. A083574E01 HV A083577E01 A083578E01 A083573E01 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–537 (c) Install the inverter with converter assembly with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 16 in.*lbf) CAUTION: Wear insulating gloves. A083599E01 (d) Install the MG1 power cable to the MG1 power cable terminal with the 5 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. A083601E02 (e) Install the MG2 power cable to the MG2 power cable terminal with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. HV A083600E02 (f) Connect the 3 connectors shown in the illustration. CAUTION: Wear insulating gloves. (g) Insert the grommet of the engine main wire harness into the U-shaped groove of the inverter case. CAUTION: Wear insulating gloves. Grommet A083555E02 (h) Connect the 3 connectors shown in the illustration. CAUTION: Wear insulating gloves. (i) Connect the connector for the air conditioning inverter, then lock the connector with the lock pin. CAUTION: Wear insulating gloves. A083554E01 HV–538 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER A083553E01 5. CONNECT FRAME WIRE (a) Connect the 2 frame wire connectors to the inverter with converter assembly. CAUTION: Wear insulating gloves. 6. CONNECT NO. 1 CIRCUIT BREAKER SENSOR CAUTION: Wear insulating gloves. 7. CONNECT NO. 6 INVERTER COOLING HOSE 8. CONNECT NO. 1 INVERTER COOLING HOSE 9. CONNECT NO. 2 INVERTER COOLING HOSE 10. INSTALL INVERTER COVER (a) Temporarily fasten the inverter cover with the 12 bolts and "torx" screw. (b) Tighten the 12 bolts. Torque: 11 N*m (112 kgf*cm, 8.1 in.*lbf) (c) Using a T30 "torx" socket, tighten the "torx" screw. Torque: 11 N*m (112 kgf*cm, 8.1 in.*lbf) 11. INSTALL RADIATOR SUPPORT OPENING COVER “Torx” Screw A083598E02 12. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 13. INSTALL WINDSHIELD WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-16) 14. INSTALL COWL TOP VENTILATOR LOUVER RH 15. INSTALL COWL TOP VENTILATOR LOUVER LH HV 16. INSTALL HOOD TO COWL TOP SEAL 17. INSTALL FRONT WIPER ARM LH (See page WW-16) 18. INSTALL FRONT WIPER ARM RH (See page WW-16) 19. INSTALL WINDSHIELD WIPER ARM COVER 20. INSTALL SERVICE PLUG GRIP (See page HB-154) 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 22. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 23. INSTALL REAR DECK FLOOR BOX (See page CH-8) 24. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 25. ADD HV COOLANT (See page HX-58) 26. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-2) 27. INSTALL ENGINE UNDER COVER RH 28. INSTALL ENGINE UNDER COVER LH P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–539 29. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU HV–539 HYBRID VEHICLE CONTROL ECU HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS UPPER INSTRUMENT PANEL FINISH PANEL INSTRUMENT PANEL HOLE COVER INSTRUMENT PANEL HOLE COVER GLOVE COMPARTMENT DOOR NO. 2 INSTRUMENT PANEL REGISTER NO. 4 INSTRUMENT PANEL REGISTER NO. 3 INSTRUMENT PANEL REGISTER HV INSTRUMENT PANEL CUSHION NO. 1 INSTRUMENT PANEL REGISTER GLOVE COMPARTMENT DOOR STOPPER LOWER INSTRUMENT PANEL FINISH PANEL GLOVE COMPARTMENT DOOR ASSEMBLY A131253E01 HV–540 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU NO. 1 INSTRUMENT PANEL SPEAKER PANEL (w/ JBL Sound System) FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CORNER PIECE RH FRONT PILLAR GARNISH CORNER PIECE LH 20 (204, 15) HV INSTRUMENT PANEL SUB-ASSEMBLY CLOCK ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL END MULTI-DISPLAY ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B126622E04 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU HV–541 NO. 3 HEATER TO REGISTER DUCT HV 5.5 (56, 49 in.*lbf) 5.5 (56, 49 in.*lbf) ECM HYBRID VEHICLE CONTROL ECU N*m (kgf*cm, ft.*lbf) : Specified torque A131251E01 HV–542 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE NO. 1 INSTRUMENT PANEL REGISTER (See page IP-5) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-6) 7. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL (See page IP-6) 8. REMOVE NO. 3 INSTRUMENT PANEL REGISTER (See page IP-6) 9. REMOVE NO. 4 INSTRUMENT PANEL REGISTER (See page IP-6) 10. REMOVE NO. 2 INSTRUMENT PANEL REGISTER (See page IP-7) HV 11. REMOVE MULTI-DISPLAY ASSEMBLY (See page NS172) 12. REMOVE GLOVE COMPARTMENT DOOR STOPPER (See page IP-7) 13. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-7) 14. REMOVE GLOVE COMPARTMENT DOOR (See page IP-7) 15. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL 16. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH 17. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH 18. REMOVE FRONT PILLAR GARNISH RH 19. REMOVE FRONT PILLAR GARNISH LH 20. DISCONNECT AIRBAG CONNECTOR 21. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (See page IP-8) P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU HV–543 22. REMOVE NO. 3 HEATER TO REGISTER DUCT (See page AC-147) 23. REMOVE ECM (See page ES-469) 24. REMOVE HYBRID VEHICLE CONTROL ECU (a) Remove the 2 nuts and hybrid vehicle control ECU. A077552E01 INSTALLATION 1. INSTALL HYBRID VEHICLE CONTROL ECU (a) Install the hybrid vehicle control ECU with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 2. INSTALL ECM (See page ES-470) 3. INSTALL NO. 3 HEATER TO REGISTER DUCT (See page AC-159) 4. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (See page IP-11) 5. CONNECT AIRBAG CONNECTOR 6. INSTALL FRONT PILLAR GARNISH RH 7. INSTALL FRONT PILLAR GARNISH LH 8. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH 9. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH A077552E01 10. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL 11. INSTALL GLOVE COMPARTMENT DOOR (See page IP-12) 12. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-12) 13. INSTALL GLOVE COMPARTMENT DOOR STOPPER 14. INSTALL MULTI-DISPLAY ASSEMBLY 15. INSTALL NO. 2 INSTRUMENT PANEL REGISTER (See page IP-12) 16. INSTALL NO. 4 INSTRUMENT PANEL REGISTER (See page IP-12) 17. INSTALL NO. 3 INSTRUMENT PANEL REGISTER (See page IP-13) HV HV–544 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU 18. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL (See page IP-13) 19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-13) 20. INSTALL NO. 1 INSTRUMENT PANEL REGISTER (See page IP-13) 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 22. CHECK SRS WARNING LIGHT 23. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 24. INSTALL REAR DECK FLOOR BOX (See page CH-8) 25. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 26. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR HV–545 WATER PUMP WITH MOTOR HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS FRONT FENDER LINER RH FRONT FENDER LINER LH FRONT BUMPER ENERGY ABSORBER HEADLIGHT ASSEMBLY LH 5.0 (51, 44 in.*lbf) RADIATOR GRILLE PROTECTOR HV FRONT BUMPER COVER CENTER NO. 4 ENGINE UNDER COVER FRONT SPOILER COVER N*m (kgf*cm, ft.*lbf) : Specified torque A131149E01 HV–546 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR INVERTER COOLING HOSE 7.0 (71, 62 in.*lbf) 7.0 (71, 62 in.*lbf) WATER PUMP WITH MOTOR CONNECTOR WATER VALVE WITH BRACKET ASSEMBLY INVERTER COOLING HOSE WATER PUMP WITH MOTOR ASSEMBLY 21 (214, 16) NO. 2 INVERTER BRACKET 25 (255, 18) HV N*m (kgf*cm, ft.*lbf) : Specified torque A117423E01 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR HV–547 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. DISCONNECT FRONT FENDER LINER LH (See page ET-3) 6. DISCONNECT FRONT FENDER LINER RH (See page ET-3) 7. REMOVE CENTER NO. 4 ENGINE UNDER COVER (See page ET-3) 8. REMOVE FRONT SPOILER COVER (See page ET-3) 9. REMOVE FRONT BUMPER COVER (See page ET-4) 10. REMOVE FRONT BUMPER ENERGY ABSORBER 11. REMOVE HEADLIGHT ASSEMBLY LH (a) Remove the headlight LH from the vehicle (see page LI-77). 12. DRAIN HV COOLANT (See page HX-58) 13. DISCONNECT WATER VALVE WITH BRACKET ASSEMBLY (a) Remove the bolt and nut, then disconnect the water valve. A083571E01 14. REMOVE WATER PUMP WITH MOTOR ASSEMBLY (a) Disconnect the 2 inverter cooling hoses shown in the illustration. A083596E01 HV HV–548 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR (b) Remove the bolt, then disconnect the water pump with motor assembly from the vehicle. (c) Disconnect the connector and remove the water pump with motor assembly. Connector A083597E01 INSPECTION 1. A053155E02 INSPECT WATER PUMP WITH MOTOR (a) Check the operation. (1) Connect the battery positive terminal to terminal 1 and the battery negative terminal to terminal 2. Specified condition: Pump motor operates properly NOTICE: • Do not connect the positive and negative terminals of the battery to the wrong water pump terminals. • Complete the check within 10 seconds of the connection. If the pump motor does not operate properly, replace the water pump with motor assembly. INSTALLATION 1. HV Connector INSTALL WATER PUMP WITH MOTOR ASSEMBLY (a) Connect the connector. (b) Install the water pump with motor assembly with the bolt. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) A083597E01 (c) Connect the 2 inverter cooling hoses. A083596E01 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR A083571E01 HV–549 2. INSTALL WATER VALVE WITH BRACKET ASSEMBLY (a) Install the water valve with the bolt and nut. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 3. INSTALL HEADLIGHT ASSEMBLY LH (a) Install the headlight LH to the vehicle (see page LI82). 4. INSTALL FRONT BUMPER ENERGY ABSORBER 5. INSTALL FRONT BUMPER COVER (See page ET-6) 6. INSTALL FRONT SPOILER COVER (See page ET-7) 7. INSTALL CENTER NO. 4 ENGINE UNDER COVER (See page ET-7) 8. INSTALL FRONT FENDER LINER LH (See page ET-7) 9. INSTALL FRONT FENDER LINER RH (See page ET-7) 10. ADD HV COOLANT (See page HX-58) 11. CHECK ENGINE COOLANT LEAKAGE (See page CO2) 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 13. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 14. INSTALL REAR DECK FLOOR BOX (See page CH-8) 15. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 16. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV HV–550 P112 HYBRID VEHICLE CONTROL – FRAME WIRE FRAME WIRE HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HV 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY TERMINAL SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E08 P112 HYBRID VEHICLE CONTROL – FRAME WIRE HV–551 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER HV REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E01 HV–552 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET 28 (286, 21) REAR NO. 4 FLOOR BOARD DECK FLOOR BOX LH FLOOR SIDE PANEL LH HV DECK TRIM SIDE PANEL LH REAR SIDE SEATBACK FRAME LH LUGGAGE HOLD BELT STRIKER REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque A124461E01 HV–553 P112 HYBRID VEHICLE CONTROL – FRAME WIRE FRONT WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E07 HV HV–554 P112 HYBRID VEHICLE CONTROL – FRAME WIRE COLUMN HOLE COVER SILENCER SHEET 35 (360, 26) 35 (360, 26) STEERING INTERMEDIATE SHAFT 157 (1,601, 116) 113 (1,152, 83) 157 (1,601, 116) 113 (1,152, 83) HV FRONT FLOOR COVER CENTER LH x5 FRONT FLOOR COVER LH ENGINE UNDER COVER LH ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque A124462E01 HV–555 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 7.5 (76, 66 in.*lbf) 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) 5.6 (57, 50 in.*lbf) 9.0 (92, 80 in.*lbf) FRAME WIRE CLAMP 9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf) NO. 1 WIRE HARNESS PROTECTOR 9.0 (92, 80 in.*lbf) WIRE HARNESS SIDE COVER FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque 9.0 (92, 80 in.*lbf) Non-reusable part 9.0 (92, 80 in.*lbf) CLAMP A124463E01 HV HV–556 P112 HYBRID VEHICLE CONTROL – FRAME WIRE REMOVAL CAUTION: • When working on high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. HV 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HV-519). 2. REMOVE FRONT WHEEL 3. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 4. REMOVE REAR DECK FLOOR BOX (See page CH-4) 5. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE SERVICE PLUG GRIP (See page HB-154) 8. REMOVE REAR DECK TRIM COVER (See page HB88) 9. REMOVE TONNEAU COVER (See page HB-89) 10. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 11. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 12. REMOVE REAR SIDE SEATBACK FRAME LH (See page HB-89) 13. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 14. REMOVE DECK FLOOR BOX LH (See page HB-90) 15. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) P112 HYBRID VEHICLE CONTROL – FRAME WIRE HV–557 16. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 17. REMOVE REAR DOOR SCUFF PLATE LH (a) Remove the clip and 4 joints shown in the illustration, and then remove the rear door scuff plate. Clip Joint A083561E02 18. REMOVE FLOOR SIDE PANEL LH (a) Remove the clip, then roll back the carpet. Clip A083560E01 (b) Remove the clip from the floor side panel. (c) Remove the 3 bolts and floor side panel. Clip 19. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 20. REMOVE JUNCTION TERMINAL CAUTION: Wear insulating gloves. A083595E01 21. REMOVE FRAME WIRE CAUTION: Wear insulating gloves. (a) Remove the 2 nuts, then remove the frame wire from the No. 2 and No. 3 system main relay. CAUTION: Insulate the removed terminals with insulating tape. Frame Wire A083533E02 HV HV–558 P112 HYBRID VEHICLE CONTROL – FRAME WIRE (b) Remove the clamps, then remove the frame wire from the rear floor. A083590E01 (c) Remove the 2 clamps, then disconnect the frame wire from the center floor panel. (d) Disconnect the connector. (e) Disconnect the grommet. Clamp 22. REMOVE WINDSHIELD WIPER ARM COVER Grommet Frame Wire 23. REMOVE FRONT WIPER ARM LH (See page WW-13) 24. REMOVE FRONT WIPER ARM RH (See page WW-13) Connector A083587E01 25. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 26. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 27. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 28. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-13) 29. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) HV 30. SEPARATE FRAME WIRE CAUTION: Wear insulating gloves. (a) Flip open the cover of the jump start terminal on the engine room relay block. Engine Room Relay Block A083592E01 (b) Remove the side cover by sliding it upward. (c) Remove the nut, then disconnect the frame wire from the engine room relay block. (d) Disconnect the clamp, then disconnect the frame wire from the side member. Side Cover : Clamp A083585E02 P112 HYBRID VEHICLE CONTROL – FRAME WIRE Clamp Frame Wire Connector HV–559 (e) Remove the 2 frame wire connectors shown in the illustration from the inverter with converter assembly. (f) Disconnect the clamp, then disconnect the frame wire from the dash panel bracket. 31. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page SR-10) 32. SEPARATE STEERING INTERMEDIATE SHAFT (See page SR-10) 33. REMOVE NO. 3 ENGINE UNDER COVER 34. REMOVE NO. 4 ENGINE UNDER COVER CENTER (See page ET-3) : Clamp A083586E02 35. REMOVE FRONT FLOOR COVER LH (a) Remove the 6 clips and front floor cover LH. A083558E01 36. REMOVE FRONT FLOOR COVER CENTER LH (a) Remove the 5 clips and front floor cover center LH. HV A083591E01 37. REMOVE NO. 1 WIRE HARNESS PROTECTOR CAUTION: Wear insulating gloves. (a) Remove the 2 nuts, bolt and wire harness protector. A083589E01 HV–560 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 38. SEPARATE FRONT SUSPENSION CROSSMEMBER (a) Support the front suspension crossmember using a jack. A083583E01 (b) Remove the 4 bolts shown in the illustration from the front suspension crossmember. A083584E01 Clamp HV A083588E01 39. REMOVE FRAME WIRE CAUTION: Wear insulating gloves. (a) Remove the 2 bolts shown in the illustration. (b) Disconnect the 2 clamps. (c) Lower the jack a little and remove both nuts labeled A. NOTICE: • Lower the jack slowly to avoid interfering with objects loaded on the front suspension crossmember. • Do not remove the jack. (d) Remove both nuts labeled B. (e) Disconnect the fit-in clamps, then remove the frame wire. Fit-in Clamp Fit-in Clamp Frame Wire Nut A Nut B Nut B Clamp A077534E04 HV–561 P112 HYBRID VEHICLE CONTROL – FRAME WIRE INSTALLATION 1. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Temporarily fasten the frame wire to the vehicle. (b) Connect the fit-in clamps to the stud in the floor panel, and then install the frame wire with both nuts labeled A. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install both nuts labeled B shown in the illustration. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Fit-in Clamp Fit-in Clamp Frame Wire Nut A Nut B Nut B Clamp A077534E04 (d) As shown in the illustration, point the arrow on the grommet in the front direction, then install the grommet. (e) Install the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (f) Install the 2 clamps. Mark Front Side Grommet Clamp A077533E01 HV HV–562 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 2. INSTALL FRONT SUSPENSION CROSSMEMBER (a) Install the front suspension crossmember with the 4 bolts. Torque: 113 N*m (1,152 kgf*cm, 83 in.*lbf) for bolt A 157 N*m (1,601 kgf*cm, 116 in.*lbf) for bolt B (b) Remove the jack. 3. INSTALL NO. 1 WIRE HARNESS PROTECTOR CAUTION: Wear insulating gloves. (a) Install the wire harness protector with the 2 bolts and nut. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 4. INSTALL FRONT FLOOR COVER CENTER LH (a) Install the floor cover with the 5 clips. 5. INSTALL FRONT FLOOR COVER LH (a) Install the floor cover with the 6 clips. 6. INSTALL NO. 3 ENGINE UNDER COVER 7. INSTALL NO. 4 ENGINE UNDER COVER CENTER 8. INSTALL STEERING INTERMEDIATE SHAFT (See page EM-107) 9. INSTALL COLUMN HOLE COVER SILENCER SHEET A083584E01 A083589E01 HV A083591E01 A083558E01 P112 HYBRID VEHICLE CONTROL – FRAME WIRE Clamp Frame Wire Connector : Clamp HV–563 10. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Connect the 2 connectors shown in the illustration to the inverter with converter assembly. (b) Connect the clamp to the engine room relay block with the nut. A083586E03 (c) Install the frame wire to the engine room relay block with the nut. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (d) Install the side cover to the engine room relay block. (e) Install the frame wire clamp to the side member. Side Cover 11. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) : Clamp A083585E03 12. INSTALL FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-16) 13. INSTALL COWL TOP VENTILATOR LOUVER RH 14. INSTALL COWL TOP VENTILATOR LOUVER LH 15. INSTALL HOOD TO COWL TOP SEAL 16. INSTALL FRONT WIPER ARM LH (See page WW-16) 17. INSTALL FRONT WIPER ARM RH (See page WW-16) 18. INSTALL FRONT WIPER ARM COVER Clamp Grommet Frame Wire Connector A083587E01 19. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Connect the grommet. (b) Connect the connector. (c) Install the 2 clamps, then connect the frame wire to the center floor panel. HV HV–564 P112 HYBRID VEHICLE CONTROL – FRAME WIRE (d) Install the frame wire to the rear floor panel with the clamp. A083590E01 (e) Install the frame wire to the No. 2 and No. 3 system main relay with 2 new nuts. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 20. INSTALL JUNCTION TERMINAL CAUTION: Wear insulating gloves. 21. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) A083533E01 22. INSTALL FLOOR SIDE PANEL LH (a) Install the clip. (b) Install the floor side panel with the 3 bolts. Clip HV A083595E01 (c) Install the carpet with the clip. 23. INSTALL REAR DOOR SCUFF PLATE LH 24. INSTALL BATTERY CARRIER BRACKET (See page HB-97) Clip 25. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 26. INSTALL DECK FLOOR BOX LH (See page HB-98) A083560E01 27. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) 28. INSTALL REAR SIDE SEATBACK FRAME LH (See page HB-99) 29. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 30. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 31. INSTALL TONNEAU COVER (See page HB-99) P112 HYBRID VEHICLE CONTROL – FRAME WIRE HV–565 32. INSTALL REAR DECK TRIM COVER (See page HB100) 33. INSTALL SERVICE PLUG GRIP (See page HB-154) 34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 35. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 36. INSTALL REAR DECK FLOOR BOX (See page CH-8) 37. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 38. INSTALL FRONT WHEEL 39. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV HV–566 P112 HYBRID VEHICLE CONTROL – ACCELERATOR PEDAL ROD ACCELERATOR PEDAL ROD HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS HV ACCELERATOR PEDAL POSITION SENSOR CONNECTOR ACCELERATOR PEDAL ROD 7.5 (77, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A117424E01 HV–567 P112 HYBRID VEHICLE CONTROL – ACCELERATOR PEDAL ROD ON-VEHICLE INSPECTION 1. INSPECT ACCELERATOR PEDAL ROD NOTICE: • Do not remove the accelerator pedal position sensor from the accelerator pedal. • Perform the inspection on the hybrid vehicle control ECU side of the connector. (a) Turn the power switch ON (IG). (b) Using a voltmeter, measure the voltage between the terminals. Standard voltage Tester Connection Hybrid Control ECU Specified Condition Normal 4.5 to 5.5 V B-26 (VPA1) - B-27 (EP1) Do not depress the accelerator pedal 0.5 to 1.1 V B-26 (VPA1) - B-27 (EP1) Gradually depress the accelerator pedal The voltage increases slowly B-26 (VPA1) - B-27 (EP1) Fully depress the accelerator pedal 2.6 to 4.5 V B-33 (VCP2) - B-35 (EP2) Normal 4.5 to 5.5 V B-34 (VPA2) - B-35 (EP2) Do not depress the accelerator pedal 1.2 to 2.0 V B-34 (VPA2) - B-35 (EP2) Gradually depress the accelerator pedal The voltage increases slowly B-34 (VPA2) - B-35 (EP2) Fully depress the accelerator pedal 3.4 to 5.3 V EP2 EP1 VPA2 Connector D Measuring Condition B-25 (VCP) - B-27 (EP1) Connector C VPA1 VCP HV VCP2 Connector B Connector A A130645E02 If the standards are not met, replace the accelerator pedal rod. HV–568 P112 HYBRID VEHICLE CONTROL – ACCELERATOR PEDAL ROD REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE ACCELERATOR PEDAL ROD (a) Disconnect the accelerator pedal position sensor connector. (b) Remove the 2 bolts, then remove the accelerator pedal rod. A087530E01 INSTALLATION 1. INSTALL ACCELERATOR PEDAL ROD (a) Install the accelerator pedal rod with the 2 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) (b) Connect the accelerator pedal position sensor connector. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 3. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV A087530E01 HV–569 P112 HYBRID VEHICLE CONTROL – IGCT RELAY IGCT RELAY ON-VEHICLE INSPECTION Integration Relay 7K 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. INSPECT INTEGRATION RELAY (IGCT RELAY) NOTICE: IGCT relay is built into the integration relay. 7I 7J A077561E03 (a) Check the resistance of the HEV fuse. If the result is not as specified, replace the fuse. (b) Measure the resistance of the IGCT relay. Standard resistance Tester Connection 7J-1 - 7J-4 Specified Condition 10 kΩ or higher 7J-1 - 7K-4 Below 1 Ω 7J-2 - 7J-3 Below 1 Ω 7J-4 - 7K-1 10 kΩ or higher 7J-1 - 7J-4 Below 1 Ω (when battery voltage is applied to terminals 7J-2 and 7J-3) 7J-1 - 7K-1 Below 1 Ω (when battery voltage is applied to terminals 7J-2 and 7J-3) If the standards are not met, replace the integration relay. HV