Inspection Procedure

CAUTION:

Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

HINT:

Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

CHECK DTC OUTPUT (HV)

Connect the intelligent tester or Techstream to the DLC3
Turn the power switch on (IG)
Select the following menu items:
1. Intelligent tester - Select: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
2. Techstream - Select: Powertrain / Hybrid Control / Trouble Codes.

Check if DTCs are output

Result

RESULT REFERENCE

Result	Proceed to
P0A1A-200, 792, or 793 only is output.	A
Any of the following DTCs are also output.	B

DTC DETECTION CONDITION AND TROUBLE AREA REFERENCE

DTC No	Relevant Diagnosis
P0A4B-253	Generator Position Sensor Circuit
P0A4C-513	Generator Position Sensor Circuit Range / Performance
P0A4D-255	Generator Position Sensor Circuit Low

B: GO TO DTC CHART (See DIAGNOSTIC TROUBLE CODE CHART )

A: Go to Next Step

CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
CAUTION: Be sure to wear insulated gloves.
1. Turn the power switch off.
2. Remove the service plug grip (See PRECAUTION )
  NOTE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
  
  NOTE: Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector does not pull out.
3. Check the connection of the low voltage connector of the inverter with converter assembly.
  OK: The connector is connected securely and there are no contact problems.
  
  HINT:
  
  When connecting the connector, insert it with the locking lever in the raised position Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage After the click is heard, pull up on the connector to confirm that it is properly connected
  
  Fig 1: Identifying Inverter With Converter Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NG: CONNECT SECURELY

OK: Go to Next Step

CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)

CAUTION: Be sure to wear insulated gloves.

Disconnect the low voltage connector from the inverter with converter assembly
Turn the power switch on (IG)

Measure the voltage according to the value(s) in the table below

Standard voltage

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-20 (GRF) - Body ground	Power switch on (IG)	Below 1 V
A77-9 (GRFG) - Body ground	Power switch on (IG)	Below 1 V
A77-18 (GSN) -Body ground	Power switch on (IG)	Below 1 V
A77-7 (GSNG) - Body ground	Power switch on (IG)	Below 1 V
A77-17 (GCS) - Body ground	Power switch on (IG)	Below 1 V
A77-6 (GCSG) - Body ground	Power switch on (IG)	Below 1 V

Fig 2: Checking Harness And Connector (Inverter With Converter Assembly - Generator Resolver)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to Next Step

CHECK GENERATOR RESOLVER

Turn the power switch off.

Measure the resistance according to the value(s) in the table below.

Standard resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-20 (GRF) - A77-9 (GRFG)	Power switch off	5.8 to 11.8 Ω
A77-18 (GSN) - A77-7 (GSNG)	Power switch off	11.7 to 17.7 Ω
A77-17(GCS) - A77-6 (GCSG)	Power switch off	11.7 to 17.7 Ω

Standard resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-20 (GRF) or A77-9 (GRFG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-18 (GSN) or A77-7 (GSNG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-17 (GCS) or A77-6 (GCSG) - Body ground and other terminals	Power switch off	10 kΩ or higher

Fig 3: Identifying A77 Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: Go to step 9

OK: Go to Next Step

CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)

Turn the power switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard voltage

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-40 (MRF) - Body ground	Power switch on (IG)	Below 1 V
A77-29 (MRFG) - Body ground	Power switch on (IG)	Below 1 V
A77-39 (MSN) - Body ground	Power switch on (IG)	Below 1 V
A77-28 (MSNG) - Body ground	Power switch on (IG)	Below 1 V
A77-38 (MCS) - Body ground	Power switch on (IG)	Below 1 V
A77-27 (MCSG) - Body ground	Power switch on (IG)	Below 1 V

Fig 4: Identifying A77 Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to Next Step

CHECK MOTOR RESOLVER

Turn the power switch off.

Measure the resistance according to the value(s) in the table below

Standard resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-40 (MRF) - A77-29 (MRFG)	Power switch off	6.0 to 12 0 Ω
A77-39 (MSN) - A77-28 (MSNG)	Power switch off	12.5 to 24.5 Ω
A77-38 (MCS) - A77-27 (MCSG)	Power switch off	12.5 to 24 5 Ω

Standard resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-40 (MRF) or A77-29 (MRFG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-39 (MSN) or A77-28 (MSNG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-38 (MCS) or A77-27 (MCSG) - Body ground and other terminals	Power switch off	10 kΩ or higher

Fig 5: Identifying A77 Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: Go to step 11

OK: Go to Next Step

CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
1. Check the connection of the generator resolver connector
  OK: The connector is connected securely and there are no contact problems.
  
  Fig 6: Locating Generator Resolver Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NG: CONNECT SECURELY

OK: Go to Next Step
CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
1. Check the connection of the motor resolver connector.
  OK: The connector is connected securely and there are no contact problems.
  
  Fig 7: Locating Motor Resolver Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NG: CONNECT SECURELY

OK: REPLACE INVERTER WITH CONVERTER ASSEMBLY (See REMOVAL )
CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
1. Check the connection of the generator resolver connector.
  OK: The connector is connected securely and there are no contact problems.
  
  Fig 8: Locating Generator Resolver Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NG: CONNECT SECURELY

OK: Go to Next Step

CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)

Disconnect the generator resolver connector.

Measure the resistance according to the value(s) in the table below

Standard resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-20 (GRF) - E59-1 (GRF)	Power switch off	Below 1 Ω
A77-9 (GRFG) - E59-5 (GRFG)	Power switch off	Below 1 Ω
A77-18 (GSN) - E59-2 (GSN)	Power switch off	Below 1 Ω
A77-7 (GSNG) - E59-6 (GSNG)	Power switch off	Below 1 Ω
A77-17 (GCS) - E59-3 (GCS)	Power switch off	Below 1 Ω
A77-6 (GCSG) - E59-7 (GCSG)	Power switch off	Below 1 Ω

Standard resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-20 (GRF) or E59-1 (GRF) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-9 (GRFG) or E59-5 (GRFG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-18 (GSN) or E59-2 (GSN) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-7 (GSNG) or E59-6 (GSNG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-17 (GCS) or E59-3 (GCS) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-6 (GCSG) or E59-7 (GCSG) - Body ground and other terminals	Power switch off	10 kΩ or higher

Fig 9: Checking Harness And Connector (Inverter With Converter Assembly - Generator Resolver)

HINT:

The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transmission assembly.

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY (See HYBRID VEHICLE TRANSMISSION )

CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
1. Check the connection of the motor resolver connector
  OK: The connector is connected securely and there are no contact problems.
  
  Fig 10: Locating Motor Resolver Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NG: CONNECT SECURELY

OK: Go to Next Step

CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)

Disconnect the motor resolver connector.

Measure the resistance according to the value(s) in the table below

Standard resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-40 (MRF) - E60-1 (MRF)	Power switch off	Below 1 Ω
A77-29 (MRFG) - E60-5 (MRFG)	Power switch off	Below 1 Ω
A77-39 (MSN) - E60-2 (MSN)	Power switch off	Below 1 Ω
A77-28 (MSNG) - E60-6 (MSNG)	Power switch off	Below 1 Ω
A77-38 (MCS) - E60-3 (MCS)	Power switch off	Below 1 Ω
A77-27 (MCSG) - E60-7 (MCSG)	Power switch off	Below 1 Ω

Fig 11: Checking Harness And Connector (Inverter With Converter Assembly - Motor Resolver)

Standard resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITION

Tester Connection	Switch Condition	Specified Condition
A77-40 (MRF) or E60-1 (MRF) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-29 (MRFG) or E60-5 (MRFG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-39 (MSN) or E60-2 (MSN) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-28 (MSNG) or E60-6 (MSNG) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-38 (MCS) or E60-3 (MCS) - Body ground and other terminals	Power switch off	10 kΩ or higher
A77-27 (MCSG) or E60-7 (MCSG) - Body ground and other terminals	Power switch off	10 kΩ or higher

HINT:

The motor resolver is not available separately If it requires replacement, replace the hybrid vehicle transmission assembly

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY (See HYBRID VEHICLE TRANSMISSION )