Part 2

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0A78-113: Drive Motor "A" Inverter Performance
P0A78-113 - Drive Motor "A" Inverter Performance (Continued)

10. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Remove the inverter cover from the inverter with converter assembly.





(c) Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.





Specified Condition:

Bolt A
8.0 N*m (82 kgf*cm, 71 in.*lbf)

Bolt B
9.2 N*m (94 kgf*cm, 81 ft.*lbf)

NOTICE:
- Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).
- Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

(d) Disconnect the motor cable from the inverter with converter assembly.

(e) Check for arc marks at the bolts for the motor cable.

Result:





(f) Connect the motor cable to the inverter with converter assembly.

(g) Install the inverter cover.

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

11. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Remove the inverter cover from the inverter with converter assembly.





(c) Disconnect the generator cable and motor cable from the inverter with converter assembly.

(d) Check MG1 for an interphase short using a milliohmmeter.





(1) Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

HINT
If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

Standard Resistance:





Text in Illustration





HINT
To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 68° F (20°C).

- R20 = Rt / {1 + 0.00393 X (T - 20)}
The calculation is based on the following:

- R20: Resistance at 68° F (20°C) (mOhms)
- Rt: Measured resistance (mOhms)
- T: Temperature when the resistance is measured (° C)

(e) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTICE:
Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:





(f) Connect the generator cable and motor cable.

(g) Install the inverter cover.

NG -- CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)
OK -- Continue to next step.

12. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Remove the inverter cover from the inverter with converter assembly.





(c) Disconnect the generator cable and motor cable from the inverter with converter assembly.

(d) Check MG2 for an interphase short using a milliohmmeter.





(1) Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

HINT
If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

Standard Resistance:





Text in Illustration





HINT
To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 68° F (20°C).

- R20 = Rt / {1 + 0.00393 X (T - 20)}
The calculation is based on the following:

- R20: Resistance at 68° F (20°C) (mOhms)
- Rt: Measured resistance (mOhms)
- T: Temperature when the resistance is measured (° C)

(e) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTICE:
Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:





(f) Connect the generator cable and motor cable.

(g) Install the inverter cover.

NG -- CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)
OK -- Continue to next step.

13. CHECK FUSE (PCU)

(a) Remove the PCU fuse from the engine room junction block assembly.





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

Standard Resistance:





Text in Illustration





(c) Install the PCU fuse.

NG -- CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)
OK -- Continue to next step.

14. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Disconnect connector A62 from inverter with converter assembly.

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





Standard Resistance:





Text in Illustration





(d) Turn the power switch on (IG).

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

Standard Voltage:





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

(f) Turn the power switch off.

(g) Connect the inverter with converter assembly connector.

NG -- REPAIR OR REPLACE POWER SOURCE CIRCUIT
OK -- Continue to next step.

15. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Turn the power switch off.

(c) Disconnect connector A62 from the inverter with converter assembly.

(d) Disconnect connector A20 from the power management control ECU.

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





Standard Resistance (Check for Open):





Standard Resistance (Check for Short):





Text in Illustration





(f) Turn the power switch on (IG).

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

Standard Voltage:





NOTICE:
Turning the power switch on (IG) with the power management control ECU and inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

(h) Turn the power switch off.

(i) Connect the power management control ECU connector.

(j) Connect the inverter with converter assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

16. CHECK POWER MANAGEMENT CONTROL ECU

(a) Disconnect connector A62 from the inverter with converter assembly.

(b) Disconnect connector A20 from the power management control ECU.

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





Standard Resistance:





Text in Illustration





(d) Connect the power management control ECU connector.

(e) Connect the inverter with converter assembly connector.

NG -- REPLACE POWER MANAGEMENT CONTROL ECU Components
OK -- Continue to next step.

17. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY

OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

21. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

22. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

23. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Disconnect connector A62 from the inverter with converter assembly.

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





Standard Resistance:





Text in Illustration





(d) Connect the inverter with converter assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

24. REPLACE INVERTER WITH CONVERTER ASSEMBLY

(a) Replace the inverter with converter assembly Components.

NEXT -- REPLACE FUSE (PCU)

25. REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT -- REPLACE FUSE (PCU)

26. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Remove the inverter with converter assembly.

(c) Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.





Specified Condition:

Bolt A
T=20 N*m {204 kgf*cm, 15 ft.*lbf}

Bolt B
T=10 N*m {102 kgf*cm, 7 ft.*lbf}

NOTICE:
- Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 and 245 kgf*cm, 12 and 18 ft.*lbf).
- Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

(d) Disconnect the generator cable from the hybrid transaxle assembly.

(e) Check for arc marks at the bolts for the generator cable.

Result:





(f) Connect the generator cable to the hybrid transaxle assembly.

(g) Install the inverter with converter assembly.

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

27. CHECK GENERATOR CABLE

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Remove the generator cable.

(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.





NOTICE:
Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:





Text in Illustration





NOTICE:
Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

Standard Resistance:





(e) Install the generator cable.

NG -- REPLACE GENERATOR CABLE Components

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

28. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.





Specified Condition:

T=10 N*m {102 kgf*cm, 7 ft.*lbf}

NOTICE:
Make sure that the tightening torque of the bolts is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

(c) Disconnect the motor cable from the hybrid transaxle assembly.

(d) Check for arc marks at the bolts for the motor cable.

Result:





(e) Connect the motor cable to the hybrid transaxle assembly.

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

29. CHECK MOTOR CABLE

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Remove the motor cable.

(c) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.





NOTICE:
Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:





Text in Illustration





NOTICE:
Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

Standard Resistance:





(e) Install the motor cable.

NG -- REPLACE MOTOR CABLE Components

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components