On-Vehicle Inspection

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT INVERTER
NOTE: Wear insulating gloves.

HINT:

Check DTCs before performing the inspections of the converter and inverter, and perform the appropriate troubleshooting.
1. Turn the power switch OFF.
2. Remove the service plug grip (see SERVICE PLUG GRIP ).
3. Remove the inverter cover (see W/CONVERTER INVERTER ASSY ).
4. Disconnect the connectors A and B shown in the illustration.
5. Turn the power switch ON (IG).
  If turning the power switch ON (IG) with the service plug grip removed, the DTC of the inter lock switch system will be output.
6. Using a voltmeter, measure the voltage. Also, using an ohmmeter, measure the resistance.
  
  Fig 1: Locating A, B, C Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The inspection should be performed on the wire harness side, not on the terminal side.
  
  Fig 2: Identifying A, B, C Connecting Terminals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard:
  
  Fig 3: Tester Connection Specified Condition Table (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 4: Tester Connection Specified Condition Table (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CONVERTER

NOTE: Wear insulating gloves.

HINT:

If the HV system warning, master warning lamp and charge warning come on at the same time, check the DTCs and perform the appropriate troubleshooting.

Fig 5: Identifying Master Warming Lamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 6: Identifying HV System Warming And Change Warning Lamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the operation.

Using a voltmeter, measure the voltage of the auxiliary battery terminal when the "READY" lamp is OFF and ON.

Fig 7: Locating Ready Lamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard:

LAMP CONDITION

"READY" Lamp	Voltage
ON	14 V
OFF	12 V

HINT:

When the "READY" lamp is ON, the converter outputs the voltage. When it is OFF, the auxiliary battery outputs the voltage.

Inspect the output current.
1. Disconnect the MG1 and MG2 power cables from the inverter (see W/CONVERTER INVERTER ASSY ).
2. Install a voltmeter and the AC/DC 400 A probe to the locations shown in the illustration.
3. Connect the MG1 and MG2 power cables to the inverter (see W/CONVERTER INVERTER ASSY ).
4. With the "READY" lamp ON, operate the 12 V electrical devices one by one, then measure the output current.
1. Standard: Approximately 80 A or less
HINT:

If the output current is 0 A or greater than 80 A, check the input output signal.

Check the input/output signal.

Disconnect the connectors shown in the illustration.

Fig 9: Disconnecting Connectors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a voltmeter, measure the voltage between the body ground and the terminal of the vehicle side wire harness connector.
1. Standard:
2. Equal to the auxiliary battery terminal voltage
Disconnect the connectors shown in the illustration.

Fig 10: Disconnecting Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

Fig 11: Identifying Converter Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard:

TESTER CONNECTION SPECIFIED CONDITION

Tester connection	Specified condition
Terminal 1 - Body ground (IGCT - Body ground)	8 to 16 V
Terminal 3 - Body ground (S - Body ground)	Equal to the auxiliary battery voltage
Terminal 4 - Body ground (NODD - Body ground)	120 to 140 kΩ (when power switch is OFF)

If the standards are not met, replace the with inverter converter assembly.

INSPECT SPEED SENSOR (RESOLVER)
1. Using an ohmmeter, measure the resistance between the terminals.
  Standard:
  
  Fig 12: Tester Connection Specified Condition
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the standards are not met, replace the hybrid vehicle transaxle assembly.
Fig 13: Locating A, B Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 14: Identifying A Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 15: Identifying B Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TEMPERATURE SENSOR
1. Using an ohmmeter, measure the resistance between the terminals.
  Standard:
  
  Fig 16: Checking Resistance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:

The standard varies according to the sensor temperature. If the standards are not met, replace the hybrid vehicle transaxle assembly.

Fig 17: Locating C Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 18: Identifying C Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 19: Temperature/Resistance Graph
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT ACCELERATOR POSITION

NOTE:

Do not remove the accelerator position sensor from the accelerator pedal.
Perform the inspection on the hybrid vehicle control ECU side of the connector.

Turn the power switch ON (IG).

Using a voltmeter, measure the voltage between the terminals.

Fig 20: Identifying Hybrid Control ECU Connector Terminals

Standard:

TERMINALS SPECIFIED CONDITION

Terminals	Measuring Condition	Specified Condition
B25 - B27 (VCP1 - EP1)	Normal	4.5 to 5.5 V
B26 - B27 (VPA1 - EP1)	Do not depress the accelerator pedal	0.5 to 1.1 V
B26 - B27 (VPA1 - EP1)	Gradually depress the accelerator pedal	The voltage increases slowly
B26 - B27 (VPA1 - EP1)	Fully depress the accelerator pedal	2.6 to 4.5 V
B33 - B35 (VCP2 - EP2)	Normal	4.5 to 5.5 V
B34 - B35 (VPA2 - EP2)	Do not depress the accelerator pedal	1.2 to 2.0 V
B34 - B35 (VPA2 - EP2)	Gradually depress the accelerator pedal	The voltage increases slowly
B34 - B35 (VPA2 - EP2)	Fully depress the accelerator pedal	3.4 to 5.3 V

If the standards are not met, replace the accelerator pedal rod assembly.