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Inspection Procedure

  1. CHECK HARNESS AND GROUND) CONNECTOR (HYBRID VEHICLE CONTROL ECU - BODY 
    1. Disconnect the C64 hybrid vehicle control ECU connector.
      2. Fig 1: Identifying C64 Hybrid Vehicle Control ECU Connector Terminals
      G05617768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminal and body ground.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      E1 (C64-14) - Body ground Below 1 Ω
    3. Reconnect the hybrid vehicle control ECU connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  2. CHECK ENGINE ROOM JUNCTION BLOCK (IGCT RELAY VOLTAGE) 
    1. Remove the engine room junction block from the engine room R/B.
      2. Fig 2: Identifying Engine Room Junction Block From Engine Room R/B
      G04973797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the power switch on (IG).
    3. Measure the voltage between the terminal and body ground.

      Standard voltage 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      5 - Body ground 9 to 14 V

    OK:  Go to step  5

    NG: Go to next step 

  3. INSPECT IGCT FUSE 
    1. Remove the IGCT fuse from the engine room R/B.
      2. Fig 3: Identifying IGCT Fuse
      G05007819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the IGCT fuse resistance.

      Standard resistance: 

      Below 1 Ω 

    3. Reinstall the IGCT fuse.

    NG: REPLACE IGCT FUSE 

    OK: Go to next step 

  4. CHECK HARNESS AND CONNECTOR (IGCT FUSE - BATTERY) 
    1. Disconnect the positive battery terminal.
    2. Remove the IGCT fuse from the engine room R/B.
      3. Fig 4: Identifying IGCT Fuse From Engine Room R/B
      G05007946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance between the terminals.

      Standard resistance (Check for open) 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      1 - Positive battery terminal Below 1 Ω
    4. Reinstall the IGCT fuse.
    5. Reconnect the positive battery terminal.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 

  5. INSPECT IGCT RELAY 
    1. Remove the IGCT relay from the engine room R/B.
      2. Fig 5: View Of Relay (ACC Relay)
      G04975584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminals.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      3 - 5 10 kΩ or higher
      3 - 5 Below 1 Ω (Apply battery voltage between terminals 1 and 2)
    3. Reinstall the IGCT relay.

    NG: REPLACE IGCT RELAY 

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - IGCT RELAY) 
    1. Disconnect the A61 hybrid vehicle control ECU connector.
      2. Fig 6: Identifying Hybrid Vehicle Control ECU Connector Terminals
      G05617773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the IGCT relay from the engine room R/B.
    3. Measure the resistance according to the value(s) in the table below.

      Standard resistance (Check for open) 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      IGCT relay (3) - +B1 (A61-2) Below 1 Ω
      IGCT relay (3) - +B2 (A61-1) Below 1 Ω

      Standard resistance (Check for short) 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      IGCT relay (3) or +B1 (A61-2) - Body ground 10 kΩ or higher
      IGCT relay (3) or +B2 (A61-1) - Body ground 10 kΩ or higher
    4. Reinstall the engine room J/B.
    5. Reconnect the hybrid vehicle control ECU connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  7. INSPECT HYBRID VEHICLE CONTROL ECU (IGSW VOLTAGE) 
    1. Disconnect the A61 hybrid vehicle control ECU connector.
      2. Fig 7: Identifying A61 Hybrid Vehicle Control ECU Connector Terminals
      G05007949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage between the terminal and body ground.

      Standard voltage 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      IGSW (A61-57) - Body ground 9 to 14 V
    3. Reconnect the hybrid vehicle control ECU connector.

    OK:  Go to step  10

    NG: Go to next step 

  8. INSPECT IG2 RELAY 
    1. Remove the IG2 relay from the engine room R/B.
      2. Fig 8: View Of EFI Relay
      G04942976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminals.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      3 - 5 10 kΩ or higher
      3 - 5 Below 1 Ω (Apply battery voltage between terminals 1 and 2)
    3. Reinstall the IG2 relay.

    NG: REPLACE IG2 RELAY 

    OK: Go to next step 

  9. CHECK HARNESS AND CONNECTOR (IG2 RELAY - BODY GROUND) 
    1. Remove the IG2 relay from the engine room R/B.
      2. Fig 9: Identifying IG2 Relay From Engine Room R/B
      G05007951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminal and body ground.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      IG2 relay terminal 2 - Body ground Below 1 Ω
    3. Reinstall the IG2 relay.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK:  Go to SMART ACCESS SYSTEM WITH PUSH-BUTTON START

  10. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BODY GROUND) 
    1. Disconnect the A61 hybrid vehicle control ECU connector.
      2. Fig 10: Identifying A61 Hybrid Vehicle Control ECU Connector Terminals
      G05007952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminal and body ground.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      MREL (A61-93) - Body ground Below 1 Ω
    3. Reconnect the hybrid vehicle control ECU connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: REPLACE HYBRID VEHICLE CONTROL ECU 

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