Toyota Avalon (XX50): Indicator Circuit. Inverter Low-voltage Circuit. Motor High-voltage Circuit

Indicator Circuit

DESCRIPTION

In accordance with the shift lever position, each shift position indicator light will turn on.

WIRING DIAGRAM

PROCEDURE

(a) Turn the power switch on (ACC).

(b) Check that each shift position indicator light turns on correctly.

(c) Turn the power switch off.

B

GO TO STEP 2

C

GO TO STEP 4

D

GO TO STEP 4

A

(a) Disconnect the G46 and G47 hybrid vehicle control ECU connectors.

(b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition G47-13 (INDP) - Body ground and other terminals Always 10 kΩ or higher G46-8 (INDR) - Body ground and other terminals Always 10 kΩ or higher G47-12 (INDN) - Body ground and other terminals Always 10 kΩ or higher G47-11 (INDD) - Body ground and other terminals Always 10 kΩ or higher G47-10 (INDM) - Body ground and other terminals Always 10 kΩ or higher

*a Rear view of wire harness connector (to Hybrid Vehicle Control ECU)

(c) Reconnect the G46 and G47 hybrid vehicle control ECU connectors.

OK

REPLACE HYBRID VEHICLE CONTROL ECU

NG

(a) Disconnect the G46 and G47 hybrid vehicle control ECU connectors.

(b) Disconnect the G116 shift position indicator connector.

(c) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition G47-13 (INDP) or G116-4 (P) - Body ground and other terminals Always 10 kΩ or higher G46-8 (INDR) or G116-3 (R) - Body ground and other terminals Always 10 kΩ or higher G47-12 (INDN) or G116-2 (N) - Body ground and other terminals Always 10 kΩ or higher G47-11 (INDD) or G116-1 (D) - Body ground and other terminals Always 10 kΩ or higher G47-10 (INDM) or G116-8 (S) - Body ground and other terminals Always 10 kΩ or higher

*a Rear view of wire harness connector (to Hybrid Vehicle Control ECU) *b Front view of wire harness connector (to Shift Position Indicator)

(d) Reconnect the G116 shift position indicator connector.

(e) Reconnect the G46 and G47 hybrid vehicle control ECU connectors.

OK

REPLACE SHIFT POSITION INDICATOR

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

(a) Disconnect the G116 shift position indicator connector.

(b) Turn the power switch on (ACC).

(c) Measure the voltage according to the value(s) in the table below. Standard Voltage: Tester Connection Condition Specified Condition G116-10 (PWR) - Body ground Power switch on (ACC) 11 to 14 V

*a Front view of wire harness connector (to Shift Position Indicator)

(d) Turn the power switch off.

(e) Reconnect the G116 shift position indicator connector.

NG

REPAIR OR REPLACE POWER SOURCE CIRCUIT

OK

(a) Turn the power switch on (ACC).

(b) Measure the voltage according to the value(s) in the table below. Standard Voltage: Tester Connection Condition Specified Condition A23-22 (ACCI) - Body ground Power switch on (ACC) 11 to 14 V

*a Component with harness connected (Hybrid Vehicle Control ECU)

(c) Turn the power switch off.

NG

REPAIR OR REPLACE POWER SOURCE CIRCUIT

OK

(a) Disconnect the G46 and G47 hybrid vehicle control ECU connectors.

(b) Turn the power switch on (ACC).

(c) Measure the voltage according to the value(s) in the table below. Standard Voltage: Tester Connection Condition Specified Condition G47-13 (INDP) - Body ground and other terminals Power switch on (ACC) 11 to 14 V G46-8 (INDR) - Body ground and other terminals Power switch on (ACC) 11 to 14 V G47-12 (INDN) - Body ground and other terminals Power switch on (ACC) 11 to 14 V G47-11 (INDD) - Body ground and other terminals Power switch on (ACC) 11 to 14 V G47-10 (INDM) - Body ground and other terminals Power switch on (ACC) 11 to 14 V

*a Rear view of wire harness connector (to Hybrid Vehicle Control ECU)

(d) Turn the power switch off.

(e) Reconnect the G46 and G47 hybrid vehicle control ECU connectors.

OK

REPLACE HYBRID VEHICLE CONTROL ECU

NG

(a) Disconnect the G46 and G47 hybrid vehicle control ECU connectors.

(b) Disconnect the G116 shift position indicator connector.

(c) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition G47-13 (INDP) - G116-4 (P) Always Below 1 Ω G46-8 (INDR) - G116-3 (R) Always Below 1 Ω G47-12 (INDN) - G116-2 (N) Always Below 1 Ω G47-11 (INDD) - G116-1 (D) Always Below 1 Ω G47-10 (INDM) - G116-8 (S) Always Below 1 Ω

*a Rear view of wire harness connector (to Hybrid Vehicle Control ECU) *b Front view of wire harness connector (to Shift Position Indicator)

(d) Reconnect the G116 shift position indicator connector.

(e) Reconnect the G46 and G47 hybrid vehicle control ECU connectors.

OK

REPLACE SHIFT POSITION INDICATOR

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

Inverter Low-voltage Circuit

DESCRIPTION

The cause of the malfunction may be the low-voltage circuit.

Check whether there is an open circuit in the inverter +B low-voltage power source system or a problem in the communication between the hybrid vehicle control ECU and inverter.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

This diagnostic procedure is referenced to in the diagnostic procedure of several DTCs.

If the result of this diagnostic procedure is normal, proceed as directed in the procedure for the DTC.

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
• After removing 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.

  *a	Without waiting for 10 minutes

  Click here

  HINT:

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

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

PROCEDURE

(a) Remove the PCU fuse from the No. 4 relay block.

*1 No. 4 Relay Block *2 PCU Fuse

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

Standard Resistance:

(c) Install the PCU fuse.

NG

GO TO STEP 5

OK

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 manual because this may cause a malfunction.

(b) Disconnect the A42 inverter with converter assembly connector.

(c) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition A42-24 (GND1) - Body ground Power switch off Below 1 Ω A42-23 (GND2) - Body ground Power switch off Below 1 Ω

*a Front view of wire harness connector (to Inverter with Converter Assembly)

(d) Connect the cable to the negative (-) auxiliary battery terminal.

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

(f) 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.

(g) Turn the power switch off.

(h) Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.

(i) Reconnect the A42 inverter with converter assembly connector.

NG

REPAIR OR REPLACE POWER SOURCE CIRCUIT

OK

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 manual because this may cause a malfunction.

(b) Disconnect the A42 inverter with converter assembly connector.

(c) Disconnect the A24 hybrid vehicle control ECU connector.

(d) Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for Open): Tester Connection Condition Specified Condition A42-20 (HMCH) - A24-31 (HMCH) Power switch off Below 1 Ω A42-19 (HMCL) - A24-30 (HMCL) Power switch off Below 1 Ω Standard Resistance (Check for Short): Tester Connection Condition Specified Condition A42-20 (HMCH) or A24-31 (HMCH) - Body ground and other terminals Power switch off 10 kΩ or higher A42-19 (HMCL) or A24-30 (HMCL) - Body ground and other terminals Power switch off 10 kΩ or higher

*a Front view of wire harness connector (to Inverter with Converter Assembly) *b Rear view of wire harness connector (to Hybrid Vehicle Control ECU)

(e) Connect the cable to the negative (-) auxiliary battery terminal.

(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 hybrid vehicle control ECU and inverter with converter assembly connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

(h) Turn the power switch off.

(i) Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.

(j) Reconnect the A24 hybrid vehicle control ECU connector.

(k) Reconnect the A42 inverter with converter assembly connector.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

(a) Disconnect the A24 hybrid vehicle control ECU connector.

(b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition A24-30 (HMCL) - A24-31 (HMCH) Power switch off 80 to 170 Ω

*a Component without harness connected (Hybrid Vehicle Control ECU)

(c) Reconnect the A24 hybrid vehicle control ECU connector.

OK

INVERTER LOW-VOLTAGE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

NG

REPLACE HYBRID VEHICLE CONTROL ECU

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 manual because this may cause a malfunction.

(b) Disconnect the A42 inverter with converter assembly connector.

(c) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition A42-6 (+B) - Body ground Power switch off 10 kΩ or higher A42-5 (+B2) - Body ground Power switch off 10 kΩ or higher

*a Front view of wire harness connector (to Inverter with Converter Assembly)

(d) Reconnect the A42 inverter with converter assembly connector.

NG

GO TO STEP 7

OK

Click here

NEXT

REPLACE FUSE (PCU)

NEXT

REPLACE FUSE (PCU)

Motor High-voltage Circuit

DESCRIPTION

The cause of the malfunction may be the high-voltage circuit of the motor.

Check the motor internal resistance and the connection condition of the high-voltage line between the inverter and motor to check whether there is an open or short circuit.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

This diagnostic procedure is referenced to in the diagnostic procedure of several DTCs.

If the result of this diagnostic procedure is normal, proceed as directed in the procedure for the DTC.

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
• After removing 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.

  *a	Without waiting for 10 minutes

  Click here

  HINT:

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

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

PROCEDURE

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 manual 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: T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

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

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

(f) Reconnect the motor cable.

(g) Reinstall the inverter cover.

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

A

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 manual because this may cause a malfunction.

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

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

(d) Using a milliohmmeter, measure the resistance according to the value(s) in the table below. HINT: If the motor (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: Tester Connection Condition Specified Condition W2-1 (W) - W2-2 (U) Power switch off 62.1 to 68.8 mΩ W2-2 (U) - W2-3 (V) Power switch off 62.1 to 68.8 mΩ W2-3 (V) - W2-1 (W) Power switch off 62.3 to 69.0 mΩ HINT: To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F). R20 = Rt / {1 + 0.00393 X (T - 20)} The calculation is based on the following: R20: Resistance at 20°C (68°F) (mΩ) Rt: Measured resistance (mΩ) T: Temperature when the resistance is measured (°C (°F).)

*1 Shield Ground *a Motor Cable (Inverter with Converter Assembly Side)

(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) Reconnect the motor cable.

(g) Reinstall the inverter cover.

OK

MOTOR HIGH-VOLTAGE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

NG

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 manual because this may cause a malfunction.

(b) Remove 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: T=10 N*m (102 kgf*cm, 7 ft.*lbf)

(d) Disconnect the motor cable from the hybrid vehicle transaxle assembly.

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

(f) Reconnect the motor cable.

(g) Reinstall the inverter with converter assembly.

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

A

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 manual because this may cause a malfunction.

(b) Remove the inverter with converter assembly.

(c) Remove the motor cable.

(d) 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:

NOTICE:

Wrap the terminal of the motor cable with insulating tape to prevent them from coming into contact with body ground.

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

Standard Resistance:

(f) Reinstall the motor cable.

(g) Reinstall the inverter with converter assembly.

OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

NG

REPLACE MOTOR CABLE