DTC    P0A78-503    Drive Motor "A" Inverter Performance

DTC    P0A78-504    Drive Motor "A" Inverter Performance

for Preparation Click here


DESCRIPTION

For a description of the inverter, (Click here).

DTC No.
INF Code
DTC Detection Condition
Trouble Area
P0A78
504
Motor inverter overvoltage signal detection (overvoltage due to hybrid vehicle transmission assembly malfunction)
  1. Wire harness or connector
  2. Hybrid vehicle transmission assembly
P0A78
503
Motor inverter overvoltage signal detection (overvoltage due to MG ECU malfunction)
Inverter with converter assembly

INSPECTION PROCEDURE

CAUTION:
  1. 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.
  2. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting, check the voltage at 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.

1.CHECK DTC OUTPUT
  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Select the following menu items: Powertrain / Hybrid Control / DTC.

  1. Check if DTCs are output.

    Result:

    DTC No.
    Relevant Diagnosis
    P0A1D (all INF codes)
    Hybrid Powertrain Control Module
    P0A1A (all INF codes)
    Generator Control Module
    P0A1B (all INF codes)
    Drive Motor "A" Control Module
    P0A72 (all INF codes)
    Generator Phase V Current
    P0A75 (all INF codes)
    Generator Phase W Current
    P0A60 (all INF codes)
    Drive Motor "A" Phase V Current
    P0A63 (all INF codes)
    Drive Motor "A" Phase W Current
    P0A51-174
    Drive Motor "A" Current Sensor Circuit
    P0A4B-253
    Generator Position Sensor Circuit
    P0A4D-255
    Generator Position Sensor Circuit Low
    P0A4C-513
    Generator Position Sensor Circuit Range / Performance
    P0A3F-243
    Drive Motor "A" Position Sensor Circuit
    P0A41-245
    Drive Motor "A" Position Sensor Circuit Low
    P0A40-500
    Drive Motor "A" Position Sensor Circuit Range / Performance
    P0A78-266, 267, 523, 586, 505, 287, 506, 806, 807, 808
    Drive Motor "A" Inverter Performance
    P0A94-585, 587, 589, 590, 554, 555, 556
    DC/DC Converter Performance
    P0A7A-517, 325, 518, 809, 810, 811
    Generator Inverter Performance
    P3004-803
    High Voltage Power Resource
    P0ADB-227
    Hybrid Battery Positive Contactor Control Circuit Low
    P0ADC-226
    Hybrid Battery Positive Contactor Control Circuit High
    P0ADF-229
    Hybrid Battery Negative Contactor Control Circuit Low

    HINT:
    P0A78-503 or 504 may be set due to a malfunction which also causes DTCs in the table above to be set. In this case, first troubleshoot the output DTCs in the table above. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.



YES
GO TO DTC CHART
NO


2.CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)


    A142953E01
  1. Check the connection of the low voltage connector of the inverter with converter assembly.

    Result:
    The connector is connected securely and there are no contact problems.



NG
CONNECT SECURELY
OK


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

CAUTION:
Be sure to wear insulated gloves.

  1. Turn the power switch off and remove the service plug grip (Click here).

    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.



    A131159E11
  1. Disconnect connector A59 (LHD), A62 (RHD) from the inverter with converter assembly.

  1. Turn the power switch on (IG).

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

    Standard voltage:
    LHD:
    Tester Connection
    Specified Condition
    GRF (A59-1) - Body ground
    Below 1 V
    GRFG (A59-12) - Body ground
    Below 1 V
    GSN (A59-14) - Body ground
    Below 1 V
    GSNG (A59-3) - Body ground
    Below 1 V
    GCS (A59-13) - Body ground
    Below 1 V
    GCSG (A59-2) - Body ground
    Below 1 V
    RHD:
    Tester Connection
    Specified Condition
    GRF (A62-1) - Body ground
    Below 1 V
    GRFG (A62-12) - Body ground
    Below 1 V
    GSN (A62-14) - Body ground
    Below 1 V
    GSNG (A62-3) - Body ground
    Below 1 V
    GCS (A62-13) - Body ground
    Below 1 V
    GCSG (A62-2) - Body ground
    Below 1 V

    NOTICE:
    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


4.CHECK GENERATOR RESOLVER


    A131159E11
  1. Turn the power switch off.

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

    Standard resistance (Check for open):
    LHD:
    Tester Connection
    Specified Condition
    GRF (A59-1) - GRFG (A59-12)
    5.8 to 11.8 Ω
    GSN (A59-14) - GSNG (A59-3)
    11.7 to 17.7 Ω
    GCS (A59-13) - GCSG (A59-2)
    11.7 to 17.7 Ω
    RHD:
    Tester Connection
    Specified Condition
    GRF (A62-1) - GRFG (A62-12)
    5.8 to 11.8 Ω
    GSN (A62-14) - GSNG (A62-3)
    11.7 to 17.7 Ω
    GCS (A62-13) - GCSG (A62-2)
    11.7 to 17.7 Ω

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

    Standard resistance (Check for short):
    LHD:
    Tester Connection
    Specified Condition
    GRF (A59-1) or GRFG (A59-12) - Body ground
    10 kΩ or more
    GSN (A59-14) or GSNG (A59-3) - Body ground
    10 kΩ or more
    GCS (A59-13) or GCSG (A59-2) - Body ground
    10 kΩ or more
    GRF (A59-1) - GCSG (A59-2)
    10 kΩ or more
    GRF (A59-1) - GCS (A59-13)
    10 kΩ or more
    GRF (A59-1) - GSNG (A59-3)
    10 kΩ or more
    GRF (A59-1) - GSN (A59-14)
    10 kΩ or more
    GRFG (A59-12) - GCSG (A59-2)
    10 kΩ or more
    GRFG (A59-12) - GCS (A59-13)
    10 kΩ or more
    GRFG (A59-12) - GSNG (A59-3)
    10 kΩ or more
    GRFG (A59-12) - GSN (A59-14)
    10 kΩ or more
    GCSG (A59-2) - GSNG (A59-3)
    10 kΩ or more
    GCSG (A59-2) - GSN (A59-14)
    10 kΩ or more
    GCS (A59-13) - GSNG (A59-3)
    10 kΩ or more
    GCS (A59-13) - GSN (A59-14)
    10 kΩ or more
    RHD:
    Tester Connection
    Specified Condition
    GRF (A62-1) or GRFG (A62-12) - Body ground
    10 kΩ or more
    GSN (A62-14) or GSNG (A62-3) - Body ground
    10 kΩ or more
    GCS (A62-13) or GCSG (A62-2) - Body ground
    10 kΩ or more
    GRF (A62-1) - GCSG (A62-2)
    10 kΩ or more
    GRF (A62-1) - GCS (A62-13)
    10 kΩ or more
    GRF (A62-1) - GSNG (A62-3)
    10 kΩ or more
    GRF (A62-1) - GSN (A62-14)
    10 kΩ or more
    GRFG (A62-12) - GCSG (A62-2)
    10 kΩ or more
    GRFG (A62-12) - GCS (A62-13)
    10 kΩ or more
    GRFG (A62-12) - GSNG (A62-3)
    10 kΩ or more
    GRFG (A62-12) - GSN (A62-14)
    10 kΩ or more
    GCSG (A62-2) - GSNG (A62-3)
    10 kΩ or more
    GCSG (A62-2) - GSN (A62-14)
    10 kΩ or more
    GCS (A62-13) - GSNG (A62-3)
    10 kΩ or more
    GCS (A62-13) - GSN (A62-14)
    10 kΩ or more



NG
Go to step 7
OK


5.CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    A138831
  1. Check the connection of the generator resolver connector.

    Result:
    The connector is connected securely and there are no contact problems.



NG
CONNECT SECURELY
OK


6.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)
  1. Disconnect connector E81 from the generator resolver.

  1. Turn the power switch off.



    A131161E04
  1. Measure the resistance according to the value(s) in the table below.

    Standard resistance (Check for open):
    LHD:
    Tester Connection
    Specified Condition
    GRF (A59-1) - GRF (E81-1)
    Below 1 Ω
    GRFG (A59-12) - GRFG (E81-5)
    Below 1 Ω
    GSN (A59-14) - GSN (E81-2)
    Below 1 Ω
    GSNG (A59-3) - GSNG (E81-6)
    Below 1 Ω
    GCS (A59-13) - GCS (E81-3)
    Below 1 Ω
    GCSG (A59-2) - GCSG (E81-7)
    Below 1 Ω
    RHD:
    Tester Connection
    Specified Condition
    GRF (A62-1) - GRF (E81-1)
    Below 1 Ω
    GRFG (A62-12) - GRFG (E81-5)
    Below 1 Ω
    GSN (A62-14) - GSN (E81-2)
    Below 1 Ω
    GSNG (A62-3) - GSNG (E81-6)
    Below 1 Ω
    GCS (A62-13) - GCS (E81-3)
    Below 1 Ω
    GCSG (A62-2) - GCSG (E81-7)
    Below 1 Ω


    Standard resistance (Check for short):
    LHD:
    Tester Connection
    Specified Condition
    GRF (A59-1) or GRF (E81-1) - Body ground
    10 kΩ or more
    GRFG (A59-12) or GRFG (E81-5) - Body ground
    10 kΩ or more
    GSN (A59-14) or GSN (E81-2) - Body ground
    10 kΩ or more
    GSNG (A59-3) or GSNG (E81-6) - Body ground
    10 kΩ or more
    GCS (A59-13) or GCS (E81-3) - Body ground
    10 kΩ or more
    GCSG (A59-2) or GCSG (E81-7) - Body ground
    10 kΩ or more
    GRF (A59-1) - GRFG (A59-12)
    10 kΩ or more
    GRF (A59-1) - GCSG (A59-2)
    10 kΩ or more
    GRF (A59-1) - GCS (A59-13)
    10 kΩ or more
    GRF (A59-1) - GSNG (A59-3)
    10 kΩ or more
    GRF (A59-1) - GSN (A59-14)
    10 kΩ or more
    GRFG (A59-12) - GCSG (A59-2)
    10 kΩ or more
    GRFG (A59-12) - GCS (A59-13)
    10 kΩ or more
    GRFG (A59-12) - GSNG (A59-3)
    10 kΩ or more
    GRFG (A59-12) - GSN (A59-14)
    10 kΩ or more
    GSN (A59-14) - GSNG (A59-3)
    10 kΩ or more
    GCSG (A59-2) - GSNG (A59-3)
    10 kΩ or more
    GCSG (A59-2) - GSN (A59-14)
    10 kΩ or more
    GCS (A59-13) - GCSG (A59-2)
    10 kΩ or more
    GCS (A59-13) - GSNG (A59-3)
    10 kΩ or more
    GCS (A59-13) - GSN (A59-14)
    10 kΩ or more
    RHD:
    Tester Connection
    Specified Condition
    GRF (A62-1) or GRF (E81-1) - Body ground
    10 kΩ or more
    GRFG (A62-12) or GRFG (E81-5) - Body ground
    10 kΩ or more
    GSN (A62-14) or GSN (E81-2) - Body ground
    10 kΩ or more
    GSNG (A62-3) or GSNG (E81-6) - Body ground
    10 kΩ or more
    GCS (A62-13) or GCS (E81-3) - Body ground
    10 kΩ or more
    GCSG (A62-2) or GCSG (E81-7) - Body ground
    10 kΩ or more
    GRF (A62-1) - GRFG (A62-12)
    10 kΩ or more
    GRF (A62-1) - GCSG (A62-2)
    10 kΩ or more
    GRF (A62-1) - GCS (A62-13)
    10 kΩ or more
    GRF (A62-1) - GSNG (A62-3)
    10 kΩ or more
    GRF (A62-1) - GSN (A62-14)
    10 kΩ or more
    GRFG (A62-12) - GCSG (A62-2)
    10 kΩ or more
    GRFG (A62-12) - GCS (A62-13)
    10 kΩ or more
    GRFG (A62-12) - GSNG (A62-3)
    10 kΩ or more
    GRFG (A62-12) - GSN (A62-14)
    10 kΩ or more
    GSN (A62-14) - GSNG (A62-3)
    10 kΩ or more
    GCSG (A62-2) - GSNG (A62-3)
    10 kΩ or more
    GCSG (A62-2) - GSN (A62-14)
    10 kΩ or more
    GCS (A62-13) - GCSG (A62-2)
    10 kΩ or more
    GCS (A62-13) - GSNG (A62-3)
    10 kΩ or more
    GCS (A62-13) - GSN (A62-14)
    10 kΩ or more

    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 (Click here)  

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

CAUTION:
Be sure to wear insulated gloves.

  1. Turn the power switch off and remove the service plug grip (Click here).

    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.



    A131159E09
  1. Disconnect connector A59 (LHD), A62 (RHD) from the inverter with converter assembly.

  1. Turn the power switch on (IG).

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

    Standard voltage:
    LHD:
    Tester Connection
    Specified Condition
    MRF (A59-33) - Body ground
    Below 1 V
    MRFG (A59-22) - Body ground
    Below 1 V
    MSN (A59-23) - Body ground
    Below 1 V
    MSNG (A59-35) - Body ground
    Below 1 V
    MCS (A59-24) - Body ground
    Below 1 V
    MCSG (A59-34) - Body ground
    Below 1 V
    RHD:
    Tester Connection
    Specified Condition
    MRF (A62-33) - Body ground
    Below 1 V
    MRFG (A62-22) - Body ground
    Below 1 V
    MSN (A62-23) - Body ground
    Below 1 V
    MSNG (A62-35) - Body ground
    Below 1 V
    MCS (A62-24) - Body ground
    Below 1 V
    MCSG (A62-34) - Body ground
    Below 1 V

    NOTICE:
    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


8.CHECK MOTOR RESOLVER


    A131159E09
  1. Turn the power switch off.

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

    Standard resistance (Check for open):
    LHD:
    Tester Connection
    Specified Condition
    MRF (A59-33) - MRFG (A59-22)
    6.0 to 12.0 Ω
    MSN (A59-23) - MSNG (A59-35)
    12.5 to 24.5 Ω
    MCS (A59-24) - MCSG (A59-34)
    12.5 to 24.5 Ω
    RHD:
    Tester Connection
    Specified Condition
    MRF (A62-33) - MRFG (A62-22)
    6.0 to 12.0 Ω
    MSN (A62-23) - MSNG (A62-35)
    12.5 to 24.5 Ω
    MCS (A62-24) - MCSG (A62-34)
    12.5 to 24.5 Ω

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

    Standard resistance (Check for short):
    LHD:
    Tester Connection
    Specified Condition
    MRF (A59-33) or MRFG (A59-22) - Body ground
    10 kΩ or more
    MSN (A59-23) or MSNG (A59-35) - Body ground
    10 kΩ or more
    MCS (A59-24) or MCSG (A59-34) - Body ground
    10 kΩ or more
    MRF (A59-33) - MCSG (A59-34)
    10 kΩ or more
    MRF (A59-33) - MCS (A59-24)
    10 kΩ or more
    MRF (A59-33) - MSNG (A59-35)
    10 kΩ or more
    MRF (A59-33) - MSN (A59-23)
    10 kΩ or more
    MRFG (A59-22) - MCSG (A59-34)
    10 kΩ or more
    MRFG (A59-22) - MCS (A59-24)
    10 kΩ or more
    MRFG (A59-22) - MSNG (A59-35)
    10 kΩ or more
    MRFG (A59-22) - MSN (A59-23)
    10 kΩ or more
    MCSG (A59-34) - MSNG (A59-35)
    10 kΩ or more
    MCSG (A59-34) - MSN (A59-23)
    10 kΩ or more
    MCS (A59-24) - MSNG (A59-35)
    10 kΩ or more
    MCS (A59-24) - MSN (A59-23)
    10 kΩ or more
    RHD:
    Tester Connection
    Specified Condition
    MRF (A62-33) or MRFG (A62-22) - Body ground
    10 kΩ or more
    MSN (A62-23) or MSNG (A62-35) - Body ground
    10 kΩ or more
    MCS (A62-24) or MCSG (A62-34) - Body ground
    10 kΩ or more
    MRF (A62-33) - MCSG (A62-34)
    10 kΩ or more
    MRF (A62-33) - MCS (A62-24)
    10 kΩ or more
    MRF (A62-33) - MSNG (A62-35)
    10 kΩ or more
    MRF (A62-33) - MSN (A62-23)
    10 kΩ or more
    MRFG (A62-22) - MCSG (A62-34)
    10 kΩ or more
    MRFG (A62-22) - MCS (A62-24)
    10 kΩ or more
    MRFG (A62-22) - MSNG (A62-35)
    10 kΩ or more
    MRFG (A62-22) - MSN (A62-23)
    10 kΩ or more
    MCSG (A62-34) - MSNG (A62-35)
    10 kΩ or more
    MCSG (A62-34) - MSN (A62-23)
    10 kΩ or more
    MCS (A62-24) - MSNG (A62-35)
    10 kΩ or more
    MCS (A62-24) - MSN (A62-23)
    10 kΩ or more



OK
REPLACE INVERTER WITH CONVERTER ASSEMBLY
NG


9.CHECK CONNECTOR CONNECTION CONDITION


    A138832
  1. Check the connection of the motor resolver connector.

    Result:
    The connector is connected securely and there are no contact problems.



NG
CONNECT SECURELY
OK


10.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)
  1. Disconnect connector E82 from the motor resolver.



    A131161E03
  1. Measure the resistance according to the value(s) in the table below.

    Standard resistance (Check for open):
    LHD:
    Tester Connection
    Specified Condition
    MRF (A59-33) - MRF (E82-1)
    Below 1 Ω
    MRFG (A59-22) - MRFG (E82-5)
    Below 1 Ω
    MSN (A59-23) - MSN (E82-2)
    Below 1 Ω
    MSNG (A59-35) - MSNG (E82-6)
    Below 1 Ω
    MCS (A59-24) - MCS (E82-3)
    Below 1 Ω
    MCSG (A59-34) - MCSG (E82-7)
    Below 1 Ω
    RHD:
    Tester Connection
    Specified Condition
    MRF (A62-33) - MRF (E82-1)
    Below 1 Ω
    MRFG (A62-22) - MRFG (E82-5)
    Below 1 Ω
    MSN (A62-23) - MSN (E82-2)
    Below 1 Ω
    MSNG (A62-35) - MSNG (E82-6)
    Below 1 Ω
    MCS (A62-24) - MCS (E82-3)
    Below 1 Ω
    MCSG (A62-34) - MCSG (E82-7)
    Below 1 Ω


    Standard resistance (Check for short):
    LHD:
    Tester Connection
    Specified Condition
    MRF (A59-33) or MRF (E82-1) - Body ground
    10 kΩ or more
    MRFG (A59-22) or MRFG (E82-5) - Body ground
    10 kΩ or more
    MSN (A59-23) or MSN (E82-2) - Body ground
    10 kΩ or more
    MSNG (A59-35) or MSNG (E82-6) - Body ground
    10 kΩ or more
    MCS (A59-24) or MCS (E82-3) - Body ground
    10 kΩ or more
    MCSG (A59-34) or MCSG (E82-7) - Body ground
    10 kΩ or more
    MRF (A59-33) - MRFG (A59-22)
    10 kΩ or more
    MRF (A59-33) - MCSG (A59-34)
    10 kΩ or more
    MRF (A59-33) - MCS (A59-24)
    10 kΩ or more
    MRF (A59-33) - MSNG (A59-35)
    10 kΩ or more
    MRF (A59-33) - MSN (A59-23)
    10 kΩ or more
    MRFG (A59-22) - MCSG (A59-34)
    10 kΩ or more
    MRFG (A59-22) - MCS (A59-24)
    10 kΩ or more
    MRFG (A59-22) - MSNG (A59-35)
    10 kΩ or more
    MRFG (A59-22) - MSN (A59-23)
    10 kΩ or more
    MCSG (A59-34) - MRFG (A59-22)
    10 kΩ or more
    MCSG (A59-34) - MSNG (A59-35)
    10 kΩ or more
    MCSG (A59-34) - MCS (A59-24)
    10 kΩ or more
    MCS (A59-24) - MSNG (A59-35)
    10 kΩ or more
    MCS (A59-24) - MSN (A59-23)
    10 kΩ or more
    RHD:
    Tester Connection
    Specified Condition
    MRF (A62-33) or MRF (E82-1) - Body ground
    10 kΩ or more
    MRFG (A62-22) or MRFG (E82-5) - Body ground
    10 kΩ or more
    MSN (A62-23) or MSN (E82-2) - Body ground
    10 kΩ or more
    MSNG (A62-35) or MSNG (E82-6) - Body ground
    10 kΩ or more
    MCS (A62-24) or MCS (E82-3) - Body ground
    10 kΩ or more
    MCSG (A62-34) or MCSG (E82-7) - Body ground
    10 kΩ or more
    MRF (A62-33) - MRFG (A62-22)
    10 kΩ or more
    MRF (A62-33) - MCSG (A62-34)
    10 kΩ or more
    MRF (A62-33) - MCS (A62-24)
    10 kΩ or more
    MRF (A62-33) - MSNG (A62-35)
    10 kΩ or more
    MRF (A62-33) - MSN (A62-23)
    10 kΩ or more
    MRFG (A62-22) - MCSG (A62-34)
    10 kΩ or more
    MRFG (A62-22) - MCS (A62-24)
    10 kΩ or more
    MRFG (A62-22) - MSNG (A62-35)
    10 kΩ or more
    MRFG (A62-22) - MSN (A62-23)
    10 kΩ or more
    MCSG (A62-34) - MRFG (A62-22)
    10 kΩ or more
    MCSG (A62-34) - MSNG (A62-35)
    10 kΩ or more
    MCSG (A62-34) - MCS (A62-24)
    10 kΩ or more
    MCS (A62-24) - MSNG (A62-35)
    10 kΩ or more
    MCS (A62-24) - MSN (A62-23)
    10 kΩ or more

    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 (Click here)