05–645

DIAGNOSTICS – HYBRID CONTROL SYSTEM 05JAW–01

DTC P0A7A/325 GENERATOR INVERTER PERFORMANCE

DTC P0A7A/517 GENERATOR INVERTER PERFORMANCE

DTC P0A7A/518 GENERATOR INVERTER PERFORMANCE

CIRCUIT DESCRIPTION
See the description of the inverter on page 05–562.
If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that in-
formation to the GFIV terminal of HV control ECU via the generator inverter fail signal line.
DTC No. INF Code DTC Detection Condition Trouble Area

Wire harness or connector

HV transaxle assembly
Generator inverter fail (GFIV) signal detection (over
P0A7A 325
Hybrid vehicle generator
current by inverter assembly malfunction)

HV control ECU

w/ converter inverter assembly

Wire harness or connector

HV transaxle assembly
Generator inverter fail (GFIV) signal detection (over
P0A7A 517
Hybrid vehicle generator
current by HV control ECU malfunction)

HV control ECU

w/ converter inverter assembly

Wire harness or connector

HV transaxle assembly
Generator inverter fail (GFIV) signal detection (over
P0A7A 518
Hybrid vehicle generator
current by HV transaxle assembly malfunction)

HV control ECU

w/ converter inverter assembly

MONITOR DESCRIPTION
If over–amperage flows through the generator inverter due to an internal short, the generator inverter trans-
mits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates
the MIL and sets a DTC.
MONITOR STRATEGY
Related DTCs P0A7A (INF 325/517/518): Generator inverter/GFIV detection over current
Required sensor/components Generator inverter
Frequency of operation Continuous
Duration TOYOTA’s intellectual property
MIL operation Immediately
Sequence of operation None

TYPICAL ENABLING CONDITIONS

The monitor will run whenever the following DTCs are not
TOYOTA’s intellectual property
present
No other condition –

TYPICAL MALFUNCTION THRESHOLDS

Generator inverter Over current (internal short)

COMPONENT OPERATING RANGE

Generator inverter DTC P0A7A (INF 325/517/518) is not detected

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DIAGNOSTICS – HYBRID CONTROL SYSTEM

WIRING DIAGRAM
Refer to DTC P0A78 (INF 279) on page 05–577.
INSPECTION PROCEDURE
CAUTION:

Before inspecting the high–voltage system, take safety precautions to prevent electrical
shocks, such as wearing insulated gloves and removing the service plug grip. After removing
the service plug grip, put it in your pocket to prevent other technicians from reconnecting it
while you are servicing the high–voltage system.

After disconnecting the service plug grip, wait at least for 5 minutes before touching any of the
high–voltage connectors or terminals.
HINT:
At least 5 minutes is required to discharge the high–voltage condenser inside the inverter.
1 READ OUTPUT DTC(HV ECU)

(a) Connect the hand–held tester to the DLC3.

(b) Turn the power switch ON (IG).
(c) Turn the hand–held tester ON.
(d) On the hand–held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / HV ECU /
DTC INFO / TROUBLE CODES.
(e) Read DTCs.
Result: DTCs listed in the table below are output
DTC No. Relevant Diagnosis
P0A1D Hybrid Powertrain Control Module
P0A2B, P0A2C or P0A2D Drive Motor ”A” Temperature Sensor Circuit System
P0A37, P0A38 or P0A39 Generator Temperature Sensor Circuit System
P0A3F, P0A40 or P0A41 Drive Motor ”A” Position Sensor Circuit System
P0A4B, P0A4C or P0A4D Generator Position Sensor Circuit System
P0A60 or P0A63 Drive Motor ”A” Current Sensor Circuit System
P0A72 or P0A75 Generator Current Sensor Circuit System
P0A78 Drive Motor ”A” Inverter Performance
P0A7A Generator Inverter Performance
P0A90 Drive Motor ”A” Performance
P0A92 Hybrid Generator Performance
P0A93 Inverter Cooling System Malfunction
P0A94 DC/DC Converter Malfunction
P0AA1, P0AA2, P0AA4 or P0AA5 System Main Relay Circuit System
P3000, P3004, P3009 or P3110 High Voltage System
P3211 Drive Motor ”A” Inverter Temperature Sensor Circuit System
P3221 Generator Inverter Temperature Sensor Circuit System
P3226 DC/DC Converter Temperature Sensor Circuit System

YES GO TO DTC CHART (See page 05–440). FIND A

PAGE NUMBER TO PROCEED TO ITS DIAG-
NOSTIC TROUBLESHOOTING FLOWCHART

NO

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DIAGNOSTICS – HYBRID CONTROL SYSTEM

2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU

CONNECTOR(LOOSENESS AND POOR CONTACT)

(a) Check the connection condition of all the connectors at

the HV control ECU.
OK: Connectors have been connected securely and
there is no poor connection.

HV Control ECU Connector A18294

NG CONNECT SECURELY

OK

3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR(LOOSENESS

AND POOR CONTACT)

CAUTION:
Wear insulated gloves before performing the following op-
eration.
(a) Turn the power switch OFF.
(b) Remove the service plug grip (see page 21–116).
NOTICE:
Turning the power switch ON (READY) with the service
plug grip removed could cause malfunction. Therefore,
never turn the power switch ON (READY) in this state.
(c) Remove the inverter cover (see page 21–23).
I10 (d) Check the connection condition of the I9 and I10 inverter
connectors.
OK: Connectors have been connected securely and
there is no poor connection.
I9

Inverter Connector

A92044
NG CONNECT SECURELY

OK

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DIAGNOSTICS – HYBRID CONTROL SYSTEM

4 CHECK HYBRID VEHICLE GENERATOR ASSY

CAUTION:
Wear insulated gloves before performing the following op-
eration.
(a) Check that the service plug grip and inverter cover have
been removed.
(b) Check if the three–phase alternating current cable instal-
lation bolts on the hybrid vehicle generator are tightened
to the specified torque.
Torque: 8.0 N⋅m (82 kgf⋅cm 71in.⋅lbf)
(c) Reinstall the inverter cover (see page 21–23).
(d) Reinstall the service plug grip (see page 21–116).

A90459
NG TIGHTEN THEM TO SPECIFIED TORQUE

OK

5 CONFIRM INFORMATION(EXCLUSIVE INFO 4)

(a) Connect the hand–held tester to the DLC3.

(b) Turn the power switch ON (IG).
HINT:
DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service
plug grip and inverter cover removed.
(c) Turn the hand–held tester ON.
(d) On the hand–held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / HV ECU /
DTC INFO / TROUBLE CODES.
(e) Select DTC P0A7A to display its freeze frame data.
(f) Select the item that has INF code 325, 517, or 518 from among INFORMATION 1 to 5, and press EN-
TER.
(g) Read EXCLUSIVE INFO 4.
Result:
Displayed in Exclusive Information 4 Proceed to
–127 to –120, –95 to –88, –63 to –56, –31 to –24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A
–119 to –112, –87 to –80, –55 to –48, –23 to –16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B
–111 to –104, –79 to –72, –47 to –40, –15 to –8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C
–103 to –96, –71 to –64, –39 to –32, –7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D

B REPLACE HYBRID VEHICLE CONTROL ECU

(See page 21–124)

C REPLACE W/CONVERTER INVERTER ASSY

(See page 21–23)

D REPLACE HYBRID VEHICLE TRANSAXLE

ASSY (See page 22–11)

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DIAGNOSTICS – HYBRID CONTROL SYSTEM

6 INSPECT HYBRID VEHICLE GENERATOR ASSY

CAUTION:
Wear insulated gloves before performing the following op-
eration.
(a) Turn the power switch OFF.
(b) Remove the service plug grip (see page 21–116).
NOTICE:
Turning the power switch ON (READY) with the service
plug grip removed could cause malfunction. Therefore,
never turn the power switch ON (READY) in this state.
(c) Remove the inverter cover (see page 21–23).
(d) Disconnect the three–phase alternating current cable for
Hybrid Vehicle Generator:
W the hybrid vehicle generator from the inverter.
V (e) Using a milliohm meter, measure the resistance between
I15 the three–phase alternating current cable terminals of the
U
hybrid vehicle generator.
NOTICE:
If the generator temperature is too high, the resistance va-
ries considerably, which hinders determining malfunction.
A92046 Therefore, measure the resistance at a minimum 8 hours
after the vehicle has been stopped.
Standard:
Tester Connection Specified Condition*
U (I15–1) – V (I15–2) Below 109 mΩ at 20C
V (I15–2) – W (I15–3) Below 109 mΩ at 20C
W (I15–3) – U (I15–1) Below 109 mΩ at 20C
*: Apply the formula given below to correct the resistance.
R20 = Rt
(1 + 0.00393 × (T – 20))
R20: Resistance converted to 20 C (mΩ)
Rt: Resistance between measured lines (mΩ)
T: Ambient air temperature during measurement (C)
(f) Calculate the difference between the maximum and mini-
mum resistance between terminals U – V, V – W, and W
– U.
Standard: Below 2 mΩ
(g) Using a megohmmeter, check the insulation resistance
between the three–phase alternating current cable termi-
nals of the hybrid vehicle generator and the body ground.
Standard:
Tester Connection Specified Condition
U (I15–1) – Body ground 10 MΩ or higher
V (I15–2) – Body ground 10 MΩ or higher
W (I15–3) – Body ground 10 MΩ or higher
(h) Reconnect the three–phase alternating current cable for
the hybrid vehicle generator.

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NG REPLACE HYBRID VEHICLE GENERATOR

ASSY

OK

7 PERFORM ACTIVE TEST BY HAND–HELD TESTER(INVERTER STOP)

CAUTION:
Wear insulated gloves before performing the following op-
eration.
(a) Check that the service plug grip and inverter cover have
been removed.
(b) Connect the hand–held tester to the DLC3.
(c) Turn the power switch ON (IG).
HINT:
DTCs for the interlock switch system are output when turning
the power switch ON (IG) with both service plug grip and invert-
er cover removed.
(d) Turn the hand–held tester ON.
(e) On the hand–held tester, enter the following menus:
DIAGNOSIS / ENHANCED OBD II / HV ECU / ACTIVE
TEST.
(f) Measure the voltage between the terminals of the inverter
I10 connector while effecting INVERTER STOP.
Standard:
I9 Tester Connection Specified Condition
GUU (I10–4) – GINV (I10–16) 12 to 16 V
GVU (I10–5) – GINV (I10–16) 12 to 16 V
Inverter Connector GWU (I10–6) – GINV (I10–16) 12 to 16 V
GUU GVU GWU (g) Turn the power switch OFF.
I10

GINV

Rear View A93730

NG Go to step 8

OK

REPLACE W/CONVERTER INVERTER ASSY (See page 21–23)

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DIAGNOSTICS – HYBRID CONTROL SYSTEM

8 PERFORM ACTIVE TEST BY HAND–HELD TESTER(INVERTER STOP)

CAUTION:
Wear insulated gloves before performing the following op-
eration.
(a) Check that the service plug grip and inverter cover have
been removed.
(b) Disconnect the I10 inverter connector.
I10 (c) Connect the hand–held tester to the DLC3.
(d) Turn the power switch ON (IG).
I9 HINT:
DTCs for the interlock switch system are output when turning
the power switch ON (IG) with both service plug grip and invert-
Inverter Connector er cover removed.
GUU GVU GWU (e) Turn the hand–held tester ON.
(f) On the hand–held tester, enter the following menus:
I10
DIAGNOSIS / ENHANCED OBD II / HV ECU / ACTIVE
TEST.
GINV (g) Measure the voltage between the terminals of the inverter
connector while effecting INVERTER STOP.
Rear View A93731 Standard:
Tester Connection Specified Condition
GUU (I10–4) – GINV (I10–16) 14 to 16 V
GVU (I10–5) – GINV (I10–16) 14 to 16 V
GWU (I10–6) – GINV (I10–16) 14 to 16 V

(h) Turn the power switch OFF.

(i) Reconnect the inverter connector.
(j) Reinstall the inverter cover (see page 21–23).
(k) Reinstall the service plug grip (see page 21–116).
NG REPLACE W/CONVERTER INVERTER ASSY
(See page 21–23)

OK

REPLACE HYBRID VEHICLE CONTROL ECU (See page 21–124)

2004 Prius – Preliminary Release (RM1075U)

Author: Date: 815