Part 1

L110 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A7A-322: Generator Inverter Performance
P0A7A-322 - Generator Inverter Performance

DESCRIPTION

For a description of the inverter, P0A78.

If the generator inverter circuit is opened or shorted, or if the circuit overheats, the information is transmitted from the inverter to the GFIV terminal of the MG ECU via the generator inverter fail signal line.

MONITOR DESCRIPTION

If the generator inverter overheats, it transmits an inverter fail signal to the MG ECU. Upon receiving this signal, the hybrid vehicle control ECU will illuminate the MIL and set a DTC.

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

INSPECTION PROCEDURE

CAUTION:
- 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.
- 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.
- After inspection, be sure to replace the inverter with converter assembly.
PROCEDURE

1. CHECK DTC OUTPUT (HV)

(a) Connect the Techstream to the DLC3.

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

(c) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

(d) Check if DTCs are output.

Result:

HINT
DTC P0A7A-322 may be set due to a malfunction which also causes DTCs in the table above to be set. First troubleshoot the output DTCs in the table above. After troubleshooting all output DTCs, be sure to replace the inverter with converter assembly.

YES -- GO TO DTC CHART
NO -- Continue to next step.

2. CHECK AMOUNT OF GASOLINE

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

(b) Check the amount of fuel by referring to the fuel gauge in the meter.

OK:

Proper amount of fuel is in the tank.

NG -- REFUEL VEHICLE
OK -- Continue to next step.

3. CHECK ENGINE START

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

(b) Check if the engine starts.

HINT
Depressing the accelerator pedal with the shift lever in the P position will cause the engine start.

OK:

The engine starts.

OK -- CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
NG -- Continue to next step.

4. INSPECT CRANKSHAFT PULLEY REVOLUTION (P POSITION)

(a) Turn the power switch off, move the shift lever to the P position, and lift up the vehicle.

(b) Turn the crank pulley using hand tools to check if the crankshaft pulley can rotate.

CAUTION:
Do not turn the power switch on (READY) while performing this inspection. Be sure to turn the power switch off before performing this inspection, to prevent the engine from starting.

OK:

The crankshaft pulley rotates.

OK -- CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)
NG -- Continue to next step.

5. INSPECT CRANKSHAFT PULLEY REVOLUTION (N POSITION)

(a) Lower the vehicle.

(b) Turn the power switch off, move the shift lever to the N position, and lift up the vehicle.

(c) Turn the crank pulley using hand tools to check if the crankshaft pulley can rotate.

CAUTION:
Do not turn the power switch on (READY) while performing this inspection. Be sure to turn the power switch off before performing this inspection, to prevent the engine from starting.

OK:

The crankshaft pulley rotates.

OK -- REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

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

(a) 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 -- Continue to next step.

7. CHECK QUANTITY OF HV COOLANT

(a) Lower the vehicle.

(b) Check for coolant leaks.

(c) Check that the water filler assembly contains coolant, and the coolant in the radiator reserve tank assembly is above the low level.

Result:

HINT
After repairing the coolant leaks and adding coolant, perform the "Activate the Water Pump" and "Control the Electric Cooling Fan" active tests and make sure that there are no malfunctions.

C -- CHECK FOR COOLANT LEAKS AND ADD COOLANT

B -- ADD COOLANT
A -- Continue to next step.

8. CHECK COOLANT HOSE

(a) Check if the hoses of the cooling system are kinked or clogged.

NG -- CORRECT THE PROBLEM
OK -- Continue to next step.

9. PERFORM ACTIVE TEST USING TECHSTREAM (WATER PUMP)

(a) Connect the Techstream to the DLC3.

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

(c) Select the following menu items: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

(d) Perform the "Activate the Water Pump" active test.

(e) During the "Activate the Water Pump" active test, open the inverter radiator cap and check that there are ripples in the coolant. Continue the active test for at least 1 minute.

Result:

There are ripples in the coolant in the water filler assembly for 1 minute.

NOTICE:
- Turning the power switch off or finishing the active test with the inverter radiator cap open will cause the coolant to overflow. Be sure to close the inverter radiator cap before turning the power switch off or finishing the active test.
- The water with motor pump assembly operates even with the power switch on (READY). However, the water with motor pump assembly will operate at low speed for 20 seconds after power switch is turned on (READY).
HINT
The water pump motor operates even in maintenance mode.

NG -- PERFORM ACTIVE TEST USING TECHSTREAM (WATER PUMP)
OK -- Continue to next step.

10. PERFORM ACTIVE TEST USING TECHSTREAM (COOLING FAN)

(a) Connect the Techstream to the DLC3.

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

(c) Select the following menu items: Powertrain / Engine and ECT / Active Test / Control the Electric Cooling Fan.

(d) Perform the "Control the Electric Cooling Fan" active test.

OK:

The cooling fan rotates.

NG -- CHECK CONNECTOR CONNECTION CONDITION (COOLING FAN ECU CONNECTOR)
OK -- Continue to next step.

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

CAUTION:
Be sure to wear insulated gloves.

(a) Turn the power switch off and remove the service plug grip L110 Hybrid Vehicle Control System.

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 connector A60 from the inverter with converter assembly.

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

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

Standard voltage:

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 -- Continue to next step.

12. CHECK GENERATOR RESOLVER

(a) Turn the power switch off.

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

Standard resistance (Check for open):

NG -- CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
OK -- Continue to next step.

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

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

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

Standard voltage:

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 -- Continue to next step.

14. CHECK MOTOR RESOLVER

(a) Turn the power switch off.

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

Standard resistance (Check for open):

NG -- CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
OK -- Continue to next step.

15. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

(b) Check for arc marks at the bolts for the generator cable.

(c) Check that the bolts for the generator cable are tightened to the specified torque, the generator cable terminals are connected securely, and there are no contact problems.

NOTICE:
Make sure that the tightening torque of the bolts is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

Result:

C -- REPLACE MALFUNCTIONING PARTS

B -- TIGHTEN TO SPECIFIED TORQUE
A -- Continue to next step.

16. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

(b) Check for arc marks at the bolts for the motor cable.

(c) Check that the bolts for the motor cable are tightened to the specified torque, the motor cable terminals are connected securely, and there are no contact problems.

NOTICE:
Make sure that the tightening torque of the bolts is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

Result:

C -- REPLACE MALFUNCTIONING PARTS

B -- TIGHTEN TO SPECIFIED TORQUE
A -- Continue to next step.

17. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1)

(a) Check that the service plug grip is not installed.

CAUTION:
Be sure to wear insulated gloves.

(b) Disconnect the generator cable and motor cable from the inverter with converter assembly Components.

(c) Using a milliohmmeter, measure the resistance according to the value(s) in the table below. (Check MG1 for an interphase short.)

HINT
If the MG1 temperature is high, the resistance varies greatly. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

Standard resistance:

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 (mOhms)
* Rt: Measured resistance (mOhms)
* T: Temperature when the resistance is measured (° C)
(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:

NG -- CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)
OK -- Continue to next step.

18. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG2)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

(b) Disconnect the generator cable and motor cable from the inverter with converter assembly Components.

(c) Using a milliohmmeter, measure the resistance according to the value(s) in the table below. (Check MG2 for an interphase short.)

HINT
If the MG2 temperature is high, the resistance varies greatly. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

Standard resistance:

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 (mOhms)
* Rt: Measured resistance (mOhms)
* T: Temperature when the resistance is measured (°C)
(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:

NG -- CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)
OK -- Continue to next step.

19. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

(a) Check the connection of the generator resolver connector.

Result:

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

NG -- CONNECT SECURELY
OK -- Continue to next step.

20. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

(a) Check the connection of the motor resolver connector.

Result:

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

NG -- CONNECT SECURELY

OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY