Hybrid Vehicle Control System

HYBRID CONTROL SYSTEM
ON-VEHICLE INSPECTION
1. INSPECT INVERTER

NOTICE: Wear insulating gloves.

HINT: Check DTCs before performing the inspections of the converter and inverter, and perform the appropriate troubleshooting.

a. Turn the power switch OFF.
b. Remove the service plug grip.
c. Remove the inverter cover.





d. Disconnect the connectors A and B shown in the illustration.
e. Turn the power switch ON (IG).
If turning the power switch ON (IG) with the service plug grip removed, the DTC of the inter lock switch system will be output.
f. Using a voltmeter, measure the voltage. Also, using an ohmmeter, measure the resistance.





NOTICE: The inspection should be performed on the wire harness side, not on the terminal side.





Standard





If the standards are not met, replace the w/ inverter converter assembly.








2. INSPECT CONVERTER

NOTICE: Wear insulating gloves.

HINT: If the HV system warning, master warning lamp and charge warning come on at the same time, check the DTCs and perform the appropriate troubleshooting.





a. Check the operation.
1. Using a voltmeter, measure the voltage of the auxiliary battery terminal when the "READY" lamp is OFF and ON.





Standard

HINT: When the "READY" lamp is ON, the converter outputs the voltage. When it is OFF, the auxiliary battery outputs the voltage.





b. Inspect the output current.
1. Disconnect the MG1 and MG2 power cables from the inverter.
2. Install a voltmeter and the AC/DC 400 A probe to the locations shown in the illustration.
3. Connect the MG1 and MG2 power cables to the inverter.
4. With the "READY" lamp ON, operate the 12 V electrical devices one by one, then measure the output current.
Standard: Approximately 80 A or less

HINT: If the output current is 0 A or greater than 80 A, check the inputs output signal.

c. Check the input/output signal.





1. Disconnect the connectors shown in the illustration.
2. Using a voltmeter, measure the voltage between the body ground and the terminal of the vehicle side wire harness connector.
Standard: Equal to the auxiliary battery terminal voltage





3. Disconnect the connectors shown in the illustration.





4. Turn the power switch ON (IG). Using a voltmeter and ohmmeter, measure the voltage and resistance between the connector terminals on the vehicle harness side.





Standard

If the standards are not met, replace the with inverter converter assembly.











3. INSPECT SPEED SENSOR (REVOLVER)
a. Using an ohmmeter, measure the resistance between the terminals.





Standard

If the standards are not met, replace the hybrid vehicle transaxle assembly.











4. INSPECT TEMPERATURE SENSOR
a. Using an ohmmeter, measure the resistance between the terminals.





Standard

HINT: The standard varies according to the sensor temperature.

If the standards are not met, replace the hybrid vehicle transaxle assembly.
5. INSPECT ACCELERATOR POSITION

NOTICE:
^ Do not remove the accelerator position sensor from the accelerator pedal.
^ Perform the inspection on the hybrid vehicle control ECU side of the connector.

a. Turn the power switch ON (IG).





b. Using a voltmeter, measure the voltage between the terminals.





Standard

If the standards are not met, replace the accelerator pedal rod assembly.

INSPECTION
1. INSPECT INTEGRATION RELAY (IGCT RELAY)
a. Check the HEV fuse.
1. Remove the 20 A fuse. Using an ohmmeter, measure the resistance between the terminals.
Standard: Below 1 ohms





If the standard is not met, replace the fuse.
b. Check the IGCT relay.
1. Using an ohmmeter, measure the resistance between the terminals.





Standard

If the standards are not met, replace the integration relay.
2. Using an ohmmeter, measure the resistance between the terminals when battery voltage is applied to terminals 7J-2 and 7J-3.





Standard

If the standards are not met, replace the integration relay.





2. INSPECT WATER W/MOTOR & BRACKET PUMP ASSY
a. Check the operation.
1. Connect the battery positive terminal to terminal 1 and the battery negative terminal to terminal 2, then check that the pump motor operates properly.

NOTICE:
^ Do not connect the positive and negative poles of the battery to the wrong terminals.
^ Complete the check within 10 seconds of connection.

If it does not operate properly, replace the water pump with motor and bracket.