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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 60 (Hybrid Control System (AWD) - Circuit Tests (2 Of 2)) >> HYBRID CONTROL SYSTEM (for AWD) >> Generator Resolver Circuit [12/2019 - 11/2023] >> Procedure

Generator Resolver Circuit [12/2019 - 11/2023]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect the C61 inverter with converter assembly connector.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      C61-8 (GRF) - Body ground Ignition switch ON Below 1 V
      C61-9 (GRFG) - Body ground Ignition switch ON Below 1 V
      C61-10 (GSN) - Body ground Ignition switch ON Below 1 V
      C61-11 (GSNG) - Body ground Ignition switch ON Below 1 V
      C61-13 (GCS) - Body ground Ignition switch ON Below 1 V
      C61-12 (GCSG) - Body ground Ignition switch ON Below 1 V
      NOTE:

      Turning the ignition switch to ON with the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

      GTY908962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    6. Turn the ignition switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.
    8. Reconnect the C61 inverter with converter assembly connector.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  2

  2. CHECK GENERATOR RESOLVER 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect the C61 inverter with converter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      C61-8 (GRF) - C61-9 (GRFG) Ignition switch off 8.9 to 14.9 Ω
      C61-10 (GSN) - C61-11 (GSNG) Ignition switch off 16.2 to 28.2 Ω
      C61-13 (GCS) - C61-12 (GCSG) Ignition switch off 18.1 to 30.1 Ω

      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).)

      Standard Resistance (Check for Short)

      Tester Connection Condition Specified Condition
      C61-8 (GRF) or C61-9 (GRFG) - Body ground and other terminals Ignition switch off 1 MΩ or higher
      C61-10 (GSN) or C61-11 (GSNG) - Body ground and other terminals Ignition switch off 1 MΩ or higher
      C61-13 (GCS) or C61-12 (GCSG) - Body ground and other terminals Ignition switch off 1 MΩ or higher
      C61-7 (DRN3) - Body ground Ignition switch off 1 MΩ or higher
      GTY1002220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Reconnect the C61 inverter with converter assembly connector.

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    GENERATOR RESOLVER CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC) 

    Result: 

    NG 

    See step  3

  3. CHECK CONNECTOR CONNECTION CONDITION (RESOLVER CONNECTOR) 
    1. Check the connection condition of the resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [12/2019 - ]

      OK

      - The connector is connected securely.

      - The terminals are not deformed and are connected securely.

      - No water or foreign matter in the connector.

      GTY904686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    Result: 

    B 

    CONNECT SECURELY 

    Result: 

    C 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    A 

    See step  4

  4. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER) 
    1. Disconnect the C63 resolver connector.
      GTY904686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      C63-1 (GRF) - C63-8 (GRFG) Ignition switch off 8.8 to 14.8 Ω
      C63-12 (GSN) - C63-2 (GSNG) Ignition switch off 16.1 to 28.1 Ω
      C63-7 (GCS) - C63-11 (GCSG) Ignition switch off 18.0 to 30.0 Ω

      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).)

      GTY939168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Generator resolver (Hybrid Vehicle Transaxle Assembly))

      Standard Resistance (Check for Short)

      Tester Connection Condition Specified Condition
      C63-1 (GRF) - Body ground and other terminals (except C63-8 (GRFG)) Ignition switch off 1 MΩ or higher
      C63-8 (GRFG) - Body ground and other terminals (except C63-1 (GRF)) Ignition switch off 1 MΩ or higher
      C63-12 (GSN) - Body ground and other terminals (except C63-2 (GSNG)) Ignition switch off 1 MΩ or higher
      C63-2 (GSNG) - Body ground and other terminals (except C63-12 (GSN)) Ignition switch off 1 MΩ or higher
      C63-7 (GCS) - Body ground and other terminals (except C63-11 (GCSG)) Ignition switch off 1 MΩ or higher
      C63-11 (GCSG) - Body ground and other terminals (except C63-7 (GCS)) Ignition switch off 1 MΩ or higher
    3. Reconnect the C63 resolver connector.

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    NG 

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022] , or refer to REMOVAL [10/2022 - 11/2023]

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