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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) >> Rear Motor High-voltage Circuit [12/2019 - 11/2023] >> Procedure

Rear Motor High-voltage Circuit [12/2019 - 11/2023]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. CHECK INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER WIRE (REAR TRACTION MOTOR CABLE) CONNECTION CONDITION) 
    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. Check that the bolts for the HV floor under wire (rear traction motor cable) are tightened to the specified torque, the HV floor under wire (rear traction motor cable) is connected securely, and there are no contact problems.

      Specified Condition

      T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

      GTY893367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the HV floor under wire (rear traction motor cable) from the inverter with converter assembly.
    4. Check for arc marks at the terminals for the HV floor under wire (rear traction motor cable).

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    5. Reconnect the HV floor under wire (rear traction motor cable).

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  2

  2. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (REAR MOTOR (MGR)) 
    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 HV floor under wire (rear traction motor cable) from the inverter with converter assembly.
      GTY893367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.
      GTY855398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a HV Floor Under Wire (Rear Traction Motor Cable)
      (Inverter with Converter Assembly Side)

      HINT: 

      If the rear motor (MGR) temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

      Standard Resistance

      Tester Connection Condition Specified Condition
      k4-1 (R-V) - k4-2 (R-U) Ignition switch off 101.1 to 111.5 mΩ
      k4-2 (R-U) - k4-3 (R-W) Ignition switch off 101.3 to 111.7 mΩ
      k4-3 (R-W) - k4-1 (R-V) Ignition switch off 101.6 to 112.0 mΩ

      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).)

    4. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      NOTE:

      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

      Tester Connection Condition Specified Condition
      k4-1 (R-V) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      k4-2 (R-U) - Body ground and shield ground Ignition switch off 100 MΩ or higher
      k4-3 (R-W) - Body ground and shield ground Ignition switch off 100 MΩ or higher
    5. Reconnect the HV floor under wire (rear traction motor cable).

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    REAR MOTOR HIGH-VOLTAGE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC) 

    Result: 

    NG 

    See step  3

  3. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (HV FLOOR UNDER WIRE (REAR TRACTION MOTOR CABLE) CONNECTION CONDITION) 
    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. Check that the bolts for the HV floor under wire (rear traction motor cable) are tightened to the specified torque, the HV floor under wire (rear traction motor cable) is connected securely, and there are no contact problems.
      GTY899195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified Condition

      T=8.0 N*m (82 kgf*cm, 71 in.*lbf)

    3. Disconnect the HV floor under wire (rear traction motor cable) from the rear traction motor with transaxle assembly.
    4. Check for arc marks at the terminals for the HV floor under wire (rear traction motor cable).

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    5. Reconnect the HV floor under wire (rear traction motor cable).

    Result: 

    B 

    REPLACE MALFUNCTIONING PARTS 

    Result: 

    C 

    CONNECT SECURELY 

    Result: 

    A 

    See step  4

  4. CHECK FLOOR UNDER WIRE (REAR TRACTION MOTOR CABLE) 
    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 HV floor under wire (rear traction motor cable) from the inverter with converter assembly.
      GTY893367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the HV floor under wire (rear traction motor cable) from the rear traction motor with transaxle assembly.
      GTY899195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      NOTE:

      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.

      GTY880110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a HV Floor Under Wire (Rear Traction Motor Cable)
      (Inverter with Converter Assembly Side)
      *b HV Floor Under Wire (Rear Traction Motor Cable)
      (Rear Traction Motor with Transaxle Assembly Side)

      Standard Resistance

      Tester Connection Condition Specified Condition
      k4-3 (R-W) or kx1-1 (W) - Shield ground Ignition switch off 100 MΩ or higher
      k4-1 (R-V) or kx1-3 (V) - Shield ground Ignition switch off 100 MΩ or higher
      k4-2 (R-U) or kx1-2 (U) - Shield ground Ignition switch off 100 MΩ or higher
      NOTE:

      Wrap the terminals of the motor cable with insulating tape to prevent them from coming into contact with body ground.

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      k4-3 (R-W) - kx1-1 (W) Ignition switch off Below 1 Ω
      k4-1 (R-V) - kx1-3 (V) Ignition switch off Below 1 Ω
      k4-2 (R-U) - kx1-2 (U) Ignition switch off Below 1 Ω
      k4-3 (R-W) - kx1-2 (U) Ignition switch off 100 MΩ or higher
      k4-1 (R-V) - kx1-1 (W) Ignition switch off 100 MΩ or higher
      k4-2 (R-U) - kx1-3 (V) Ignition switch off 100 MΩ or higher
    6. Reconnect the HV floor under wire (rear traction motor cable) to the rear traction motor with transaxle assembly.
    7. Reconnect the HV floor under wire (rear traction motor cable) to the inverter with converter assembly.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE FLOOR UNDER WIRE 

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

    Result: 

    OK 

    See step  5

  5. CHECK REAR TRACTION MOTOR CABLE 
    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. Remove the rear traction motor cable from the rear traction motor with transaxle assembly.

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

    3. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.
      NOTE:

      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

      Tester Connection Condition Specified Condition
      R-W - Shield ground Ignition switch off 100 MΩ or higher
      R-V - Shield ground Ignition switch off 100 MΩ or higher
      R-U - Shield ground Ignition switch off 100 MΩ or higher
      GTY1104008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shield Ground
      *a Rear Traction Motor Cable
    4. Install the rear traction motor cable.

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY 

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

    Result: 

    NG 

    REPLACE REAR TRACTION MOTOR CABLE 

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

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