di838-03 dtc p3125 converter & inverter assembly...

A14140

C4Converter

Hybrid Vehicle Control ECU

NODD4

L - ONODD

4

H12

-DIAGNOSTICS HYBRID VEHICLE CONTROL SYSTEMDI-271

431Author: Date:

2002 PRIUS (RM883U)

DTC P3125 Converter & Inverter Assembly Malfunction

CIRCUIT DESCRIPTIONIf driving the vehicle with the DCDC converter malfunctioning, the voltage of the auxiliary battery will drop,which will make it impossible to keep driving the vehicle. Therefore, HV ECU checks the operation of theDCDC converter and gives warning to the driver if malfunction is detected.HINT: When using an OBD scan tool other than TOYOTA hand-held tester, check all the steps. When using TOYOTA hand-held tester, confirm the information code and check it.

DTC P3125 - Information code 263, 264, 265

INF. Code. Detecting Condition Trouble Area

263 +B short in DCDC converter NODD wiring

264 DCDC converter malfunctionConverter & inverter assembly

Wire harness265 Open or GND short in DCDC converter NODD wiring

Wire harness

WIRING DIAGRAM

DI838-03

DI-272-DIAGNOSTICS HYBRID VEHICLE CONTROL SYSTEM

432Author: Date:

2002 PRIUS (RM883U)

INSPECTION PROCEDURE

1 Check for open, short and +B short in wire harness between HV ECU NODD ter-minal and converter & inverter NODD terminal (See page IN-41 ).

HINT:The converter has +B short if the battery voltage is always applied to the HV ECU NODD terminal with theignition ON.

NG Repair or replace wire harness.

OK

Replace converter & inverter assembly.

A14121

InverterHybrid Vehicle Control ECU

VBY

5

I10

6

I9M-GINVB

20

H11

26

H11

VB

MIVG


433Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the inverter voltage and detects malfunction.DTC P3125 - Information code 266, 267, 268, 269, 270


266 Open or GND short in inverter voltage signal circuit

267 +B short in inverter voltage signal circuit

268 Inverter voltage signal is inconsistent with battery voltageConverter & inverter assembly

269 Inverter voltage sensor malfunctionConverter & inverter assembly

Wire harness

270

Abnormality of line connection of inverter voltage signal

circuit (when there is a history that the state of malfunction

continued during inverter fail safe mode)

Wire harness

WIRING DIAGRAM


434Author: Date:

2002 PRIUS (RM883U)


1 Check for open, short and +B short in wire harness between HV ECU VB andMIVG terminals and converter & inverter assembly VB and M-GINV terminal (Seepage IN-41 ).

HINT:Confirm that there is no open circuit in the wire harness. If the voltage between the HV ECU VB or MIVGterminal and body ground is always more than 5V with the ignition ON, the inverter voltage signal circuit has+B short.


OK

2 Is there DTC P3100 being output?

YES Check applicable DTC.

NO


A14124


G3

I9

1

I9M-VUW

6

H11

5

H11

MWU

MVU

MUU

4

H11R

I9

2

M-UU

M-WU


435Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU detects faulty line connection inside the inverter.DTC P3125 - Information code 272


272

Abnormality of line connection of motor PWM (when there

is a history that the state of malfunction continued during

inverter fail safe mode)

Wire harness

Converter & inverter assembly

WIRING DIAGRAM


436Author: Date:

2002 PRIUS (RM883U)


1 Check open and short in wire harness between HV ECU terminals (MUU, MVU,MWU) and inverter terminals.


OK



NO


A14120


M-SDOWNY

4

I9

13

MSDNH11


437Author: Date:

2002 PRIUS (RM883U)



273 Motor inverter malfunctionConverter & inverter assembly

Wire harness

WIRING DIAGRAM


1 Check for open and short in wire harness between HV ECU MSDN terminal andconverter & inverter M-SDOWN terminal.


OK


A14121

Inverter Hybrid Vehicle Control ECU

M-SINVG

7

I10

6

I9M-GINVB

21MSIV

MIVG

26

H11

H11


438Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the inverter temperature and controls the load limitation in order to prevent the inverterfrom overheating. Also, it detects the abnormality of the line connection of the inverter temperature sensorand the malfunction of the sensor itself.DTC P3125 - Information code 274, 275, 276, 277


274 Open or +B short in motor inverter temperature sensor

275 GND short in motor inverter temperature sensorConverter & inverter assembly

276 Motor inverter temperature sensor malfunction


Wire harness

277 Motor inverter temperature sensor performance problem

WIRING DIAGRAM


439Author: Date:

2002 PRIUS (RM883U)


1 Check for open, short and +B short in wire harness between HV ECU MIT andMIVG terminals and converter & inverter M-INVT, M-GINV terminals (See pageIN-41 ).

HINT:Confirm that there is no open circuit in the wire harness. If the voltage between the HV ECU MIT or MIVGterminal and body ground is always more than 5V with the ignition ON, the motor inverter temperature sensorcircuit has +B short.


OK

Check for open in motor inverter temperature sensor and then replace converter & inverter as-sembly. Check motor inverter temperature sensor (See page HV-14 ).

A14121


M-SINVG

7

I10

6

I9M-GINVB

21MSIV

MIVG

26

H11

H11


440Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the line connection of the motor inverter stop signal circuit and enters the fail safe mode(limited output driving) if malfunction is detected.DTC P3125 - Information code 278, 280


278 +B short in motor inverter stop signal circuitConverter & inverter assembly

280 Open or GND short in motor inverter stop signal circuit


Wire harness

WIRING DIAGRAM


1 Check for open, short and +B short in wire harness between HV ECU MSIV andMIVG terminals and converter & inverter assembly M-SINV and M-GIVN termi-nals (See page IN-41 ).

HINT:The motor inverter stop signal circuit has +B short if the voltage between the HV ECU MSIV or MIGV terminaland body ground is always more than 13 V with the ignition ON (”READY” light OFF).


OK



441Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONDTC P3125 - Information code 279, 281, 282


279 Over voltage of inverter

281 Voltage drop of inverter power source Converter & inverter assembly

282 Inverter circuit broken


INSPECTION PROCEDUREIf the information code 279 or 281 is output, check if other DTC or information codes are recorded. If theyare recorded, check and repair those codes first.If the information code 279 or 281 alone is recorded, replace the converter & inverter assembly.If the information code 282 is output, replace the converter & inverter assembly.

A14121


M-GINVB

6

I9

8

I10M-FINVB

26

MFIV14

H11

H11

MIVG


442Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the line connection of the motor inverter fail signal circuit and detects malfunction.DTC P3125 - Information code 283, 285


283 +B short in motor inverter fail signal circuitConverter & inverter assembly

285 Open or GND short in motor inverter fail signal circuit


Wire harness

WIRING DIAGRAM


1 Check for open, short and +B short in wire harness between HV ECU MFIV andMIVG terminals and converter & inverter assembly M-FINV and M-GINV termi-nals (See page IN-41 ).

HINT:The motor inverter fail signal circuit has +B short if the voltage between the HV ECU MIVG or MFIV terminaland body ground is always more than 13 V with the ignition ON (”READY” light OFF).


OK



443Author: Date:

2002 PRIUS (RM883U)



284 Inverter overheating

286 Inverter circuit broken Converter & inverter assembly

287 Inverter internal short


INSPECTION PROCEDUREIf the information code 284 or 287 is output, check if other DTC or information codes are recorded. If theyare recorded, check and repair those codes first.If the information code 284 or 287 alone is recorded, replace the converter & inverter assembly.If the information code 286 is output, replace the converter & inverter assembly.

A14123


M-GINVB

2

I10M-IW AR

B

W

G4

I10

3

I10

1

I10

6I9

M-IWB

M-IVB

M-IV A

MIVG

MIWA

MIWB

MIVB

MIVA

26

16

7

17

25

H11

H11

H11

H11

H11


444Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU detects the malfunction of the motor inverter current sensor. It detects the malfunction of thesensor system, not of the high voltage system.DTC P3125 - Information code 288, 289, 290, 292, 294, 296, 297, 298, 300, 302,


289 Open in motor inverter current sensor (V phase sub sensor)

292Open in motor inverter current sensor (V phase main sen-

sor)

297Open in motor inverter current sensor (W phase sub sen-

sor)

300Open in motor inverter current sensor (W phase main sen-

sor)

288Motor inverter current sensor malfunction (V phase sub

sensor)C t & i t bl

290Motor inverter current sensor malfunction (V phase main

sensor)


Wire harness

294Motor inverter current sensor V phase performance prob-

lem

296Motor inverter current sensor malfunction (W phase sub

sensor)

298Motor inverter current sensor malfunction (W phase main

sensor)

302Motor inverter current sensor W phase performance prob-

lem

WIRING DIAGRAM


445Author: Date:

2002 PRIUS (RM883U)


1 Check continuity of wire harness between HV ECU and converter & inverter as-sembly (See page IN-41 ).

OK:Continuity: Less then 1 Ω

HV ECU Terminals Inverter Terminals

MIVA M-IVA

MIVB M-IVB

MIWA M-IWA

MIWB M-IWB

MIVG M-GINV


OK


A14123


M-GINVB

2

I10M-IW AR

B

W

G4

I10

3

I10

1

I10

6I9

M-IWB

M-IVB

M-IV A

MIVG

MIWA

MIWB

MIVB

MIVA

26

16

7

17

25

H11

H11

H11

H11

H11


446Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU detects the malfunction of the motor inverter current sensor. It detects the malfunction of thesensor system, not of the high voltage system.DTC P3125 - Information code 291, 293, 295, 299, 301, 303


291

293

295 When there is a history that the state of malfunction contin- Converter & inverter assembly

299

When there is a history that the state of malfunction contin

ued during inverter fail safe mode.


Wire harness

301

g

303

WIRING DIAGRAM


447Author: Date:

2002 PRIUS (RM883U)





MIVA M-IVA

MIVB M-IVB

MIWA M-IWA

MIWB M-IWB

MIVG M-GINV


OK



NO



448Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU detects the malfunction of the motor inverter current sensor. It detects the malfunction of thesensor system, not of the high voltage system.DTC P3125 - Information code 306, 307


306 Failure in monitoring motor torque performanceC t & i t bl

307 Abnormal current value of motorConverter & inverter assembly

INSPECTION PROCEDUREIf the information code 306 or 307 is output, check if other DTC or information codes are recorded. If theyare recorded, check and repair those codes first.If the information code 306 or 307 alone is recorded, replace the converter & inverter assembly.

CIRCUIT DESCRIPTIONIf the HV ECU detects the collision signal from the airbag or inverter, the HV ECU recognizes it as the destruc-tion of the vehicle and then shuts down the high voltage system to ensure safety.DTC P3125 - Information code 308


308 Input of collision signal from airbag or inverter -

HINT:When the vehicle collision occurs and the airbag is deployed, this information code will be recorded and thehigh voltage system will be shut down.

A14120


M-SDOWNY

4

I9

13

MSDNH11


449Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the line connection of the motor gate shutdown signal circuit and detects malfunction.DTC P3125 - Information code 304, 305


304 +B short in motor gate shutdown signal circuitConverter & inverter assembly

305 Open or GND short in motor gate shutdown signal circuit


Wire harness

WIRING DIAGRAM


450Author: Date:

2002 PRIUS (RM883U)


1 Check for open, short and +B short in wire harness between HV ECU MSDN ter-minal and converter & inverter assembly M-SDOWN terminals (See page IN-41 ).

HINT:Confirm that there is no open circuit in the wire harness. The motor gate shutdown signal circuit has +B shortif the battery voltage is always applied to the HV ECU MSDN terminal with the ignition ON.


OK


A14124


G3

I11

2

I11G-UUR

3

H11

1

H11

GWU

GUU

GVU

2

H11W

I11

1

G-VU

G-WU


451Author: Date:

2002 PRIUS (RM883U)



309Open or short in generator inverter switching wiring (GUU,

GVU, GWU)

Wire harness


WIRING DIAGRAM


452Author: Date:

2002 PRIUS (RM883U)


1 Check for open and short in wire harness between HV ECU terminals (GUU, GVU,GWU) and inverter terminals.


OK



NO


A14120


G-SDOWNY

4

I11

12

GSDNH11


453Author: Date:

2002 PRIUS (RM883U)



311 Generator inverter malfunctionConverter & inverter assembly

Wire harness

WIRING DIAGRAM


1 Check for open and short in wire harness between HV ECU GSDN terminal andconverter & inverter S-DOWN terminal.


OK


A14121


G-INVTL

5I11

6

I11G-GINVB

23GIT

GIVG

27

H11

H11


454Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the generator temperature and controls the load limitation in order to prevent the gener-ator from overheating. Also, it detects the abnormality of the line connection of the generator temperaturesensor and the malfunction of the sensor itself.DTC P3125 - Information code 312, 313, 314, 315


312 Open or +B short in generator inverter temperature sensor

313 GND short in generator inverter temperature sensorC t & i t bl

314 Generator inverter temperature sensor malfunctionConverter & inverter assembly

Wire harness

315Generator inverter temperature sensor performance prob-

lem

Wire harness

WIRING DIAGRAM


455Author: Date:

2002 PRIUS (RM883U)


1 Check for open, short and +B short in wire harness between HV ECU GIT andGIVG terminals and converter & inverter G-GINV or G-GINV terminals (See pageIN-41 ).

HINT:Confirm that there is no open circuit in the wire harness. The generator inverter temperature sensor circuithas +B short if the voltage between the HV ECU GIT or GIVG terminal and body ground is always more than5V with the ignition ON.


OK

Check for open in generator inverter temperature sensor and then replace converter & inverterassembly. Check generator inverter temperature sensor (See page HV-14 ).

A14121


G-GINVB

6

I11

7

I12G-SINVG

27GIVG

GSIV

15

H11

H11


456Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the line connection of the generator inverter stop signal circuit and enters the fail safemode (limited driving) if malfunction is detected.DTC P3125 - Information code 316, 318


316 +B short in generator inverter stop signal circuitConverter & inverter assembly

318 Open or GND short in generator inverter stop signal circuit


Wire harness

WIRING DIAGRAM


457Author: Date:

2002 PRIUS (RM883U)


1 Check for open, short and +B short in wire harness between HV ECU GSIV andGIVG terminals and converter & inverter assembly G-SINV and G-GINV termi-nals (See page IN-41 ).

HINT:The generator inverter stop signal circuit has +B short if the voltage between the HV ECU GSIV or GIVGterminal and body ground is always more than 13 V with the ignition ON (”READY” light OFF).


OK




317 Over voltage of inverter

319 Voltage drop of inverter power source Converter & inverter assembly

320 Inverter circuit broken


INSPECTION PROCEDUREIf the information code 317 or 319 is output, check if other information codes are recorded. If they are re-corded, check and repair those codes first.If the information code 317 or 319 alone is recorded, replace the converter & inverter assembly.If the information code 320 is output, replace the converter & inverter assembly.

A14121


G-GINVB

6I11

8

I12G-FINVB

27GIVG

GFIV

24

H11

H11


458Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the line connection of the generator inverter fail signal circuit and detects malfunction.DTC P3125 - Information code 321, 323


321 +B short in generator inverter fail signal circuitConverter & inverter assembly

323 Open or GND short in generator inverter fail signal circuit


Wire harness

WIRING DIAGRAM


459Author: Date:

2002 PRIUS (RM883U)


1 Check for open, short and +B short in wire harness between HV ECU GFIV andGIVG terminals and converter & inverter assembly G-FINV and G-GINV terminals(See page IN-41 ).

HINT:The generator inverter fail signal circuit has +B short if the voltage between the HV ECU GFIV or GIVG termi-nal and body ground is always more than 13 V with the ignition ON (”READY” light OFF).


OK




322 Inverter overheating

324 Inverter circuit broken Converter & inverter assembly

325 Inverter internal short


INSPECTION PROCEDUREIf the information code 322 or 325 is output, check if other information codes are recorded. If they are re-corded, check and repair those codes first.If the information code 322 or 325 alone is recorded, replace the converter & inverter assembly.If the information code 324 is output, replace the converter & inverter assembly.

A14123


G-IV AB

5I11G-INVT

L

W

G

R2I12

4I12

3I12

1I12

G-IW A

G-IWB

G-IVB

GIVA

GIT

GIWA

GIWB

GIVB

19

8

18

28

23H11

H11

H11

H11

H11


460Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU detects the malfunction of the generator inverter current sensor. It detects the malfunction ofthe sensor system, not of the high voltage system.DTC P3125 - Information code 326, 327, 328, 330, 332, 334, 335, 336, 338, 340


327Open in generator inverter current sensor (V phase sub

sensor)

330Open in generator inverter current sensor (V phase main

sensor)

335Open in generator inverter current sensor (W phase sub

sensor)

338Open in generator inverter current sensor (W phase main

sensor)

326Generator inverter current sensor malfunction (V phase sub

sensor)Converter & inverter assembly

328Generator inverter current sensor malfunction (V phase

main sensor)


Wire harness

332Generator inverter current sensor V phase performance

problem

334Generator inverter current sensor malfunction (W phase

sub sensor)

336Generator inverter current sensor malfunction (W phase

main sensor)

340Generator inverter current sensor W phase performance

problem

WIRING DIAGRAM


461Author: Date:

2002 PRIUS (RM883U)





GIVA G-IVA

GIVB G-IVB

GIWA G-IW A

GIWB G-IWB

GIVG G-GINV


OK


A14123


G-IV AB

5I11G-INVT

L

W

G

R2I12

4I12

3I12

1I12

G-IW A

G-IWB

G-IVB

GIVA

GIT

GIWA

GIWB

GIVB

19

8

18

28

23H11

H11

H11

H11

H11


462Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU detects the malfunction of the generator inverter current sensor. It detects the malfunction ofthe sensor system, not of the high voltage system.DTC P3125 - Information code 329, 331, 333, 337, 339, 341


329

331

333 When there is a history that the state of malfunction contin- Converter & inverter assembly

337

When there is a history that the state of malfunction contin

ued during inverter fail safe mode


Wire harness

339

g

341

WIRING DIAGRAM


463Author: Date:

2002 PRIUS (RM883U)





GIVA G-IVA

GIVB G-IVB

GIWA G-IW A

GIWB G-IWB

GIVG G-GINV


OK



NO



464Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU detects the malfunction of the generator inverter current sensor. It detects the malfunction ofthe sensor system, not of the high voltage system.DTC P3125 - Information code 344, 345


344 Failure in monitoring generator torque performanceC t & i t bl

345 Abnormal current value of generatorConverter & inverter assembly

INSPECTION PROCEDUREIf the information code 344 or 345 is output, check if other DTC or information codes are recorded. If theyare recorded, check and repair those codes first.If the information code 344 or 345 alone is recorded, replace the converter & inverter assembly.

A14120


G-SDOWNY

4I11

12

GSDNH11


465Author: Date:

2002 PRIUS (RM883U)

CIRCUIT DESCRIPTIONThe HV ECU checks the line connection of the generator gate shutdown signal circuit and detects malfunc-tion.DTC P3125 - Information code 342, 343


342 +B short in generator gate shutdown signal circuitC t & i t bl

343Open or GND short in generator gate shutdown signal cir-

cuit


Wire harness

WIRING DIAGRAM


466Author: Date:

2002 PRIUS (RM883U)


1 Check for open, short and +B short in wire harness between HV ECU GSDN ter-minal and converter & inverter assembly G-SDOWN terminals (See page IN-41 ).

HINT:Confirm that there is no open circuit in the wire harness. The generator gate shutdown signal circuit has +Bshort if the battery voltage is always applied to the HV ECU GSDN terminal with the ignition ON.


OK


di838-03 dtc p3125 converter & inverter assembly...

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