1. Service Point

2. Transferring Procedure
Service Point
Inspection Mode
In the inspection mode, engine is continuously operated (P range) and motor TRC is turned off
Mode
Vehicle Condition
Purpose
Transferring Procedure
Inspection Mode-2WD Inspection (Inspection Mod1)
Keeps engine running (P range)
Motor TRC is OFF
Exhaust gas test
Engine adjusting
Speedometer test
Manual procedure
Intelligent tester (Active Test)
Inspection Mode-2WD Chassis-Dynamo (Inspection Mod2)
Speedometer test (chassis dynamometer)
Inspection Mode
- Engine will always run when shift lever is set to P.
- Motor traction control is turned off.
Inspection mode is used to the following cases:
- Engine adjusting
- Exhaust gas testing
- Speedometer testing
Note: If the accelerator pedal is depressed >>> Engine speed: rpm.
Notice: Traveling on a road without resetting the inspection mode may damage the transaxle.
Note: Other hybrid vehicle has several types of inspection mode. For derails, please refer to the repair manual.

3. Change the power mode to OFF  inspection mode is canceled
Service Point
Inspection Mode
Manual procedure
within 60 seconds
with brake
Accelerator Pedal
[Transfer to the Inspection Mode (Manual Procedure)]
Note: Perform the following steps in order within 60 seconds.
1. Change the power mode from OFF to IG-ON.
2. In P position, depress the accelerator pedal twice.
3. In N position (with brake pedal depressing), depress the accelerator pedal twice.
4. In P position, depress the accelerator pedal twice.
5. Change the power mode to READY for continuous engine operations.
Note: In the inspection mode, engine is continuously operated (P range) and motor TRC is turned off.
To cancel the inspection mode, turn off the power mode.
OFF 
IG-ON
IG-ON 
READY
Depress twice
Depress twice
Depress twice
Change the power mode to OFF  inspection mode is canceled

4. Service Point Diagnosis Each DTC has information code [INF Code]
It contains detailed information
Detailed Information
Freeze Frame Data
DTC
Each DTC has information code [INF Code] (HV ECU and ECB ECU only).
It contains detailed information.
Note: INF Code cannot be referred to unless Freeze Frame Data is checked.
INF Codes

5. (Hybrid Generator Performance)
Service Point
Diagnosis
In the hybrid system, DTCs and INF code are provided to narrow down the trouble areas
Detection Item
Detection Condition
DTC No.
INF. Code
Trouble Area
P0A92
(Hybrid Generator Performance)
261
MG1 magnetic force deterioration or same phase short circuit
521
MG1 system malfunction
606
MG1 power balance malfunction (small power balance)
607
MG1 power balance malfunction (large power balance)
In the hybrid system, DTCs and detailed information are provided to narrow down the trouble areas.
INF code shows detection condition / area.

6. Service Point
Diagnosis
Data list for hybrid vehicle
Data List
Click!

7. Active Test Service Point Diagnosis Active test for hybrid vehicle
Click!

8. High-voltage Wire Harness High-voltage Wire Harness
Service Point
High-voltage Wire Harness
All high-voltage wire harness and connectors are colored orange
High-voltage Wire Harness
All high-voltage wire harness and connectors are colored orange.
High-voltage Wire Harness

9. Electrical Leakage Detection Circuit
Service Point
High-voltage Wire Harness
Insulation resistance between the high-voltage circuit and the body is always monitored HV
ECU
Meter a
High-voltage Circuit
Load
Battery ECU
Electrical Leakage Detection Circuit
Battery ECU monitors the insulation resistance between high-voltage circuit and ground.
Insulation Resistance
Body

10. Reference (Service Point)
High-voltage Wire Harness
Electrical leakage detection area
INF. Code: 612
(HV Battery Area)
INF. Code: 614
(High Voltage Direct Current Area)
INF. Code: 613
(Transaxle Area)
Resister
SMR1
SMR1
MG1
Inverter
Inverter
SMR2
SMR2
Boost Converter
MG2
Power Cable
A/C Inverter
A/C Inverter
- Reference -
INF. Code: 611
(A/C Area)
SMR3
SMR3
DC – DC Converter
Battery ECU
Electrical Leakage Detection Circuit

11. Basically use the 500V range
Service Point
High-voltage Wire Harness
Use a megohmmeter to measure the insulation resistance (Standard: 2  10 M)
It cannot check the insulation resistance correctly by the TOYOTA Electrical Tester
When you check the insulation resistance, use a megohmmeter.
Basically use the 500V range.
Notice: If you use the 1000V range, it causes the breakdown of the parts.
Note: It cannot check the insulation resistance correctly by the TOYOTA Electrical Tester. Because the insulation resistance is very high.
Standard Value of Insulation Resistance: 2 – 10 M or higher (standard value is different depending on the measurement position)
Megohmmeter
Basically use the 500V range
Notice: If you use the 1000V range, it causes the breakdown of the parts

12. Service Point High-voltage Wire Harness Risk of electric shock
Case
Condition
Risk of Electric Shock
Touch the high-voltage + side
No risk
Touch the body (high-voltage - side) when there is a electrical leakage
Touch the high-voltage + side when there is a electrical leakage
Possibility of electric shock
Touch the high-voltage + and - side
Electric shock !

13. Service Point Safety Precautions
Before servicing the high voltage area
Make sure to perform the followings;
1. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign
2. Turn the power mode to off
3. Remove the key from key slot and carry the key
4. Disconnect auxiliary battery negative terminal
5. Check the insulated gloves
6. Remove the service plug
7. Wait 5 min. or more
8. Measure the inverter terminal voltage (0V check)
When servicing the high voltage area, make sure to perform the followings;
1. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign.
2. Turn the power mode to off.
3. Remove the key from key slot and carry the key.
4. Disconnect auxiliary battery negative terminal.
5. Check the insulated gloves.
6. Remove the service plug.
7. Wait 5 min. or more.
8. Measure the inverter terminal voltage (0V check).

14. Service Point Safety Precautions
Before servicing the high voltage area
1.Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers
Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers that a high-voltage system is being inspected and/or repaired.

15. Not cracked, ruptured, torn, or damaged
Service Point
Safety Precautions
Before servicing the high voltage area
5.Check the insulated gloves
Not cracked, ruptured, torn, or damaged
Insulated glove - not cracked, ruptured, torn, or damaged
- not wet
Not wet

16. Remove before servicing
Service Point
Safety Precautions
Before servicing the high voltage area
6.Remove the service plug
Carry in your pocket
Service Plug
Before inspecting or servicing the high-voltage system, remove service plug to prevent electrocution.
Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while you are servicing the vehicle.
Remove before servicing

17. High-voltage Condenser
Service Point
Safety Precautions
Before servicing the high voltage area
7.Wait 5 minutes or more to discharge high-voltage condenser in the inverter
5 min.
High-voltage Condenser
Discharge
Service plug disconnection
Elect-ricity 0V
Inverter Assembly
After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
Note: 5 minutes are required to discharge the high-voltage condenser inside the inverter assembly.

18. Service Point Safety Precautions
Before servicing the high voltage area
8.Measure the inverter terminal voltage (0V check)
0 V
Between 3 phases
3 phases and body ground
Using a voltmeter, measure the voltage between terminals of 3 phases (U-V, V-W, U-W) and between each terminal and body ground to verify that they are approx. 0V.
Caution: Wear the insulated gloves.
0 V
Inverter Assembly

19. Service Point Safety Precautions
During servicing the high voltage area
Insulate the tools by vinyl tape
Insulated Vinyl Tape

20. Service Point Safety Precautions
During servicing the high voltage area
Insulate the disconnected high-voltage connector with insulated vinyl tape
Insulated Vinyl Tape
After disconnecting a high-voltage connector or terminal, insulate it with insulated vinyl tape.

21. Junction Block x Module
Service Point
Safety Precautions
During servicing the high voltage area
Non-reusable nut is used to the installation of high voltage line
New
Example of use
Wire x SMR
Non-reusable nut is used to the installation of high voltage line.
Used
Non-reusable
Junction Block x Module

22. Service Point Safety Precautions After servicing the high voltage area
Before reinstalling the service plug, check again the following
You have not left a part or tool inside
The high-voltage terminal nuts and screws are properly tightened
The connectors are correctly connected
Before reinstalling the service plug, check again that - you have not left a part or tool inside.
- the high-voltage terminal screws are properly tightened.
- the connectors are correctly connected.

23. Service Point After servicing Safety Precautions
After servicing the high voltage area
Be sure to install the service plug before starting the hybrid system
Vehicle damages
After servicing
Be sure to install the service plug before starting the hybrid system.
Starting the hybrid system with the service plug removed may damage the vehicle.
Installation
READY ON

24. Service Point Response When The Auxiliary Battery (12V) Runs Out
Vehicle conditions when auxiliary battery low voltage
9.5 V
0 V
Shift position indicator doesn’t light up
Multi display goes out
Shift position indicator blinks
Normal
Black Out
Shift position indicator doesn’t light up >>> by the command from HV ECU
Shift position indicator blinks >>> by the operation of Combination Meter
READY ON

25. Service Point Response When The Auxiliary Battery (12V) Runs Out
Charge the auxiliary battery by jump starting or battery charger
Slow
Charge
When the auxiliary battery runs out, charge it by jump starting or battery charger.
Note: The 12V auxiliary battery jumper terminal is located in the engine compartment.
Notice: Charge the auxiliary battery by slow charge.
Jump Starting
Battery Charger

26. Service Point Response When The HV Battery (201.6V) Runs Out
Vehicle conditions when HV battery low voltage
HV Battery Warning Light illuminates
Can not READY ON
DTC P (HV Battery Malfunction) is detected

27. Note: THS charger is the recommended tool
Service Point
Response When The HV Battery (201.6V) Runs Out
Charge the HV Battery using THS Charger
When the HV battery runs out, charge it by THS Charger.
Charging time for engine start: Approx. 10 minute (at 25°C)
Caution:
Wear the insulated gloves when connect / disconnect the THS charger.
Never disconnect the THS charger connecter during charging.
THS Charger
THS Charger
Note: THS charger is the recommended tool

28. Neutralize battery electrolyte
Service Point
Battery Pack Removal / Installation
If the HV battery electrolyte leaks, don’t touch it
Neutralize battery electrolyte
Don’t touch the battery electrolyte !
Boric Acid Solution
[Caution at battery pack removal]
- The HV battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues.
- To neutralize battery electrolyte, use a boric acid solution or vinegar.
Boric Acid
(800 g)
Water
(20 liters)

29. Service Point Short-circuit of MG1, MG2
Use a milliohm meter to judge the short-circuit in the motor coil
Short-circuit
It cannot check the motor coil resistance correctly by the TOYOTA Electrical Tester
Use a milliohm meter to judge the short-circuit in the motor coil.
Note: It cannot check the insulation resistance correctly by the TOYOTA Electrical Tester. Because the resistance is very low.
Measurement: Measure the resistance between 3 phases.
Standard (at 20°C): MG1 >>> Approx. 109 m / MG2 >>> Approx. 135 m / Difference between 3 phases >>> 2m or less
Note: If the MG1 / MG2 temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped.
Milliohm Meter

30. Service Point
Towing
Notice: If there is a electrical leakage, motor regenerates the electricity by wheel rotation