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Inspection Procedure

  1. CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - BODY GROUND) 
    1. Disconnect the C64 hybrid vehicle control ECU connector.
      Fig 1: Identifying C64 Hybrid Vehicle Control ECU Connector
      G05007943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminal and body ground.

      Standard resistance 

      STANDARD RESISTANCE

      Tester Connection Specified Condition
      E1 (C64-14) - Body ground Below 1 Ω
    3. Reconnect the hybrid vehicle control ECU connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  2. CHECK ENGINE ROOM JUNCTION BLOCK (IGCT RELAY VOLTAGE) 
    1. Remove the engine room junction block from the engine room R/B.
    2. Turn the power switch on (IG).
    3. Measure the voltage between the terminal and body ground.

      Standard voltage 

      STANDARD VOLTAGE

      Tester Connection Specified Condition
      5 - Body ground 9 to 14 V

    OK:  Go to STEP  5

    Fig 2: Identifying Engine Room Junction Block From Engine Room R/B
    G04973797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: Go to next step 

  3. INSPECT IGCT FUSE 
    1. Remove the IGCT fuse from the engine room R/B.
      Fig 3: Identifying IGCT Fuse From Engine Room R/B
      G05007819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the IGCT fuse resistance.

      Standard resistance: 

      Below 1 Ω 

    3. Reinstall the IGCT fuse.

    NG: REPLACE IGCT FUSE 

    OK: Go to next step 

  4. CHECK HARNESS AND CONNECTOR (IGCT FUSE - BATTERY) 
    1. Disconnect the positive battery terminal.
    2. Remove the IGCT fuse from the engine room R/B.
      Fig 4: Identifying IGCT Fuse From Engine Room R/B
      G05007946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance between the terminals.

      Standard resistance (Check for open) 

      STANDARD RESISTANCE

      Tester Connection Specified Condition
      1 - Positive battery terminal Below 1 Ω
    4. Reinstall the IGCT fuse.
    5. Reconnect the positive battery terminal.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 

  5. INSPECT IGCT RELAY 
    1. Remove the IGCT relay from the engine room R/B.
      Fig 5: Identifying IGCT Relay From Engine Room R/B
      G04975584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminals.

      Standard resistance 

      STANDARD RESISTANCE

      Tester Connection Specified Condition
      3-5 10 kΩ or higher
      3-5 Below 1 Ω (Apply battery voltage between terminals 1 and 2)
    3. Reinstall the IGCT relay.

    NG: REPLACE IGCT RELAY 

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - IGCT RELAY) 
    1. Disconnect the A61 hybrid vehicle control ECU connector.
      Fig 6: Identifying A61 Hybrid Vehicle Control ECU Connector (1 Of 2)
      G05007948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the engine IGCT relay from the engine room R/B.
    3. Measure the resistance according to the value(s) in STANDARD RESISTANCE TABLE .

      Standard resistance (Check for open) 

      STANDARD RESISTANCE TABLE

      Tester Connection Specified Condition
      IGCT relay (3) - +B (A61-2) Below 1 Ω
      IGCT relay (3) - +B2 (A61-1) Below 1 Ω

      Standard resistance (Check for short) 

      STANDARD RESISTANCE

      Tester Connection Specified Condition
      IGCT relay (3) or +B (A61-2) - Body ground 10 kΩ or higher
      IGCT relay (3) or +B2 (A61-1) - Body ground 10 kΩ or higher
    4. Reinstall the engine room J/B.
    5. Reconnect the hybrid vehicle control ECU connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  7. INSPECT ECM (IGSW VOLTAGE) 
    1. Disconnect the A61 hybrid vehicle control ECU connector.
      Fig 7: Identifying A61 Hybrid Vehicle Control ECU Connector (2 Of 2)
      G05007949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage between the terminal and body ground.

      Standard voltage 

      STANDARD VOLTAGE

      Tester Connection Specified Condition
      IGSW (A61-57) - Body ground 9 to 14 V
    3. Reconnect the hybrid vehicle control ECU connector.

    OK:  Go to STEP  10

    NG: Go to next step 

  8. INSPECT IGNITION RELAY NO. 2 
    1. Remove the IG2 relay from the engine room R/B.
      Fig 8: Identifying IG2 Relay From Engine Room R/B
      G04942976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminals.

      Standard resistance 

      STANDARD RESISTANCE

      Tester Connection Specified Condition
      3-5 10 kΩ or higher
      3-5 Below 1 Ω (Apply battery voltage between terminals 1 and 2)
    3. Reinstall the IG2 relay.

    NG: REPLACE IGNITION RELAY NO. 2 

    OK: Go to next step 

  9. CHECK HARNESS AND CONNECTOR (IG2 RELAY - BODY GROUND) 
    1. Remove the IG2 relay from the engine room R/B.
      Fig 9: Identifying IG2 Relay From Engine Room R/B
      G05007951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance between the terminal and body ground.

      Standard resistance 

      STANDARD RESISTANCE

      Tester Connection Specified Condition
      IG2 relay terminal 2 - Body ground Below 1 Ω
    3. Reinstall the IG2 relay.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: GO TO SMART ACCESS SYSTEM WITH PUSH-BUTTON START 

  10. CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - BODY GROUND) 
    1. Disconnect the A61 hybrid vehicle control ECU connector.
    2. Measure the resistance between the terminal and body ground.

      Standard resistance 

      STANDARD RESISTANCE

      Tester Connection Specified Condition
      MREL (A61-93) - Body ground Below 1 Ω
    3. Reconnect the hybrid vehicle control ECU connector.
      Fig 10: Identifying A61 Hybrid Vehicle Control ECU Connector
      G05007952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: REPLACE HYBRID VEHICLE CONTROL ECU 

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