Technical Service BULLETIN

Transcription

1 Technical Service BULLETIN November 20, 2002 Title: Models: Prius EG ENGINE Introduction Under certain driving conditions, some Prius vehicles may exhibit a Master, Hybrid and M.I.L. Warning Lights ON condition where DTC P3125, information code 287 ONLY has set in the Hybrid Vehicle Control Unit (HV ECU). Use the following procedure to identify whether the HV ECU or inverter/converter assembly should be replaced. NOTE: The HV ECU is to be replaced ONLY if the recorded information code 287 data satisfies ALL of the following 3 conditions: Vehicle speed is between mph. Throttle opening is 60% or more. Vehicle indicated speed is greater than the recorded MG2 revolutions. If 1 or more of the above conditions DO NOT apply, use the Prius Manual P3125, information code 287 Fault Isolation (FIP). Applicable Vehicles model year Prius vehicles produced BEFORE the Production Change Effective VIN shown below. Production Change Effective MODEL Prius PRODUCTION CHANGE EFFECTIVE VIN JT2BK18U* Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY Computer, Hybrid Vehicle Control 1 Warranty Information OP CODE DESCRIPTION TIME OFP T1 T R & R HV ECU 0.3 Combo X Connection of Toyota Diagnostic Tester Applicable Warranty*: This repair is covered under the Toyota Hybrid Vehicle System Warranty. This warranty is in effect for 96 months or 100,000 miles, whichever occurs first, from the vehicle s in-service date. * Warranty application is limited to correction of a problem based upon a customer s specific complaint. Toyota Supports ASE Certification Page 1 of 7

2 Required Tools & Material TOOLS & MATERIAL PART NUMBER QUANTITY Standard Metric Socket Set and Hand Tools As Required Toyota Diagnostic Tester Kit* Toyota Diagnostic Tester VP414 Printer Kit Megabyte Diagnostic Tester Program Card with version 9.3a Software (or later)* Prius Automatic Trickle Charger YA * Essential SSTs. NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX/OTC at Page 2 of 7

3 Diagnostic 1 Figure 1 Connect the Toyota Diagnostic Tester & print the DTC P3125, Information code 287 freeze frame data (or store as a Techview file using TIS [Technical Information System]). A *APPLICATION SELECT* 1: DIAGNOSIS 2: CUSTOMIZE 3: ECU REPROGRAM B FUNCTION SELECT FOR NORTH AMERICA 1: 1 OBD/MOBD 2 ENHANCED OBD II 3: CARB OBD II 4: BREAK OUT BOX 5: NVH 6: AUTOPROBE 7: 02 RPM CHECK 8: SNAPSHOT REVIEW 9: SETUP 0: GAS ANALYSIS C VEHICLE SELECT VEHICLE SELECT: *2002 PRIUS [YES] to Confirm [EXIT] to Return D OBD/MOBD MENU 1: CODES (ALL) 2: ENGINE AND ECT 3: ABS 4: EMPS 5: CCS 6: IMMOBILISER 7: SRS AIRBAG 8: HV ECU 9: HV BATTERY G COOLANT TEMP. 87 C TACHO METER rpm VEHICLE SPD... 38MPH INTAKE AIR C INFORMATION INFORMATION 2. 0 INFORMATION 3. 0 INFORMATION 4. 0 INFORMATION 5. 0 Record This Value E CHECK CODES ENGINE AND ECT OK ABS OK EMPS OK CCS OK SRS AIRBAG.... OK HV ECU NG OK HV BATTERY.... OK [ENTER] to Read DTCs [EXIT] to Continue H INFORMATION MG1 REV rpm MG2 REV rpm MG1 TORQ Nm MG2 TORQ Nm Shift Sensor 1... D ACC SENSOR MAIN 91.72% ENG STOP RQST NO IDLING REQUEST NO F DIAG. TROUBLE CODES ECU: HV_ECU Number of DTCs: 1 *P3125 Inverter Malfunction Record This Value Record This Value [ENTER] to Read DTCs [EXIT] to Continue * Applicable to 2001 or 2002 Prius Vehicles Go 2 Check the recorded vehicle speed. Is the vehicle speed between mph? Vehicle Speed is. YES NO Refer to Manual. 3 Check the Accelerator Sensor Main value. Is it 60% or more? Accelerator Sensor Main Value is. YES NO Refer to Manual. Page 3 of 7

4 Diagnostic 4 Go Check and note the recorded MG2 Revolution speed from the Info 287 freeze frame data. MG2 Revolution is. 5 Perform the following calculation to convert the vehicle speed value. *Multiply the vehicle speed (mph) noted in step 2 by 57.6 (or multiply by 36 if vehicle speed is measured in km/h) and subtract 100. Is this value greater than the recorded MG2 revolution speed recorded in step 4? Example: If vehicle is travelling at 38 mph, then: 38 (mph) x 57.6= Then subtract 100 from the above number to find the vehicle speed value: = 2089 (rpm) Go 6 Compare the MG2 Revolution speed (Step 4) to the converted vehicle speed value found in Step 5. Is the vehicle speed value higher than the MG2 Revolution Speed? YES NO Refer to Manual. Replace the HV ECU. Please follow the below. A. Removal and Replacement of HV ECU. Please refer to Figure 6 on page 7 and the following instructions to remove and replace the HV ECU: 1. Turn the ignition key on, push the radio power button and the audio button. Record the radio presets. Turn off all lights and accessories. 2. Turn ignition key off and remove the key. 3. Remove the auxiliary battery cover. 4. Disconnect the negative ( ) terminal from the auxiliary battery. To prevent damage to the battery terminal, loosen the cable nut and raise the terminal straight up without twisting or prying the cable. Figure 2 Auxiliary Battery Cover Removal Page 4 of 7

5 5. Remove the R/F door scuff plate and cowl side trim (see Figure 6 on page 7). 6. Fold the carpet back towards the passenger seat. 7. Unbolt and remove the ECU Bracket (See Figure 6 on page 7). 8. Unbolt and remove the HV ECU. Carefully remove the wire harness protector and unplug the electrical connectors from the HV ECU. Peel the (plastic) ECU Cover off the HV ECU (See Figure 6 on page 7). 9. Unscrew and remove the HV ECU mounting brackets. 10. Screw the mounting brackets onto the new HV ECU. Install the (plastic) ECU Cover. 11. Carefully plug each electrical connector and install the wire harness protector. 12. Install the HV ECU and torque the mounting nuts. Torque: 52 in. lbf (6.0 N m, 60 kgf cm). 13. Install the ECU Bracket. Torque the mounting bolts and nuts. Torque: 52 in. lbf (6.0 N m, 60 kgf cm). 14. Roll out the carpet and install the front door scuff plate and cowl side trim. 15. Connect the negative ( ) battery terminal and tighten the cable nut. Torque: 52 in. lbf (6.0 N m, 60 kgf cm). 16. Remove the positive (+) battery terminal cover. 17. Connect the 12 volt Prius Automatic Trickle Charger SST (P/N YA122 01) to the auxiliary battery. Red charger clamp to the positive (+) terminal and the black charger clamp to the negative ( ) battery terminal. 18. Plug the charger into a grounded 110V nominal outlet and verify the red POWER light is on. Push the charger current toggle switch to the 10 amp position. Ensure the yellow CHARGING light is on. Figure 3 Negative Terminal Figure 4 Prius Automatic Trickle Charger (P/N YA122 01) 10 Amp Switch Yellow Light (Charging) Green Light (Charged) Page 5 of 7

6 B. HV Immobilizer Key Code Registration. 1. Ensure the parking brake is applied and the running mode selector lever is in P. 2. Insert the ignition key and turn the ignition switch to the ON position. Leave the vehicle in this condition for at least 30 minutes. 3. After a minimum of 30 minutes has elapsed, turn the ignition key OFF. 4. Unplug the charger from the 110V outlet. Remove the red and black charger clamps from the battery. 5. Install the battery positive (+) terminal cover. 6. Install the auxiliary battery cover. 7. Depress the brake pedal, turn and hold the ignition switch to START until the green READY indicator light remains on and steady. Then release the ignition key. 8. Ensure no trouble lights are illuminated on the Instrument panel or Multi Information Display (MID). 9. Reset all recorded radio stations. Turn the power on, press AUDIO. Tune to desired station, press and hold until a beep is heard. Repeat for each station, FM1, FM2, and AM. 10. Reset the clock to the current time. Figure 5 Page 6 of 7

7 Figure 6 Wire Harness Protector HV ECU Cowl Side Trim 6.0 (60, 52 in. lbf ECU Cover (Plastic) ECU Bracket 6.0 (60, 52 in. lbf Front Door Scuff Plate N m (kgf cm, ft lbf) : Specified Torque Page 7 of 7 Copyright Service Solutions, Inc.