Jeza

The engine will always start up when cold before switching to hybrid mode, does the engine turn over when trying to start? The first start from ignition off is by the gearbox motor/generator so that could be an issue or the inverter if the engine does not turn over. Any codes?

You need to obtain a Certificate of Conformity, CoC, from https://japaninspection.org/certificate-of-conformity-coc/ not Toyota. You fill out a couple of forms and email them back, if they can find the export cert for you Alphard they will be able to issue a CoC after you have given them some money, cheaper at the moment because of the exchange rate. On the CoC will be the emissions details and a statement that it complies with Euro 4 standard. Send a copy of the form along with your V5 to DVLA with a cover letter asking them to update your V5 with the emission details, they will also add your engine s/n. The lez's will only take the info from the DVLA so once your emissions are updated the various lez's will update your vehicle, including London ulez. 2003 Toyota Alphard 2.4 hybrid.

You can get code readers specifically for Japanese vehicles which can read JOBD format data, an ODB2 will not work. Ancel and iCarsoft make these and there are others as well. I have an iCarsoft which will read hybrid data but I tend to use Techstream as it is easier to view all the parameters on one screen, you just need a Mini VCI J2534 Cable to connect laptop to the ODB port.

Because of where the horns are located they corrode as do the connectors , check the power supply at the connectors with the horn pressed also the earth point. Replacement horns on Amazon or ebay, just generic two tone horns. Check the fuse and horn relay which are both in the engine bay main fuse/relay box. If you can earth pin 2 on the relay that will bypass the clock spring sounding the horn.

It has been a while since I needed to use Techstream, but I think if you go to System select or stored date where the code has been flagged up. Double click on the code which should open another page with the data, in the header or first line in the data list hopefully will be a three digit number. This goes with the main code P3125- xxx to give the cause of the fault, there are about 100 sub codes!!

The "catalytic converter" warning light is actually an overheat warning for the front or rear motor, or inverter. Once that clears, cooled down, the hybrid warning might stay on for a couple of short trips before resetting itself. The pump runs with just the ignition on, which makes it easier to hear it running .

Under the passenger seat on a hybrid is the battery cooling fan, relays, battery ECU and one end of the hybrid battery assy. The aux 12v battery on mine is under the drivers seat the original fitted by CampervanCo was a Optima Red Top Starting only 44Ah 730A which was a mystery to me because the Hybrid does not need a high Ampage battery as the hybrid battery starts the engine, but it does need a high capacity. I managed to squeeze in a slightly larger battery Exide AGM 62Ah, 680A part number EK620. L02 size 242 x 175 x 190. There is quite a high drain on the battery when parked up for any length of time from various ecu's alarm radio central locking, and once the battery has been discharged it won't be able to supply enough power for the hybrid ecu to start the engine. on turning on the ignition I have found the voltage can drop by nearly 2 v.

Who did your conversion?

Wiring diagrams attached hdam3860.pdf hdam3810.pdf hdam3820.pdf hdam3830.pdf hdam3840.pdf hdam3850.pdf

I have another picture for the location of the 2-way compressor control amplifier and it is to the side of the blower, possibly get access by removing the two passenger storage bins and the trim panel. From the manual, which I have nearly finished translating, It outputs a compressor drive signal to the A/C inverter according to the operation enable signal from the HV control computer and the signal from the dual automatic air conditioning computer. In addition, when belt drive is used, it inputs a variable capacity signal from the dual automatic air conditioning computer to control the compressor control valve. The computer is built into the control panel. There is a self test that can be performed on the panel; While simultaneously pressing the "AUTO" switch and the "Inside/Outside Air Change" switch on the control panel, change the IG switch from the OFF position to the engine start position. When panel diagnosis is activated, an indicator check is performed automatically. Check that all indicators and setting display sections light up and go out four times at 1 second intervals. Once the indicator check is complete, a sensor check will be performed automatically. Press the “inside/outside air change” switch to perform an actuator check. After the actuator check is completed, press the “AUTO” switch to perform a sensor check again. The result of the sensor check is displayed on the set temperature display. To end the panel diagnosis, press the “OFF” switch. [Electronic Technical Manual] AC fault codes.pdf

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Hi, is the 12v battery good? monitor the voltage when the ignition is turned on if it drops below 10-11 v this will affect the ECU's, they won't play. The HV battery cells are all connected in series so only as good as the weakest cell, just like a chain. If there was a problem with block 10 you would get code P3020 P3004 depends on what the sub code is: -131 When the EV battery fuse is blown, the service plug grip is dislodged, or the high voltage wiring resistance is broken. -132 Inverter voltage sensor abnormality or high voltage wiring resistance increase -133 Abnormal signal received from battery computer ASSY -268 Inverter voltage signal is out of sync with HV battery voltage

Are you sure it is P1325 as inverter faults are P3123-xxx, if so, you need to find the sub code (-xxx) to identify the part in the inverter or wiring to the ECU's.

Because of its small capacity of 44Ah, it is important to keep it charged up if not regularly using the vehicle, at least once a week. I plug in the AC hook up every week ,with a dehumidifier running inside as well when not using the van after the roads have been gritted or a foot of snow as we have now.

Check with your conversion company to see what battery they installed. It has to be low enough to clear the underside of the seat, I guess it is raised up slightly with a swivel base. If it is a CampervanCo conversion they installed a Red top AGM battery in mine.