Jeza

Check the engine earth strap as well

Don't use Gen 1 cells. 10 series Alphards came with Gen2 cells, I have had the pack replaced with Gen 4 Prius cells.

Air con system wiring diagram, 10 series hybrid. The Air conditioner amplifier (2 way) is located to the left of the radio head unit. The Air Conditioner Amplifier is within the heat/vent/distribution control panel below the head unit. Air con system wiring ATH10.pdf

After individual cell replacement in 2023 a year later another cell went bad so I decided to bite the bullet and replace the whole pack. 2003 with 130,000km is not a bad life for the battery. I went with Gen 4 cells which are the latest and I certainly notice a difference, slightly better acceleration and longer battery only around town. hanks to Hybrid Battery Repair, Glasgow.

Yes I do, I will have a look and get it posted up but the A/C system is complicated as it is tied into several systems.

Wiring diagrams of the HV system with most of the Japanese translated manually, and using GIMP to add the text. I could not find any other way to do it with this type of pdf with embedded text within images and retain the quality. Hope it is of some use to you all. Alphard HV wiring 10 series pt1.pdf Alphard HV wiring 10 series pt2.pdf

On the Hybrid there is no starter relay as such, the engine is initially started using the Hybrid motor in the gearbox. Subsequent stop/starts uses the starter generator via the serpentine belt. Check the gear lever is in park and "P" is displayed on the dash.

The Hybrid battery system never fully charges the battery during general driving so there is spare capacity for regeneration braking. This also keeps the battery temp down as the inner cells of the pack are prone to overheat and fail as I have found out.

Yes there are, but it will not change the road tax, likewise very little info will get transferred from the Japanese Type Certificate to the logbook. The log book info all comes from the Europe Type approval regs and as the Japan one is not in the correct format DVLA can not transfer the info. Mine is just a Toyota, I did get the fuel changed to Gas Bi-Fuel and added exhaust emissions. pictures from V5 and CofC

I presume it is the ABS unit which has an electric pump and accumulator in it. I have had an unexpected leak from the accumulator, after it had been in the garage for an MOT, which lights up several warnings. I suspect they had pushed the brake pads back away from the disc, anyway a few hard pumps of the brake pedal cleared the fault. A bit of muck on a check valve?

You just need to remove the lower glove box, unship the ECU, the fuse box is up behind next to the bulkhead. Lie on your back in the passenger foot well look up and you should see it. You will need a pair of long nose pliers.

All early 10 series hybrids are 96kw at 5600rpm. (109kw including the hybrid motors)

I have only found one point under the bonnet, which also has a sight glass to check the level of refrigerant. I assume the temp control flap actuator is moving correctly and is not stuck on hot? Do the pipes on the compressor have a significant temp difference? I can not find anywhere in the manual how or where to connect the aircon test tool. Attached are some files which may be of some help. Refrigerant is HFC-134a (R134a) amount 830+/- 30g. Extraction of refrigerant.pdf Refrigerant check.pdf

Hi, I have made a short video while repairing my 2003 Alphard heater air blend door actuator by replacing the tracked disk within the unit. Hope it helps if you have a noisy or intermittent actuator. https://www.youtube.com/watch?v=Tr0H7cIDzPE

P3125-496 is a starter generator fault, "Load short circuit due starter motor inverter abnormality" not much help really. If DTC P3125-448 is also shown then goto related diagnosis, however I can't find what this code is.