U0110-657 - Lost Communication With Driver Motor Control Module

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: U0110-159, U0110-656, U0110-657: Lost Communication with Driver Motor Control Module
U0110-657 - Lost Communication with Driver Motor Control Module

DESCRIPTION

* For a description of the inverter P0A78.

The inverter with converter assembly (MG ECU) controls MG2 based on commands from the power management control ECU (HV CPU). The inverter with converter assembly (MG ECU) monitors communication data and detects malfunctions.

WIRING DIAGRAM

INSPECTION PROCEDURE

CAUTION:
* Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
* After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work Hybrid Control System: Precaution.
HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

NOTICE:
* After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.
* If any of the DTCs U0110-159, U0110-656, and U0110-657 was set due to incomplete engagement of the connectors, and if the system returns to normal when the power switch is turned on (IG) after clearing the DTCs, DTC P324E-788 will be set. Proceed to troubleshooting without considering DTC P324E-788.

PROCEDURE

1. CHECK FUSE (PCU)

(a) Remove the PCU fuse from the engine room junction block assembly.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Text in Illustration

(c) Install the PCU fuse.

NG -- REPLACE FUSE (PCU)
OK -- Continue to next step.

2. CLEAR DTC P0A09

NEXT -- Continue to next step.

3. CHECK DTC OUTPUT (HYBRID CONTROL)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check if DTCs are output.

Result:

(e) Turn the power switch off.

B -- CHECK FOR INTERMITTENT PROBLEMS Check for Intermittent Problems
A -- Continue to next step.

4. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

5. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

6. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) P0A78

NG -- CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)
OK -- Continue to next step.

7. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) P0A78

NG -- CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)
OK -- Continue to next step.

8. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)

CAUTION:
Be sure to wear insulated gloves.

(a) Turn the power switch off.

(b) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(c) Disconnect connector A62 from the inverter with converter assembly.

(d) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Text in Illustration

(e) Turn the power switch on (IG).

(f) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

NOTICE:
Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

(g) Turn the power switch off.

(h) Connect the inverter with converter assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

9. CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

(a) Connect an oscilloscope between the power management control ECU terminals specified in the following table.

(b) Turn the power switch on (IG).

(c) Measure the waveform.

Result:

Text in Illustration

Result:

Text in Illustration

Result:

Text in Illustration

HINT
* Inspect with the connector connected.
* If pulses are generated, the shape of the waveform can be assumed to be normal.
* The shape of the waveform may vary according to communication conditions.

(d) Turn the power switch off.

B -- CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

A -- REPLACE POWER MANAGEMENT CONTROL ECU Components

12. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Disconnect connector A20 from the power management control ECU.

(c) Disconnect connector A62 from the inverter with converter assembly.

(d) Turn the power switch on (IG).

(e) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Text in Illustration

NOTICE:
Turning the power switch on (IG) with the power management control ECU connector and the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

(f) Turn the power switch off.

(g) Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

(h) Connect the inverter with converter assembly connector.

(i) Connect the power management control ECU connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

13. CHECK INVERTER WITH CONVERTER ASSEMBLY

(a) Disconnect connector A20 from the power management control ECU.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Text in Illustration

(c) Connect the power management control ECU connector.

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

OK -- REPLACE POWER MANAGEMENT CONTROL ECU Components

14. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Disconnect connector A20 from the power management control ECU.

(c) Disconnect connector A62 from the inverter with converter assembly.

(d) Turn the power switch on (IG).

(e) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Text in Illustration

Standard Resistance (Check for Short):

(h) Connect the inverter with converter assembly connector.

(i) Connect the power management control ECU connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

15. CHECK INVERTER WITH CONVERTER ASSEMBLY

(a) Disconnect connector A20 from the power management control ECU.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Text in Illustration

(c) Connect the power management control ECU connector.

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

OK -- REPLACE POWER MANAGEMENT CONTROL ECU Components

16. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Disconnect connector A20 from the power management control ECU.

(c) Disconnect connector A62 from the inverter with converter assembly.

(d) Turn the power switch on (IG).

(e) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Text in Illustration

Standard Resistance (Check for Short):

(h) Connect the inverter with converter assembly connector.

(i) Connect the power management control ECU connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

17. CHECK POWER MANAGEMENT CONTROL ECU

(a) Disconnect connector A62 from the inverter with converter assembly.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Text in Illustration

(c) Connect the inverter with converter assembly connector.

NG -- REPLACE POWER MANAGEMENT CONTROL ECU Components

OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

18. REPLACE FUSE (PCU)

(a) Replace the PCU fuse.

Text in Illustration

(b) Turn the power switch on (READY).

(c) Check if there is an open circuit in the PCU fuse in engine room junction block assembly.

OK:

There is no open circuit in the PCU fuse.

HINT
If the fuse does not become open again after turning the power switch on (READY), it can be assumed that the previous fuse failed due to age.

(d) Turn the power switch off.

NG -- CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)

OK -- COMPLETED

19. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

(b) Remove the PCU fuse from the engine room junction block assembly.

Text in Illustration

(c) Disconnect connector A62 from the inverter with converter assembly.

(d) Measure the resistance according to the value(s) in the table below.

Text in Illustration

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

(e) Connect the inverter with converter assembly connector.

(f) Install the PCU fuse.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

20. REPLACE INVERTER WITH CONVERTER ASSEMBLY

(a) Replace the inverter with converter assembly Components.

NEXT -- REPLACE FUSE (PCU)

21. REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT -- REPLACE FUSE (PCU)

22. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

23. CHECK GENERATOR CABLE P0A78

NG -- REPLACE GENERATOR CABLE Components

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

24. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

25. CHECK MOTOR CABLE P0A78

NG -- REPLACE MOTOR CABLE Components

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components