From 08/2009

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: U0110-160: Lost Communication with Driver Motor Control Module
U0110-160 - Lost Communication with Driver Motor Control Module

DESCRIPTION

* The inverter contains a three-phase bridge circuit, which consists of six power transistors (IGBTs) each for MG1, MG2 and MGR. The inverter converts high-voltage direct current from the HV battery into three-phase alternating current for MG1, MG2 and MGR; it also converts three-phase alternating current supplied by MG1, MG2 and MGR into direct current for the HV battery. The MG ECU controls the actuation of the power transistors (IGBTs). The inverter transmits information necessary for control, such as amperage and voltage, to the MG ECU.

* 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 disconnecting 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.
NOTICE:
If the DTC U0110-160 was set due to incomplete engagement of the connectors, and if the system returns to normal when the power switch is on (IG) after clearing the DTCs, DTC P324E-788 will be set. Proceed to troubleshooting without considering DTC P324E-788.

HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CLEAR DTC P0A09

NEXT -- Continue to next step.

2. CHECK DTC OUTPUT (HV)

(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.

3. CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

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

(b) Connect an oscilloscope between the power management control ECU terminals specified in the following table, and measure the waveform.

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.
(c) Turn the power switch off.

B -- CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)
A -- Continue to next step.

4. CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

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

(b) Connect an oscilloscope between the power management control ECU terminals specified in the following table, and measure the waveform.

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.
(c) Turn the power switch off.

B -- CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)
A -- Continue to next step.

5. CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

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

(b) Connect an oscilloscope between the power management control ECU terminals specified in the following table, and measure the waveform.

Text in Illustration

(c) Turn the power switch off.

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

A -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

6. 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 manual because this may cause a malfunction.

(b) Disconnect the A81 connector from the power management control ECU.

(c) Disconnect the A79 connector 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 connector of the power management control ECU 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.

7. CHECK INVERTER WITH CONVERTER ASSEMBLY U0110

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

OK -- REPLACE POWER MANAGEMENT CONTROL ECU Components

8. 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 manual because this may cause a malfunction.

(b) Disconnect the A81 connector from the power management control ECU.

(c) Disconnect the A79 connector 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.

9. CHECK INVERTER WITH CONVERTER ASSEMBLY U0110

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

OK -- REPLACE POWER MANAGEMENT CONTROL ECU Components

10. 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 manual because this may cause a malfunction.

(b) Disconnect the A81 connector from the power management control ECU.

(c) Disconnect the A79 connector 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.

11. CHECK INVERTER WITH CONVERTER ASSEMBLY

(a) Disconnect the A81 connector 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