Up to 08/2009
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
* 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 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.
HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
PROCEDURE
1. CHECK FUSE (PCU)
(a) Remove the PCU fuse from the engine room relay block No. 2.
(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 (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.
4. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)
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 A79 connector from the inverter with converter assembly.
(c) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Text in Illustration
(d) Turn the power switch on (IG).
(e) 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.
(f) Turn the power switch off.
(g) Connect the inverter with converter assembly connector.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)
OK -- 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
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.
Result:
(c) Turn the power switch off.
B -- CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)
A -- Continue to next step.
6. 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
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.
Result:
(c) Turn the power switch off.
B -- CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)
A -- Continue to next step.
7. 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
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.
Result:
(c) Turn the power switch off.
B -- CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)
A -- 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
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.
9. 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
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
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.
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
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 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 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 POWER MANAGEMENT CONTROL ECU
(a) Disconnect the A79 connector 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 power management control ECU connector.
NG -- REPLACE POWER MANAGEMENT CONTROL ECU Components
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components
14. 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 relay block No. 2.
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
15. 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 manual because this may cause a malfunction.
(b) Remove the PCU fuse from the engine room relay block No. 2.
Text in Illustration
(c) Disconnect the A79 connector 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.
16. REPLACE INVERTER WITH CONVERTER ASSEMBLY
(a) Replace the inverter with converter assembly Components.
NEXT -- REPLACE FUSE (PCU)
17. REPAIR OR REPLACE HARNESS OR CONNECTOR
NEXT -- REPLACE FUSE (PCU)