U0110-657

P310 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: U0110-159: Lost Communication with Driver Motor Control Module

DTC U0110-159 - Lost Communication with Driver Motor Control Module

DTC U0110-656 - Lost Communication with Driver Motor Control Module

DTC U0110-657 - Lost Communication with Driver Motor Control Module

DESCRIPTION

The inverter contains three-phase bridge circuits, which consist of six power transistors each for MG2, MG1 and MGR. The inverter converts high-voltage direct current from the HV battery into three-phase alternating current for MG2, MG1 and MGR, it also converts three-phase alternating current supplied by MG2, MG1 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.
HINT: The term "drive motor A" indicates MG2."

The MG ECU uses a voltage sensor, which is built into the inverter, to detect boosted high voltage for boost control.
The inverter voltage sensor outputs voltage that varies between 0 and 5 V in accordance with the changes in the high voltage. The higher the high-voltage, the higher the output voltage, and the lower the high-voltage, the lower the output voltage.
The MG ECU monitors the inverter voltage and detects a malfunction.

The inverter with converter assembly (MG ECU) controls MG2 based on commands from the hybrid vehicle control ECU via serial communication.
The inverter with converter assembly (MG ECU) monitors communication data and detects a malfunction.

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 5 minutes before touching any of the high-voltage connectors or terminals. After waiting for 5 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.
NOTE: 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 P0A1B-788 (power source IC reset) will be set. Proceed to troubleshooting without considering DTC P0A1B-788.
HINT: Waiting for at least 5 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CHECK FUSE (IGCT NO. 2)

(a) Check if there is an open circuit in the fuse (IGCT NO. 2) in the No. 2 engine room relay block.
OK:
There is no open circuit in the fuse (IGCT NO. 2).
NG -- REPLACE FUSE (IGCT NO. 2)
OK -- Continue to next step.
2. CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM)

(a) Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the following table, and measure the waveform.

Result:

HINT: The shape of the waveform may vary according to communication conditions.

B -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MG ECU)
A -- Continue to next step.
3. CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM)

(a) Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the following table, and measure the waveform.

Result:

HINT: The shape of the waveform may vary according to communication conditions.

B -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MG ECU)
A -- Continue to next step.
4. CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM)

(a) Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the following table, and measure the waveform.

Result:

HINT: The shape of the waveform may vary according to communication conditions.

B -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MG ECU)
A -- REPLACE HYBRID VEHICLE CONTROL ECU
5. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MG ECU)
CAUTION: Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) Remove the service plug grip Removal.
(c) Disconnect connector A43 from the hybrid vehicle control ECU.
(d) Remove the inverter cover Removal.
NOTICE:
- Wrap the round interlock terminal for the inverter cover with insulating tape to prevent it from shorting to ground.
- Be sure to prevent coolant in the inverter reserve tank from entering the inverter.
- Removing the inverter cover causes the MG ECU board to be exposed. Therefore, temporarily install the inverter cover for each area to be inspected.
(e) Disconnect connector A42 from the MG ECU.
(f) Turn the power switch on (IG).

(g) Measure the voltage according to the value(s) in the table below.
HINT: Turning the power switch on (IG) with the service plug grip and inverter cover removed causes an interlock switch system DTC (P0A0D-350) to be set.

Standard voltage:

(h) Turn the power switch off.
(i) Measure the resistance according to the value(s) in the table below.
Standard resistance (Check for open):

Standard resistance (Check for short):

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
6. CHECK INVERTER WITH CONVERTER ASSEMBLY
(a) Connect connector A42 to the MG ECU.

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

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
OK -- Continue to next step.
7. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY)
(a) Turn the power switch on (IG).

(b) Measure the voltage according to the value(s) in the table below.
Standard voltage:

HINT: Turning the power switch on (IG) with the service plug grip and inverter cover removed causes an interlock switch system DTC (P0A0D-350) to be set.

NG -- REPAIR POWER SOURCE CIRCUIT
OK -- REPLACE HYBRID VEHICLE CONTROL ECU
8. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MG ECU)
CAUTION: Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) Remove the service plug grip Removal.
(c) Disconnect connector A43 from the hybrid vehicle control ECU.
(d) Remove the inverter cover Removal.
NOTICE:
- Wrap the round interlock terminal for the inverter cover with insulating tape to prevent it from shorting to ground.
- Be sure to prevent coolant in the inverter reserve tank from entering the inverter.
- Removing the inverter cover causes the MG ECU board to be exposed. Therefore, temporarily install the inverter cover for each area to be inspected.
(e) Disconnect connector A42 from the MG ECU.
(f) Turn the power switch on (IG).

(h) Turn the power switch off.
(i) Measure the resistance according to the value(s) in the table below.
Standard resistance (Check for open):

Standard resistance (Check for short):

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
9. CHECK INVERTER WITH CONVERTER ASSEMBLY
(a) Connect connector A42 to the MG ECU.

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

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
OK -- Continue to next step.
10. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY)
(a) Turn the power switch on (IG).

(b) Measure the voltage according to the value(s) in the table below.
Standard voltage:

HINT: Turning the power switch on (IG) with the service plug grip and inverter cover removed causes an interlock switch system DTC (P0A0D-350) to be set.

NG -- REPAIR POWER SOURCE CIRCUIT
OK -- REPLACE HYBRID VEHICLE CONTROL ECU
11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MG ECU)
CAUTION: Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) Remove the service plug grip Removal.
(c) Disconnect connector A43 from the hybrid vehicle control ECU.
(d) Remove the inverter cover Removal.
NOTICE:
- Wrap the round interlock terminal for the inverter cover with insulating tape to prevent it from shorting to ground.
- Be sure to prevent coolant in the inverter reserve tank from entering the inverter.
- Removing the inverter cover causes the MG ECU board to be exposed. Therefore, temporarily install the inverter cover for each area to be inspected.
(e) Disconnect connector A42 from the MG ECU.
(f) Turn the power switch on (IG).

(h) Turn the power switch off.
(i) Measure the resistance according to the value(s) in the table below.
Standard resistance (Check for open):

Standard resistance (Check for short):

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
12. CHECK INVERTER WITH CONVERTER ASSEMBLY
(a) Connect connector A42 to the MG ECU.

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

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
OK -- Continue to next step.
13. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY)
(a) Turn the power switch on (IG).

(b) Measure the voltage according to the value(s) in the table below.
Standard voltage:

(a) Replace the fuse (IGCT NO. 2) in the No. 2 engine room relay block.
(b) Turn the power switch on (READY).
(c) Check if there is an open circuit in the fuse (IGCT NO. 2) in the No. 2 engine room relay block.
OK:
There is no open circuit in the fuse (IGCT NO. 2).
HINT:
- If no open circuit in the fuse (IGCT NO. 2) is found after turning the power switch on (READY), there was a long-term deterioration.
- If there is an open circuit in the fuse (IGCT NO. 2), replace the fuse.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- END