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

for Preparation Click here


DESCRIPTION

  1. For a description of the inverter with converter assembly (Click here).
    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.

DTC No.
INF Code
DTC Detection Condition
Trouble Area
U0110
159
Error in reception from inverter with converter assembly (MG ECU) via serial communication (out of communication standard)
  1. Wire harness or connector
  2. Inverter with converter assembly
  3. Generator cable
  4. Motor cable
  5. Hybrid vehicle transaxle assembly
  6. Power management control ECU
  7. PCU fuse
U0110
656
Error in reception from inverter with converter assembly (MG ECU) via serial communication (out of communication standard)
U0110
657
Error in reception from inverter with converter assembly (MG ECU) via serial communication (no reception)

WIRING DIAGRAM


A204497E09


INSPECTION PROCEDURE

CAUTION:
  1. 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.
  2. 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 (Click here).

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

NOTICE:
  1. 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 (Click here).
  2. 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.

1.CHECK FUSE (PCU)

  1. Remove the PCU fuse from the engine room junction block assembly.



    A248222E01

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    PCU fuse terminals
    		Always
    		Below 1 Ω

    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		PCU Fuse

  1. Install the PCU fuse.



NG
Go to step 18
OK


2.CLEAR DTC

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Enter the following menus: Powertrain / Hybrid Control / DTC.

  1. Clear DTCs and freeze frame data.


NEXT


3.CHECK DTC OUTPUT (HYBRID CONTROL)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Enter the following menus: Powertrain / Hybrid Control / DTC.

  1. Check if DTCs are output.

    Result:
    Result
    		Proceed to
    DTC U0110-159, 656 or 657 is output.
    		A
    DTC U0110-159, 656 and 657 are not output.
    		B

  1. Turn the power switch off.



B
CHECK FOR INTERMITTENT PROBLEMS (Click here)
A


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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A215643E02

  1. Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

    Specified Condition:
    Bolt A:
    T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
    Bolt B:
    T=9.2 N*m {94 kgf*cm, 81 ft.*lbf}

    NOTICE:
    1. Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).
    2. Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

  1. Disconnect the generator cable from the inverter with converter assembly.

  1. Check for arc marks at the bolts for the generator cable.

    Result:
    Result
    		Proceed to
    The terminals are connected securely and there are no contact problems.
    		There are no arc marks.
    		A
    The terminals are not connected securely and there is a contact problem.
    		There are arc marks.
    		B
    The terminals are not connected securely and there is a contact problem.
    		There are no arc marks.
    		C
    The terminals are connected securely and there are no contact problems.
    		There are arc marks.
    		B

  1. Connect the generator cable to the inverter with converter assembly.

  1. Install the inverter cover.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A215644E02

  1. Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

    Specified Condition:
    Bolt A:
    T=8.0 N*m {82 kgf*cm, 71 in.*lbf}
    Bolt B:
    T=9.2 N*m {94 kgf*cm, 81 ft.*lbf}

    NOTICE:
    1. Make sure that the tightening torque of the bolt A is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).
    2. Make sure that the tightening torque of the bolt B is between 6.4 and 12 N*m (65 and 122 kgf*cm, 57 and 106 in.*lbf).

  1. Disconnect the motor cable from the inverter with converter assembly.

  1. Check for arc marks at the bolts for the motor cable.

    Result:
    Result
    		Proceed to
    The terminals are connected securely and there are no contact problems.
    		There are no arc marks.
    		A
    The terminals are not connected securely and there is a contact problem.
    		There are arc marks.
    		B
    The terminals are not connected securely and there is a contact problem.
    		There are no arc marks.
    		C
    The terminals are connected securely and there are no contact problems.
    		There are arc marks.
    		B

  1. Connect the motor cable to the inverter with converter assembly.

  1. Install the inverter cover.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


6.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.

  1. Disconnect the generator cable and motor cable from the inverter with converter assembly.



    A215629E09

  1. Check MG1 for an interphase short using a milliohmmeter.

    1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

      HINT:
      If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

      Standard Resistance:
      Tester Connection
      		Switch Condition
      		Specified Condition
      d1-1 (W) - d1-2 (U)
      		Power switch off
      		89.5 to 98.9 mΩ
      d1-2 (U) - d1-3 (V)
      		Power switch off
      		89.5 to 98.9 mΩ
      d1-3 (V) - d1-1 (W)
      		Power switch off
      		89.5 to 98.9 mΩ

      Text in Illustration 
      *1
      		Generator Cable
      *2
      		Shield Ground

      HINT:
      To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).
      1. R20 = Rt / {1 + 0.00393 X (T - 20)}
      The calculation is based on the following:
      1. R20: Resistance at 20°C (68°F) (mΩ)
      2. Rt: Measured resistance (mΩ)
      3. T: Temperature when the resistance is measured (°C)

  1. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

    NOTICE:
    Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    d1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

  1. Connect the generator cable and motor cable.

  1. Install the inverter cover.



NG
Go to step 22
OK


7.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2)

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.

  1. Disconnect the generator cable and motor cable from the inverter with converter assembly.



    A215630E10

  1. Check MG2 for an interphase short using a milliohmmeter.

    1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

      HINT:
      If the MG2 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

      Standard Resistance:
      Tester Connection
      		Switch Condition
      		Specified Condition
      c1-1 (W) - c1-2 (U)
      		Power switch off
      		152.6 to 169.0 mΩ
      c1-2 (U) - c1-3 (V)
      		Power switch off
      		157.6 to 174.0 mΩ
      c1-3 (V) - c1-1 (W)
      		Power switch off
      		151.6 to 168.0 mΩ

      Text in Illustration 
      *1
      		Motor Cable
      *2
      		Shield Ground

      HINT:
      To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).
      1. R20 = Rt / {1 + 0.00393 X (T - 20)}
      The calculation is based on the following:
      1. R20: Resistance at 20°C (68°F) (mΩ)
      2. Rt: Measured resistance (mΩ)
      3. T: Temperature when the resistance is measured (°C)

  1. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

    NOTICE:
    Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    c1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

  1. Connect the generator cable and motor cable.

  1. Install the inverter cover.



NG
Go to step 24
OK


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

CAUTION:
Be sure to wear insulated gloves.

  1. Turn the power switch off.

  1. 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.

  1. Disconnect connector A62 from the inverter with converter assembly.



    A215725E48

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-28 (GND1) - Body ground
    		Power switch off
    		Below 1 Ω
    A62-27 (GND2) - Body ground
    		Power switch off
    		Below 1 Ω

    Text in Illustration 
    *a
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

  1. Turn the power switch on (IG).

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-10 (+B) - Body ground
    		Power switch on (IG)
    		11 to 14 V
    A62-9 (+B2) - Body ground
    		Power switch on (IG)
    		11 to 14 V

    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.

  1. Turn the power switch off.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


9.CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

  1. Connect an oscilloscope between the power management control ECU terminals specified in the following table.

  1. Turn the power switch on (IG).



    A204496E09

  1. Measure the waveform.
    Item
    		Contents
    Tester Connection
    		CH1: A20-21 (CLK+) - H3-6 (E1)
    CH2: A20-20 (CLK-) - H3-6 (E1)
    Equipment Setting
    		1V/DIV., 1μs/DIV.
    Condition
    		Power switch on (IG)

    Result:
    Result
    		Proceed to
    The waveform appears as shown in the illustration.
    		A
    The waveform differs from the one shown in the illustration.
    		B

    Text in Illustration 
    *a
    		Component with harness connected
    (Power Management Control ECU)

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

  1. Turn the power switch off.



B
Go to step 12
A


10.CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

  1. Connect an oscilloscope between the power management control ECU terminals specified in the following table.

  1. Turn the power switch on (IG).



    A204500E10

  1. Measure the waveform.
    Item
    		Contents
    Tester Connection
    		CH1: A20-33 (REQ+) - H3-6 (E1)
    CH2: A20-32 (REQ-) - H3-6 (E1)
    Equipment Setting
    		1V/DIV., 1ms/DIV.
    Condition
    		Power switch on (IG)

    Result:
    Result
    		Proceed to
    The waveform appears as shown in the illustration.
    		A
    The waveform differs from the one shown in the illustration.
    		B

    Text in Illustration 
    *a
    		Component with harness connected
    (Power Management Control ECU)

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

  1. Turn the power switch off.



B
Go to step 14
A


11.CHECK POWER MANAGEMENT CONTROL ECU (CHECK WAVEFORM)

  1. Connect an oscilloscope between the power management control ECU terminals specified in the following table.

  1. Turn the power switch on (IG).



    A204498E15

  1. Measure the waveform.
    Item
    		Contents
    Tester Connection
    		CH1: A20-30 (MTH+) - H3-6 (E1)
    CH2: A20-29 (MTH-) - H3-6 (E1)
    Equipment Setting
    		1V/DIV., 200μs/DIV.
    Condition
    		Power switch on (IG)

    Result:
    Result
    		Proceed to
    The waveform appears as shown in the illustration.
    		A
    The waveform differs from the one shown in the illustration.
    		B

    Text in Illustration 
    *a
    		Component with harness connected
    (Power Management Control ECU)

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

  1. Turn the power switch off.



B
Go to step 16
A

REPLACE POWER MANAGEMENT CONTROL ECU (Click here)  

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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.

  1. Disconnect connector A20 from the power management control ECU.

  1. Disconnect connector A62 from the inverter with converter assembly.

  1. Turn the power switch on (IG).



    A216634E19

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-21 (CLK+) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A20-20 (CLK-) - Body ground
    		Power switch on (IG)
    		Below 1 V

    Text in Illustration 
    *a
    		Rear view of wire harness connector
    (to Power Management Control ECU)
    *b
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

    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.

  1. Turn the power switch off.

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

    Standard Resistance (Check for Open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-21 (CLK+) - A62-5 (CLK+)
    		Power switch off
    		Below 1 Ω
    A20-20 (CLK-) - A62-15 (CLK-)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-21 (CLK+) or A62-5 (CLK+) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A20-20 (CLK-) or A62-15 (CLK-) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

  1. Connect the inverter with converter assembly connector.

  1. Connect the power management control ECU connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


13.CHECK INVERTER WITH CONVERTER ASSEMBLY

  1. Disconnect connector A20 from the power management control ECU.



    A204444E24

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-21 (CLK+) - A20-20 (CLK-)
    		Power switch off
    		80 to 170 Ω

    Text in Illustration 
    *a
    		Rear view of wire harness connector
    (to Power Management Control ECU)

  1. Connect the power management control ECU connector.



NG
REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)
OK

REPLACE POWER MANAGEMENT CONTROL ECU (Click here)  

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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.

  1. Disconnect connector A20 from the power management control ECU.

  1. Disconnect connector A62 from the inverter with converter assembly.

  1. Turn the power switch on (IG).



    A216634E20

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-33 (REQ+) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A20-32 (REQ-) - Body ground
    		Power switch on (IG)
    		Below 1 V

    Text in Illustration 
    *a
    		Rear view of wire harness connector
    (to Power Management Control ECU)
    *b
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

    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.

  1. Turn the power switch off.

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

    Standard Resistance (Check for Open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-33 (REQ+) - A62-6 (REQ+)
    		Power switch off
    		Below 1 Ω
    A20-32 (REQ-) - A62-16 (REQ-)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-33 (REQ+) or A62-6 (REQ+) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A20-32 (REQ-) or A62-16 (REQ-) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

  1. Connect the inverter with converter assembly connector.

  1. Connect the power management control ECU connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


15.CHECK INVERTER WITH CONVERTER ASSEMBLY

  1. Disconnect connector A20 from the power management control ECU.



    A204444E25

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-33 (REQ+) - A20-32 (REQ-)
    		Power switch off
    		80 to 170 Ω

    Text in Illustration 
    *a
    		Rear view of wire harness connector
    (to Power Management Control ECU)

  1. Connect the power management control ECU connector.



NG
REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)
OK

REPLACE POWER MANAGEMENT CONTROL ECU (Click here)  

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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.

  1. Disconnect connector A20 from the power management control ECU.

  1. Disconnect connector A62 from the inverter with converter assembly.

  1. Turn the power switch on (IG).



    A216634E21

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-30 (MTH+) - Body ground
    		Power switch on (IG)
    		Below 1 V
    A20-29 (MTH-) - Body ground
    		Power switch on (IG)
    		Below 1 V

    Text in Illustration 
    *a
    		Rear view of wire harness connector
    (to Power Management Control ECU)
    *b
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

    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.

  1. Turn the power switch off.

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

    Standard Resistance (Check for Open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-30 (MTH+) - A62-7 (MTH+)
    		Power switch off
    		Below 1 Ω
    A20-29 (MTH-) - A62-17 (MTH-)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-30 (MTH+) or A62-7 (MTH+) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher
    A20-29 (MTH-) or A62-17 (MTH-) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

  1. Connect the inverter with converter assembly connector.

  1. Connect the power management control ECU connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


17.CHECK POWER MANAGEMENT CONTROL ECU

  1. Disconnect connector A62 from the inverter with converter assembly.



    A249168E06

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A20-30 (MTH+) - A20-29 (MTH-)
    		Power switch off
    		80 to 170 Ω

    Text in Illustration 
    *a
    		Component with harness connected
    (Power Management Control ECU)

  1. Connect the inverter with converter assembly connector.



NG
REPLACE POWER MANAGEMENT CONTROL ECU (Click here)
OK

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)  

18.REPLACE FUSE (PCU)


    A248222E01

  1. Replace the PCU fuse.
    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		PCU Fuse

  1. Turn the power switch on (READY).

  1. 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.

  1. Turn the power switch off.



NG
Go to step 19
OK

COMPLETED 

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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A248222E01

  1. Remove the PCU fuse from the engine room junction block assembly.
    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    *2
    		PCU Fuse

  1. Disconnect connector A62 from the inverter with converter assembly.



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


    A248223E02


    Text in Illustration 
    *1
    		Engine Room Junction Block Assembly
    		*2
    		PCU Fuse
    *a
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)
    		-
    		-

    Standard Resistance (Check for Open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-10 (+B) - 2 (PCU fuse terminal)
    		Power switch off
    		Below 1 Ω
    A62-9 (+B2) - 2 (PCU fuse terminal)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-10 (+B), A62-9 (+B2) or 2 (PCU fuse terminal) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

  1. Connect the inverter with converter assembly connector.

  1. Install the PCU fuse.



NG
Go to step 21
OK


20.REPLACE INVERTER WITH CONVERTER ASSEMBLY

  1. Replace the inverter with converter assembly (Click here).


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)

CAUTION:
Be sure to wear insulated gloves.

  1. 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.

  1. Remove the inverter with converter assembly.



    A217462E01

  1. Check that the bolts for the generator cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

    Specified Condition:
    Bolt A:
    T=20 N*m {204 kgf*cm, 15 ft.*lbf}
    Bolt B:
    T=10 N*m {102 kgf*cm, 7 ft.*lbf}

    NOTICE:
    1. Make sure that the tightening torque of the bolt A is between 16 and 24 N*m (163 and 245 kgf*cm, 12 and 18 ft.*lbf).
    2. Make sure that the tightening torque of the bolt B is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

  1. Disconnect the generator cable from the hybrid transaxle assembly.

  1. Check for arc marks at the bolts for the generator cable.

    Result:
    Result
    		Proceed to
    The terminals are connected securely and there are no contact problems.
    		There are no arc marks.
    		A
    The terminals are not connected securely and there is a contact problem.
    		There are arc marks.
    		B
    The terminals are not connected securely and there is a contact problem.
    		There are no arc marks.
    		C
    The terminals are connected securely and there are no contact problems.
    		There are arc marks.
    		B

  1. Connect the generator cable to the hybrid transaxle assembly.

  1. Install the inverter with converter assembly.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


23.CHECK GENERATOR CABLE

CAUTION:
Be sure to wear insulated gloves.

  1. 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.

  1. Remove the generator cable.



    A217727E05

  1. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

    NOTICE:
    Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    d1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    d1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

    Text in Illustration 
    *1
    		Generator Cable
    (Inverter with Converter Assembly Side)
    *2
    		Shielded Ground
    *3
    		Generator Cable
    (Hybrid Vehicle Transaxle Assembly Side)

    NOTICE:
    Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    d1-1 (W) - d2-3 (W)
    		Power switch off
    		Below 1 Ω
    d1-2 (U) - d2-2 (U)
    		Power switch off
    		Below 1 Ω
    d1-3 (V) - d2-1 (V)
    		Power switch off
    		Below 1 Ω
    d1-1 (W) - d2-2 (U)
    		Power switch off
    		100 MΩ or higher
    d1-2 (U) - d2-1 (V)
    		Power switch off
    		100 MΩ or higher
    d1-3 (V) - d2-3 (W)
    		Power switch off
    		100 MΩ or higher

  1. Install the generator cable.



NG
REPLACE GENERATOR CABLE (Click here)
OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)  

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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A217463

  1. Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

    Specified Condition:
    T=10 N*m {102 kgf*cm, 7 ft.*lbf}

    NOTICE:
    Make sure that the tightening torque of the bolts is between 8 and 12 N*m (82 and 122 kgf*cm, 71 and 106 in.*lbf).

  1. Disconnect the motor cable from the hybrid transaxle assembly.

  1. Check for arc marks at the bolts for the motor cable.

    Result:
    Result
    		Proceed to
    The terminals are connected securely and there are no contact problems.
    		There are no arc marks.
    		A
    The terminals are not connected securely and there is a contact problem.
    		There are arc marks.
    		B
    The terminals are not connected securely and there is a contact problem.
    		There are no arc marks.
    		C
    The terminals are connected securely and there are no contact problems.
    		There are arc marks.
    		B

  1. Connect the motor cable to the hybrid transaxle assembly.



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


25.CHECK MOTOR CABLE

CAUTION:
Be sure to wear insulated gloves.

  1. 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.

  1. Remove the motor cable.



    A217728E06

  1. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

    NOTICE:
    Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    c1-1 (W) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-2 (U) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher
    c1-3 (V) - Body ground and shield ground
    		Power switch off
    		100 MΩ or higher

    Text in Illustration 
    *1
    		Motor Cable
    (Inverter with Converter Assembly Side)
    *2
    		Shielded Ground
    *3
    		Motor Cable
    (Hybrid Vehicle Transaxle Assembly Side)

    NOTICE:
    Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    c1-1 (W) - c2-1 (W)
    		Power switch off
    		Below 1 Ω
    c1-2 (U) - c2-3 (U)
    		Power switch off
    		Below 1 Ω
    c1-3 (V) - c2-2 (V)
    		Power switch off
    		Below 1 Ω
    c1-1 (W) - c2-3 (U)
    		Power switch off
    		100 MΩ or higher
    c1-2 (U) - c2-2 (V)
    		Power switch off
    		100 MΩ or higher
    c1-3 (V) - c2-1 (W)
    		Power switch off
    		100 MΩ or higher

  1. Install the motor cable.



NG
REPLACE MOTOR CABLE (Click here)
OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)