HYBRID CONTROL SYSTEM, Diagnostic DTC:U0110-159, U0110-656, U0110-657

DTC Code DTC Name
U0110-159 Lost Communication with Drive Motor Control Module "A"
U0110-656 Lost Communication with Drive Motor Control Module "A"
U0110-657 Lost Communication with Drive Motor Control Module "A"

DESCRIPTION

For a description of the inverter Click here.

The MG ECU, which is built into in the inverter with converter assembly, controls motor (MG2) based on commands from the power management control ECU. The MG ECU monitors communication data and detects malfunctions.

The power management control ECU monitors communication data and detects malfunctions. A communication error between the MG ECU and power management control ECU.

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 trip detection logic)

  • Wire harness or connector

  • Inverter with converter assembly

  • Generator cable

  • Motor cable

  • Hybrid vehicle transaxle assembly

  • Power management control ECU

  • INV fuse
656

Error in reception from inverter with converter assembly (MG ECU) via serial communication (out of communication standard)

(1 trip detection logic)
657

Error in reception from inverter with converter assembly (MG ECU) via serial communication (no reception)

(1 trip detection logic)

WIRING DIAGRAM

A01I67VE13

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 Click here.

    Tech Tips

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

Note


  • 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.

  • 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.

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


  1. Turn the power switch on (IG) and wait for 2 minutes or more.

PROCEDURE


  1. CHECK FUSE (INV)


    1. Remove the INV fuse from the No. 2 engine room relay block.

    2. A01I3YQE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 INV Fuse

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      INV fuse terminals Always Below 1 Ω

    3. Install the INV fuse.


    NG

    REPLACE FUSE (INV) Click here

    OK

  2. CLEAR DTC


    1. Connect the Techstream to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Clear DTCs and freeze frame data.

    5. Turn the power switch off.


    NEXT

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the Techstream to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. 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

    5. 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.

      Note

      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.

    2. A01I3C2

      Remove the upper inverter cover (generator cable side) from the inverter with converter assembly.

    3. A01I4TX

      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
      T=8.0 N*m (82 kgf*cm, 71 in.*lbf)

      Note

      Make sure that the tightening torque of the bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

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

    5. Check for arc marks at the terminals 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

    6. Reconnect the generator cable to the inverter with converter assembly.

    7. Install the upper 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.

      Note

      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.

    2. A01I3ON

      Remove the upper inverter cover (motor cable side) from the inverter with converter assembly.

    3. A01I63K

      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=8.0 N*m (82 kgf*cm, 71 in.*lbf)

      Note

      Make sure that the tightening torque of the bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

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

    5. Check for arc marks at the terminals 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

    6. Reconnect the motor cable to the inverter with converter assembly.

    7. Install the upper inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  6. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR (MG1))

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. A01I4TT

      Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.

    3. A01I3AIE05
      Text in Illustration
      *1 Generator Cable
      *2 Motor Cable

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

    4. A01I62VE05
      Text in Illustration
      *1 Shield Ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      Check generator (MG1) for an interphase short using a milliohmmeter.


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

        Tech Tips

        If the generator (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
        o1-1 (W) - o1-3 (U) Power switch off 59.1 to 67.5 mΩ
        o1-2 (V) - o1-1 (W) Power switch off 59.1 to 67.5 mΩ
        o1-3 (U) - o1-2 (V) Power switch off 62.1 to 70.5 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68° F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at 20°C (68° F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. When checking for a short circuit between generator phases without using a milliohmmeter.

      Note

      The generator generates current when wheels are rotated by hand. Before performing the inspection, wrap the generator cable terminals with insulation tape.

      Tech Tips

      A short circuit between the generator phases can be checked simply without using a milliohmmeter.


      1. Connect the cable to the negative (-) auxiliary battery terminal.

      2. Turn the power switch on (IG).

        Note

        Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

      3. Move the shift lever to N.

      4. Lift up the vehicle.

      5. Rotate the front wheels in the same direction simultaneously by hand.

        Standard
        Front wheels rotate smoothly (No short circuit between phases)

        Tech Tips

        If a short circuit exists between the generator phases, the front wheels do not rotate smoothly (some resistance is felt).

      6. Lower the vehicle.

      7. Move the shift lever to P.

      8. Turn the power switch off.

      9. Disconnect the cable from the negative (-) auxiliary battery terminal.

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

      Note

      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
      o1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      o1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      o1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

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

      Tech Tips

      Perform this procedure only when checking for a short circuit between generator phases without using a milliohmmeter.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      o1-2 (V) - o1-3 (W) Power switch off Below 1 Ω
      o1-1 (U) - o1-2 (V) Power switch off Below 1 Ω

    8. Reconnect the generator cable and motor cable.

    9. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).


    NG

    Click here

    OK

  7. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR (MG2))

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. A01I4TT

      Remove the upper inverter cover (generator cable side) and upper inverter cover (motor cable side) from the inverter with converter assembly.

    3. A01I3AIE05
      Text in Illustration
      *1 Generator Cable
      *2 Motor Cable

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

    4. A01I62VE06
      Text in Illustration
      *1 Shield Ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)

      Check motor (MG2) for an interphase short using a milliohmmeter.


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

        Tech Tips

        If the motor (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
        n1-1 (W) - n1-3 (U) Power switch off 71.4 to 81.0 mΩ
        n1-2 (V) - n1-1 (W) Power switch off 71.4 to 81.0 mΩ
        n1-3 (U) - n1-2 (V) Power switch off 74.4 to 84.1 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68° F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at 20°C (68° F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. When checking for a short circuit between motor phases without using a milliohmmeter.

      Note

      The motor generates current when wheels are rotated by hand. Before performing the inspection, wrap the motor cable terminals with insulation tape.

      Tech Tips

      A short circuit between the motor phases can be checked simply without using a milliohmmeter.


      1. Connect the cable to the negative (-) auxiliary battery terminal.

      2. Turn the power switch on (IG).

        Note

        Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

      3. Move the shift lever to N.

      4. Lift up the vehicle.

      5. Rotate the front wheels in the same direction simultaneously by hand.

        Standard
        Front wheels rotate smoothly (No short circuit between phases)

        Tech Tips

        If a short circuit exists between the motor phases, the front wheels do not rotate smoothly (some resistance is felt).

      6. Lower the vehicle.

      7. Move the shift lever to P.

      8. Turn the power switch off.

      9. Disconnect the cable from the negative (-) auxiliary battery terminal.

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

      Note

      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
      n1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      n1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

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

      Tech Tips

      Perform this procedure only when checking for a short circuit between motor phases without using a milliohmmeter.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      n1-2 (V) - n1-3 (W) Power switch off Below 1 Ω
      n1-1 (U) - n1-2 (V) Power switch off Below 1 Ω

    8. Reconnect the generator cable and motor cable.

    9. Install the upper inverter cover (generator cable side) and upper inverter cover (motor cable side).


    NG

    Click here

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. A01I5YK

      Disconnect the A14 inverter with converter assembly connector.

    3. A01I645E01
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A14-10 (GND1) - Body ground Power switch off Below 1 Ω
      A14-11 (GND2) - Body ground Power switch off Below 1 Ω

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A14-30 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A14-31 (+B2) - Body ground Power switch on (IG) 11 to 14 V

      Note

      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.

    7. Turn the power switch off.

    8. Reconnect the A14 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.

    2. Turn the power switch on (IG).

    3. A01I50WE20
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

      Measure the waveform.

      Item Contents
      Tester Connection

      CH1: A38-29 (CLK+) - I3-6 (E1)

      CH2: A38-28 (CLK-) - I3-6 (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

      Tech Tips


      • 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.

    4. Turn the power switch off.


    B

    CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) Click here

    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.

    2. Turn the power switch on (IG).

    3. A01I2S1E21
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

      Measure the waveform.

      Item Contents
      Tester Connection

      CH1: A38-32 (REQ+) - I3-6 (E1)

      CH2: A38-31 (REQ-) - I3-6 (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

      Tech Tips


      • 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.

    4. Turn the power switch off.


    B

    CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) Click here

    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.

    2. Turn the power switch on (IG).

    3. A01I3T6E37
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

      Measure the waveform.

      Item Contents
      Tester Connection

      CH1: A38-21 (MTH+) - I3-6 (E1)

      CH2: A38-20 (MTH-) - I3-6 (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

      Tech Tips


      • 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.

    4. Turn the power switch off.


    B

    CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) Click here

    A

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. Disconnect the A38 power management control ECU connector.

    3. Disconnect the A14 inverter with converter assembly connector.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A01I5W7E01
      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)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A38-29 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A38-28 (CLK-) - Body ground Power switch on (IG) Below 1 V

      Note

      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.

    7. Turn the power switch off.

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A38-29 (CLK+) - A14-7 (CLK+) Power switch off Below 1 Ω
      A38-28 (CLK-) - A14-18 (CLK-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A38-29 (CLK+) or A14-7 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-28 (CLK-) or A14-18 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher

    9. Disconnect the cable from the negative (-) auxiliary battery terminal.

    10. Reconnect the A14 inverter with converter assembly connector.

    11. Reconnect the A38 power management control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  13. CHECK INVERTER WITH CONVERTER ASSEMBLY


    1. Disconnect the A38 power management control ECU connector.

    2. A01I5EDE55
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A38-29 (CLK+) - A38-28 (CLK-) Power switch off 80 to 170 Ω

    3. Reconnect the A38 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 ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. Disconnect the A38 power management control ECU connector.

    3. Disconnect the A14 inverter with converter assembly connector.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A01I5W7E02
      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)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A38-32 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A38-31 (REQ-) - Body ground Power switch on (IG) Below 1 V

      Note

      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.

    7. Turn the power switch off.

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A38-32 (REQ+) - A14-26 (REQ+) Power switch off Below 1 Ω
      A38-31 (REQ-) - A14-37 (REQ-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A38-32 (REQ+) or A14-26 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-31 (REQ-) or A14-37 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher

    9. Disconnect the cable from the negative (-) auxiliary battery terminal.

    10. Reconnect the A14 inverter with converter assembly connector.

    11. Reconnect the A38 power management control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  15. CHECK INVERTER WITH CONVERTER ASSEMBLY


    1. Disconnect the A38 power management control ECU connector.

    2. A01I5EDE56
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A38-32 (REQ+) - A38-31 (REQ-) Power switch off 80 to 170 Ω

    3. Reconnect the A38 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 ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. Disconnect the A38 power management control ECU connector.

    3. Disconnect the A14 inverter with converter assembly connector.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A01I5W7E03
      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)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A38-21 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A38-20 (MTH-) - Body ground Power switch on (IG) Below 1 V

      Note

      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.

    7. Turn the power switch off.

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A38-21 (MTH+) - A14-8 (MTH+) Power switch off Below 1 Ω
      A38-20 (MTH-) - A14-19 (MTH-) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A38-21 (MTH+) or A14-8 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A38-20 (MTH-) or A14-19 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher

    9. Disconnect the cable from the negative (-) auxiliary battery terminal.

    10. Reconnect the A14 inverter with converter assembly connector.

    11. Reconnect the A38 power management control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  17. CHECK POWER MANAGEMENT CONTROL ECU

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. Disconnect the A14 inverter with converter assembly connector.

    3. A01I5EKE32
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      A38-21 (MTH+) - A38-20 (MTH-) Power switch off 80 to 170 Ω

    4. Reconnect the A14 inverter with converter assembly connector.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  18. REPLACE FUSE (INV)


    1. A01I3YQE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 INV Fuse

      Replace the INV fuse.

    2. Turn the power switch on (READY).

    3. Check if there is an open circuit in the INV fuse in the No. 2 engine room relay block.

      OK
      There is no open circuit in the INV fuse.

      Tech Tips

      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.

    4. Turn the power switch off.


    NG

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - INV FUSE) Click here

    OK

    COMPLETED

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      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.

    2. A01I3YQE01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block
      *2 INV Fuse

      Remove the INV fuse from the No. 2 engine room relay block.

    3. Disconnect the A14 inverter with converter assembly connector.

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

      A01I662E01
      Text in Illustration
      *1 No. 2 Engine Room Relay Block *2 INV Fuse
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 - -
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A14-30 (+B), A14-31 (+B2) or 2 (INV fuse terminal) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Reconnect the A14 inverter with converter assembly connector.

    6. Install the INV fuse.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    OK

  20. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here


    NEXT

    REPLACE FUSE (INV)

  21. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

    REPLACE FUSE (INV)

  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.

      Note

      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.

    2. Remove the inverter with converter assembly Click here.

    3. A01I5CU

      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
      T=8.5 N*m (87 kgf*cm, 75 in.*lbf)

      Note

      Make sure that the tightening torque of the bolt is between 6.4 and 10.5 N*m (65 and 107 kgf*cm, 5 and 8 ft.*lbf).

    4. Disconnect the generator cable from the hybrid vehicle transaxle assembly.

    5. Check for arc marks at the terminals 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

    6. Reconnect the generator cable to the hybrid vehicle transaxle assembly.

    7. 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.

      Note

      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.

    2. Remove the generator cable Click here.

    3. A01I324E01
      Text in Illustration
      *1 Shield ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)
      *b

      Generator Cable

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

      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
      o1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      o1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      o1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the generator cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      o1-1 (W) - o2-1 (W) Power switch off Below 1 Ω
      o1-2 (V) - o2-2 (V) Power switch off Below 1 Ω
      o1-3 (U) - o2-3 (U) Power switch off Below 1 Ω
      o1-1 (W) - o2-3 (U) Power switch off 100 MΩ or higher
      o1-2 (V) - o2-1 (W) Power switch off 100 MΩ or higher
      o1-3 (U) - o2-2 (V) Power switch off 100 MΩ or higher

    5. Install the generator cable.

      Result
      Result Proceed to
      OK (When Not Using the Engine Support Bridge) A
      OK (When Using the Engine Support Bridge) B
      NG C

    B

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (When Using the Engine Support Bridge) Click here

    C

    REPLACE GENERATOR CABLE Click here

    A

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (When Not Using the Engine Support Bridge) 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.

      Note

      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.

    2. A01I2XF

      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=8.5 N*m (87 kgf*cm, 75 in.*lbf)

      Note

      Make sure that the tightening torque of the bolt is between 6.4 and 10.5 N*m (65 and 107 kgf*cm, 5 and 8 ft.*lbf).

    3. Disconnect the motor cable from the hybrid vehicle transaxle assembly.

    4. Check for arc marks at the terminals 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

    5. Reconnect the motor cable to the hybrid vehicle 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.

      Note

      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.

    2. Remove the motor cable Click here.

    3. A01I615E01
      Text in Illustration
      *1 Shield ground
      *a

      Motor Cable

      (Inverter with Converter Assembly Side)
      *b

      Motor Cable

      (Hybrid Vehicle Transaxle Assembly Side)

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

      Note

      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
      n1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      n1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      n1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the motor cable with insulating tape to prevent them from coming into contact with body ground

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      n1-1 (W) - n2-3 (W) Power switch off Below 1 Ω
      n1-2 (V) - n2-2 (V) Power switch off Below 1 Ω
      n1-3 (U) - n2-1 (U) Power switch off Below 1 Ω
      n1-1 (W) - n2-1 (U) Power switch off 100 MΩ or higher
      n1-2 (V) - n2-3 (W) Power switch off 100 MΩ or higher
      n1-3 (U) - n2-2 (V) Power switch off 100 MΩ or higher

    5. Install the motor cable.

      Result
      Result Proceed to
      OK (When Not Using the Engine Support Bridge) A
      OK (When Using the Engine Support Bridge) B
      NG C

    B

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (When Using the Engine Support Bridge) Click here

    C

    REPLACE MOTOR CABLE Click here

    A

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (When Not Using the Engine Support Bridge) Click here