LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2012 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 115 (Hybrid Vehicle Control System (Diagnostic Codes (P0ADB-227 - U0424-537) & Circuit Tests)) (Hybrid)) >> Hybrid Control System >> 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 >> Procedure

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: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. CHECK FUSE (PCU) 
    1. Remove the PCU fuse from the engine room relay block No. 2.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 1: Identifying PCU Fuse & Engine Room Relay Block No. 2
      GTY302280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      PCU fuse terminals Always Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block No. 2
      *2 PCU Fuse
    3. Install the PCU fuse.

    NG → See step   14 

    OK: Go to next step 

  2. CLEAR DTC. Refer to  PROCEDURE - Step 4 

    NEXT: Go to next step 

  3. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    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 ignition switch off.

    B → See step   18 

    A: Go to next step 

  4. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect the A64 connector from the inverter with converter assembly.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 2: Checking Harness And Connector (Inverter With Converter Assembly Power Source Circuit)
      GTY300955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A64-10 (GND1) - Body ground Ignition switch off Below 1 Ω
      A64-11 (GND2) - Body ground Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A64-30 (+B) - Body ground Ignition switch ON 10 to 14 V
      A64-31 (+B2) - Body ground Ignition switch ON 10 to 14 V
      NOTE:

      Turning the ignition switch to ON 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.

    6. Turn the ignition switch off.
    7. Connect the inverter with converter assembly connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT) 

    OK: Go to next step 

  5. CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM) 
    1. Turn the ignition switch to ON.
    2. Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the following table, and measure the waveform.
      Fig 3: Checking Hybrid Vehicle Control ECU With Waveform Reference
      GTY301613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Contents
      Tester Connection CH1: A66-21 (CLK+) - D72-6 (E1)
      CH2: A66-20 (CLK-) - D72-6 (E1)
      Equipment Setting 1 V/DIV., 1 μs/DIV.
      Condition Ignition switch ON
      TEXT IN ILLUSTRATION

      *a Component with harness connected
      (Hybrid Vehicle Control ECU)

      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

      Result Proceed to
      The waveform appears as shown in the illustration. A
      The waveform differs from the one shown in the illustration. B
    3. Turn the ignition switch off.

    B → See step   8 

    A: Go to next step 

  6. CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM) 
    1. Turn the ignition switch to ON.
    2. Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the following table, and measure the waveform.
      Fig 4: Checking Hybrid Vehicle Control ECU With Waveform Reference
      GTY298218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Contents
      Tester Connection CH1: A66-33 (REQ+) - D72-6 (E1)
      CH2: A66-32 (REQ-) - D72-6 (E1)
      Equipment Setting 1 V/DIV., 1 ms/DIV.
      Condition Ignition switch ON
      TEXT IN ILLUSTRATION

      *a Component with harness connected
      (Hybrid Vehicle Control ECU)

      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

      Result Proceed to
      The waveform appears as shown in the illustration. A
      The waveform differs from the one shown in the illustration. B
    3. Turn the ignition switch off.

    B → See step   10 

    A: Go to next step 

  7. CHECK HYBRID VEHICLE CONTROL ECU (CHECK WAVEFORM) 
    1. Turn the ignition switch to ON.
    2. Connect an oscilloscope between the hybrid vehicle control ECU terminals specified in the following table, and measure the waveform.
      Fig 5: Checking Hybrid Vehicle Control ECU With Waveform Reference
      GTY296966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Contents
      Tester Connection CH1: A66-30 (MTH+) - D72-6 (E1)
      CH2: A66-29 (MTH-) - D72-6 (E1)
      Equipment Setting 1 V/DIV., 200 μs/DIV.
      Condition Ignition switch ON
      TEXT IN ILLUSTRATION

      *a Component with harness connected
      (Hybrid Vehicle Control ECU)

      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

      Result Proceed to
      The waveform appears as shown in the illustration. A
      The waveform differs from the one shown in the illustration. B
    3. Turn the ignition switch off.

    B → See step   12 

    A → See step   19 

  8. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect the A66 connector from the hybrid vehicle control ECU.
    3. Disconnect the A64 connector from the inverter with converter assembly.
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.
      Fig 6: Checking Harness And Connector (Hybrid Vehicle Control ECU - Inverter With Converter)
      GTY304300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A66-21 (CLK+) - Body ground Ignition switch ON Below 1 V
      A66-20 (CLK-) - Body ground Ignition switch ON Below 1 V
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
      *b Front view of wire harness connector
      (to Inverter with Converter Assembly)
      NOTE:

      Turning the ignition switch to ON with the hybrid vehicle 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.

    6. Turn the ignition switch off.
    7. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      A66-21 (CLK+) - A64-7 (CLK+) Ignition switch off Below 1 Ω
      A66-20 (CLK-) - A64-18 (CLK-) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A66-21 (CLK+) or A64-7 (CLK+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-20 (CLK-) or A64-18 (CLK-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
    8. Connect the inverter with converter assembly connector.
    9. Connect the hybrid vehicle control ECU connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  9. CHECK INVERTER WITH CONVERTER ASSEMBLY 
    1. Disconnect the A66 connector from the hybrid vehicle control ECU.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 7: Checking Inverter With Converter Assembly
      GTY298322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A66-21 (CLK+) - A66-20 (CLK-) Ignition switch off 109 to 131 Ω
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
    3. Connect the hybrid vehicle control ECU connector.

    NG → See step   20 

    OK → See step   19 

  10. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect the A66 connector from the hybrid vehicle control ECU.
    3. Disconnect the A64 connector from the inverter with converter assembly.
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.
      Fig 8: Checking Harness And Connector (Hybrid Vehicle Control ECU - Inverter With Converter)
      GTY304307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A66-33 (REQ+) - Body ground Ignition switch ON Below 1 V
      A66-32 (REQ-) - Body ground Ignition switch ON Below 1 V
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
      *b Front view of wire harness connector
      (to Inverter with Converter Assembly)
      NOTE:

      Turning the ignition switch to ON with the hybrid vehicle 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.

    6. Turn the ignition switch off.
    7. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      A66-33 (REQ+) - A64-26 (REQ+) Ignition switch off Below 1 Ω
      A66-32 (REQ-) - A64-37 (REQ-) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A66-33 (REQ+) or A64-26 (REQ+) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      A66-32 (REQ-) or A64-37 (REQ-) - Body ground and other terminals Ignition switch off 10 kΩ or higher
    8. Connect the inverter with converter assembly connector.
    9. Connect the hybrid vehicle control ECU connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  11. CHECK INVERTER WITH CONVERTER ASSEMBLY 
    1. Disconnect the A66 connector from the hybrid vehicle control ECU.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 9: Checking Inverter With Converter Assembly
      GTY298323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A66-33 (REQ+) - A66-32 (REQ-) Ignition switch off 109 to 131 Ω
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
    3. Connect the hybrid vehicle control ECU connector.

    NG → See step   20 

    OK → See step   19 

  12. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect the A66 connector from the hybrid vehicle control ECU.
    3. Disconnect the A64 connector from the inverter with converter assembly.
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.
      Fig 10: Checking Harness And Connector (Hybrid Vehicle Control ECU - Inverter With Converter)
      GTY304305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A66-30 (MTH+) - Body ground Ignition switch ON Below 1 V
      A66-29 (MTH-) - Body ground Ignition switch ON Below 1 V
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
      *b Front view of wire harness connector
      (to Inverter with Converter Assembly)
      NOTE:

      Turning the ignition switch to ON with the hybrid vehicle 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.

    6. Turn the ignition switch off.
    7. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      A66-30 (MTH+) - A64-8 (MTH+) Ignition switch off Below 1 Ω
      A66-29 (MTH-) - A64-19 (MTH-) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A66-30 (MTH+) or A64-8 (MTH+) -
      Body ground and other terminals      		 Ignition switch off 10 kΩ or higher
      A66-29 (MTH-) or A64-19 (MTH-) -
      Body ground and other terminals      		 Ignition switch off 10 kΩ or higher
    8. Connect the inverter with converter assembly connector.
    9. Connect the hybrid vehicle control ECU connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  13. CHECK HYBRID VEHICLE CONTROL ECU 
    1. Disconnect the A64 connector from the inverter with converter assembly.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 11: Checking Hybrid Vehicle Control ECU
      GTY304136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A66-30 (MTH+) - A66-29 (MTH-) Ignition switch off 109 to 131 Ω
      TEXT IN ILLUSTRATION

      *a Component with harness connected
      (Hybrid Vehicle Control ECU)
    3. Connect the hybrid vehicle control ECU connector.

    NG → See step   19 

    OK → See step   20 

  14. REPLACE FUSE (PCU) 
    1. Replace the PCU fuse.
      Fig 12: Identifying PCU Fuse & Engine Room Relay Block No. 2
      GTY302280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block No. 2
      *2 PCU Fuse
    2. Turn the ignition switch to ON (READY).
    3. 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 ignition switch to ON (READY), it can be assumed that the previous fuse failed due to age.

    4. Turn the ignition switch off.

    NG → See step   15 

    OK → COMPLETED 

  15. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the PCU fuse from the engine room relay block No. 2.
      Fig 13: Checking Harness And Connector (Inverter With Converter Assembly - PCU Fuse)
      GTY305244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block No. 2
      *2 PCU Fuse
      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    3. Disconnect the A64 connector from the inverter with converter assembly.
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      A64-30 (+B) - 2 (PCU fuse) Ignition switch off Below 1 Ω
      A64-31 (+B2) - 2 (PCU fuse) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A64-30 (+B) or A64-31 (+B2) or 2 (PCU fuse) - Body ground and other terminals Ignition switch off 10 kΩ or higher
    5. Connect the inverter with converter assembly connector.
    6. Install the PCU fuse.

    NG → See step   17 

    OK: Go to next step 

  16. REPLACE INVERTER WITH CONVERTER ASSEMBLY 
    1. Replace the inverter with converter assembly. Refer to REMOVAL .

    NEXT → REPLACE FUSE (PCU) 

  17. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT → REPLACE FUSE (PCU) 

  18. CHECK FOR INTERMITTENT PROBLEMS. Refer to  CHECK FOR INTERMITTENT PROBLEMS 
  19. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
  20. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL 
scientia non olet · About LEMON Manuals