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Home >> Toyota >> 2017 >> Prius V Two >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control System - (Diagnostic Codes (P0E32-585 - U0424-537) & Circuit Tests) >> Hybrid Control System >> DTC U0110-159: Lost Communication with Drive Motor Control Module "A"; DTC U0110-656: Lost Communication with Drive Motor Control Module "A"; DTC U0110-657: Lost Communication with Drive Motor Control Module "A" [08/2015 - ] >> Procedure

DTC U0110-159: Lost Communication with Drive Motor Control Module "A"; DTC U0110-656: Lost Communication with Drive Motor Control Module "A"; DTC U0110-657: Lost Communication with Drive Motor Control Module "A" [08/2015 - ]: Procedure

  1. CHECK FUSE (PCU) 
    1. Remove the PCU fuse from the engine room relay block and junction block assembly.
    2. Measure the resistance according to the value(s) in the table below.
      GTY447396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

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

      *1 Engine Room Relay Block and Junction Block Assembly
      *2 PCU Fuse
    3. Install the PCU fuse.

    NG → Refer to   18 

    OK: Go to next step 

  2. CLEAR DTC. Refer to  PROCEDURE - Step 4 

    NEXT: Go to next step 

  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 → Refer to   27 

    A: Go to next step 

  4. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 9 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  5. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 10 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  6. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1). Refer to  PROCEDURE - Step 11 

    NG → Refer to   22 

    OK: Go to next step 

  7. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2). Refer to  PROCEDURE - Step 12 

    NG → Refer to   24 

    OK: Go to next step 

  8. 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 power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Disconnect connector A59 from the inverter with converter assembly.
    3. Measure the resistance according to the value(s) in the table below.
      GTY325269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A59-28 (GND1) - Body ground Power switch off Below 1 Ω
      A59-27 (GND2) - Body ground Power switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    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
      A59-10 (+B) - Body ground Power switch on (IG) 11 to 14 V
      A59-9 (+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. Connect the inverter with converter assembly connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  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. Measure the waveform.
      GTY333250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Contents
      Tester Connection CH1: A22-21 (CLK+) - L5-6 (E1)
      CH2: A22-20 (CLK-) - L5-6 (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: 

      • 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 → Refer to   12 

    A: Go to next step 

  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. Measure the waveform.
      GTY338216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Contents
      Tester Connection CH1: A22-33 (REQ+) - L5-6 (E1)
      CH2: A22-32 (REQ-) - L5-6 (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: 

      • 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 → Refer to   14 

    A: Go to next step 

  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. Measure the waveform.
      GTY340119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Contents
      Tester Connection CH1: A22-30 (MTH+) - L5-6 (E1)
      CH2: A22-29 (MTH-) - L5-6 (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: 

      • 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 → Refer to   16 

    A → Refer to   26 

  12. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) 
    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 power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Disconnect connector A22 from the power management control ECU.
    3. Disconnect connector A59 from the inverter with converter assembly.
    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.
      GTY340840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A22-21 (CLK+) - Body ground Power switch on (IG) Below 1 V
      A22-20 (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)
      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
      A22-21 (CLK+) - A59-5 (CLK+) Power switch off Below 1 Ω
      A22-20 (CLK-) - A59-15 (CLK-) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A22-21 (CLK+) or A59-5 (CLK+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-20 (CLK-) or A59-15 (CLK-) - Body ground and other terminals Power switch off 10 kΩ or higher
    9. Disconnect the cable from the negative (-) auxiliary battery terminal.
    10. Connect the inverter with converter assembly connector.
    11. Connect the power management control ECU connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  13. CHECK INVERTER WITH CONVERTER ASSEMBLY 
    1. Disconnect connector A22 from the power management control ECU.
    2. Measure the resistance according to the value(s) in the table below.
      GTY338089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A22-21 (CLK+) - A22-20 (CLK-) Power switch off 80 to 170 Ω
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Power Management Control ECU)
    3. Connect the power management control ECU connector.

    NG → Refer to   28 

    OK → Refer to   26 

  14. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) 
    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 power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Disconnect connector A22 from the power management control ECU.
    3. Disconnect connector A59 from the inverter with converter assembly.
    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.
      GTY324580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A22-33 (REQ+) - Body ground Power switch on (IG) Below 1 V
      A22-32 (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)
      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
      A22-33 (REQ+) - A59-6 (REQ+) Power switch off Below 1 Ω
      A22-32 (REQ-) - A59-16 (REQ-) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A22-33 (REQ+) or A59-6 (REQ+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-32 (REQ-) or A59-16 (REQ-) - Body ground and other terminals Power switch off 10 kΩ or higher
    9. Disconnect the cable from the negative (-) auxiliary battery terminal.
    10. Connect the inverter with converter assembly connector.
    11. Connect the power management control ECU connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  15. CHECK INVERTER WITH CONVERTER ASSEMBLY 
    1. Disconnect connector A22 from the power management control ECU.
    2. Measure the resistance according to the value(s) in the table below.
      GTY338090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A22-33 (REQ+) - A22-32 (REQ-) Power switch off 80 to 170 Ω
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Power Management Control ECU)
    3. Connect the power management control ECU connector.

    NG → Refer to   28 

    OK → Refer to   26 

  16. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY) 
    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 power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Disconnect connector A22 from the power management control ECU.
    3. Disconnect connector A59 from the inverter with converter assembly.
    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.
      GTY340839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      A22-30 (MTH+) - Body ground Power switch on (IG) Below 1 V
      A22-29 (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)
      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
      A22-30 (MTH+) - A59-7 (MTH+) Power switch off Below 1 Ω
      A22-29 (MTH-) - A59-17 (MTH-) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A22-30 (MTH+) or A59-7 (MTH+) - Body ground and other terminals Power switch off 10 kΩ or higher
      A22-29 (MTH-) or A59-17 (MTH-) - Body ground and other terminals Power switch off 10 kΩ or higher
    9. Disconnect the cable from the negative (-) auxiliary battery terminal.
    10. Connect the inverter with converter assembly connector.
    11. Connect the power management control ECU connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  17. CHECK POWER MANAGEMENT CONTROL ECU 
    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 power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Disconnect connector A59 from the inverter with converter assembly.
    3. Measure the resistance according to the value(s) in the table below.
      GTY330353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A22-30 (MTH+) - A22-29 (MTH-) Power switch off 80 to 170 Ω
      TEXT IN ILLUSTRATION

      *a Component with harness connected
      (Power Management Control ECU)
    4. Connect the inverter with converter assembly connector.

    NG → Refer to   26 

    OK → Refer to   28 

  18. REPLACE FUSE (PCU) 
    1. Replace the PCU fuse.
      GTY447396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block and Junction Block Assembly
      *2 PCU Fuse
    2. Turn the power switch on (READY).
    3. Check if there is an open circuit in the PCU fuse in engine room relay block and 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.

    4. Turn the power switch off.

    NG → Refer to   19 

    OK → COMPLETED 

  19. 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 power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Remove the PCU fuse from the engine room relay block and junction block assembly.
      GTY447396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block and Junction Block Assembly
      *2 PCU Fuse
    3. Disconnect connector A59 from the inverter with converter assembly.
    4. Measure the resistance according to the value(s) in the table below.
      GTY436015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room Relay Block and 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
      A59-10 (+B) - 2 (PCU fuse terminal) Power switch off Below 1 Ω
      A59-9 (+B2) - 2 (PCU fuse terminal) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A59-10 (+B), A59-9 (+B2) or 2 (PCU fuse terminal) - Body ground and other terminals Power switch off 10 kΩ or higher
    5. Connect the inverter with converter assembly connector.
    6. Install the PCU fuse.

    NG → Refer to   21 

    OK: Go to next step 

  20. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS 

    Refer to DTC CHECK / CLEAR [08/2015 - ]

    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). Refer to  PROCEDURE - Step 26 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  23. CHECK GENERATOR CABLE. Refer to  PROCEDURE - Step 27 

    NG → Refer to   29 

    OK → Refer to   31 

  24. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION). Refer to  PROCEDURE - Step 28 

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  25. CHECK MOTOR CABLE. Refer to  PROCEDURE - Step 29 

    NG → Refer to   30 

    OK → Refer to   31 

  26. REPLACE POWER MANAGEMENT CONTROL ECU. Refer to  COMPONENTS [08/2015 - ] 
  27. CHECK FOR INTERMITTENT PROBLEMS. Refer to  CHECK FOR INTERMITTENT PROBLEMS [08/2015 - ] 
  28. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS. Refer to  DTC CHECK / CLEAR [08/2015 - ] 
  29. REPLACE GENERATOR CABLE. Refer to  COMPONENTS [08/2015 - ] 
  30. REPLACE MOTOR CABLE. Refer to  COMPONENTS [08/2015 - ] 
  31. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY. Refer to  COMPONENTS [08/2015 - ] 
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