MOTOR GENERATOR CONTROL SYSTEM, Diagnostic DTC:P1CA51D

Info Added 2017-10-06

DTC Code DTC Name
P1CA51D Hybrid Generator Circuit Current Out of Range

DTC SUMMARY


  1. MALFUNCTION DESCRIPTION

    This DTC indicates that current does not flow as commanded due to a generator output circuit malfunction. The cause of this malfunction may be one of the following:

    Area Main Malfunction Description
    Inside of inverter The connectors are not connected properly
    Hybrid vehicle transaxle assembly

    • Generator (MG1) internal malfunction (entry of foreign matter, etc.)

    • Open or short circuit in the generator coils
    Inverter low-voltage circuit Inverter with converter assembly internal circuit malfunction
    Motor cable (for MG1)

    • Defective motor cable connection condition

    • Open circuit or poor insulation in motor cable
    Hybrid vehicle control ECU Hybrid vehicle control ECU internal circuit malfunction

DESCRIPTION

For a description of the inverter.

Click here

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P1CA51D Hybrid Generator Circuit Current Out of Range

Generator system malfunction:

If current does not flow as commanded, the generator high voltage system may be malfunctioning.

Malfunction is detected when the vehicle is stopped or the engine is starting.

(1 trip detection logic)

  • Hybrid vehicle transaxle assembly

  • Inverter with converter assembly

  • Wire harness or connector

  • Hybrid vehicle control ECU

 Comes on

Master Warning Light:

Comes on

CONFIRMATION DRIVING PATTERN

Tech Tips

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click here


  1. Connect the GTS to the DLC3.

  2. Turn the power switch on (IG) and turn the GTS on.

  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

  4. Turn the power switch off and wait for 2 minutes or more.

  5. Turn the power switch on (IG) and turn the GTS on.

  6. Turn the power switch on (READY) with the shift lever in P.

  7. With the engine stopped, depress the accelerator pedal and start the engine.

  8. Release the accelerator pedal immediately. (Start and stop the engine several times)

  9. Enter the following menus: Powertrain / Motor Generator / Utility / All Readiness.

  10. Check the DTC judgment result.

    Tech Tips


    • If the judgment result shows NORMAL, the system is normal.

    • If the judgment result shows ABNORMAL, the system has a malfunction.

    • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

WIRING DIAGRAM

Refer to the wiring diagram for the Generator High-voltage Circuit.

Click here

Refer to the wiring diagram for the Shut Down Signal Circuit.

Click here

CAUTION / NOTICE / HINT

CAUTION:


  • B0048QQ

    Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.


    • Inspecting the high-voltage system

    • Disconnecting the low voltage connector of the inverter with converter assembly

    • Disconnecting the low voltage connector of the HV battery

  • A005NJP

    To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

  • A005NAH

    After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • B0048M5C01
    *a Without waiting for 10 minutes

    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

Tech Tips

If an abnormality occurs after disconnecting and connecting the motor cable, reconfirm the cable connection condition.

PROCEDURE


  1. CHECK DTC OUTPUT


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Powertrain > Motor Generator > Trouble Codes
      Result
      Result Proceed to
      P1CA51D only is output, or DTCs except the ones in the tables below are also output. A
      DTCs of hybrid control system in the tables below are output. B
      DTCs of motor generator control system in the tables below are output. C
      Table 1
      Malfunction Content Relevant DTC
      Insulation Malfunction P1C7C49 Hybrid/EV Battery Voltage System (A/C Area) Insulation Resistance Decreased
      P1C7D49 Hybrid/EV Battery Voltage System (Hybrid/EV Battery Area) Insulation Resistance Decreased
      P1C7E49 Hybrid/EV Battery Voltage System (Transaxle Area) Insulation Resistance Decreased
      P1C7F49 Hybrid/EV Battery Voltage System (Direct Current Area) Insulation Resistance Decreased
      System Main Relay or High Voltage Circuit Malfunction P0AD911 Hybrid/EV Battery Positive Contactor Circuit Short to Ground
      P0AD915 Hybrid/EV Battery Positive Contactor Circuit Short to Battery or Open
      P0ADD11 Hybrid/EV Battery Negative Contactor Circuit Short to Ground
      P0ADD15 Hybrid/EV Battery Negative Contactor Circuit Short to Battery or Open
      P1C8449 High Voltage Power Resource Circuit Short during Ready ON
      Table 2
      Malfunction Content System Relevant DTC
      Microcomputer malfunction Motor generator control system P0A1A47 Generator Control Module
      P0A1A49 Drive Motor "A" Control Module
      P0A1B1F Drive Motor "B" Control Module
      P1C2A1C Hybrid Powertrain Control Module
      P1C2A49 Generator A/D Converter Circuit
      P1C2B1C Drive Motor "A" A/D Converter Circuit
      P1C2B49 Drive Motor "B" A/D Converter Circuit
      P313383 Generator Control Module Malfunction
      P313386 Drive Motor Control Module Malfunction
      P313387 Drive Motor "B" Control Module Malfunction
      P313483 Generator Position Sensor Angle Malfunction
      P313486 Drive Motor "A" Position Sensor Angle Malfunction
      P313487 Drive Motor "B" Position Sensor Angle Malfunction
      Hybrid control system P0A1B49 Generator Position Sensor REF Signal Cycle Malfunction
      Power source circuit malfunction Motor generator control system P06B01C Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range
      P06D61C Generator Control Module Offset Power Circuit Voltage Out of Range
      Sensor and actuator circuit malfunction Motor generator control system P0A3F16 Drive Motor "A" Position Sensor Circuit Voltage Below Threshold
      P0A3F21 Drive Motor "A" Position Sensor Signal Amplitude < Minimum
      P0A3F22 Drive Motor "A" Position Sensor Signal Amplitude > Maximum
      P0A4B16 Generator Position Sensor Circuit Voltage Below Threshold
      P0A4B21 Generator Position Sensor Signal Amplitude < Minimum
      P0A4B22 Generator Position Sensor Signal Amplitude > Maximum
      P0A6012 Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Battery
      P0A6014 Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Ground or Open
      P0A601C Drive Motor "A" Phase V Current (High Resolution) Circuit Voltage Out of Range
      P0A6312 Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Battery
      P0A6314 Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Ground or Open
      P0A631C Drive Motor "A" Phase W Current (High Resolution) Circuit Voltage Out of Range
      P0BE512 Drive Motor "A" Phase U Current Sensor Circuit Short to Battery
      P0BE514 Drive Motor "A" Phase U Current Sensor Circuit Short to Ground or Open
      P0BE528 Drive Motor "A" Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
      P0BE912 Drive Motor "A" Phase V Current Sensor Circuit Short to Battery
      P0BE914 Drive Motor "A" Phase V Current Sensor Circuit Short to Ground or Open
      P0BE928 Drive Motor "A" Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
      P0BED12 Drive Motor "A" Phase W Current Sensor Circuit Short to Battery
      P0BED14 Drive Motor "A" Phase W Current Sensor Circuit Short to Ground or Open
      P0BED28 Drive Motor "A" Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
      P0BFD62 Drive Motor "A" Phase U-V-W Current Sensor Signal Compare Failure
      P0C5013 Drive Motor "A" Position Sensor Circuit "A" Circuit Open
      P0C5016 Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Below Threshold
      P0C5017 Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Above Threshold
      P0C5A13 Drive Motor "A" Position Sensor Circuit "B" Circuit Open
      P0C5A16 Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Below Threshold
      P0C5A17 Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Above Threshold
      P0C6413 Generator Position Sensor Circuit "A" Circuit Open
      P0C6416 Generator Position Sensor Circuit "A" Circuit Voltage Below Threshold
      P0C6417 Generator Position Sensor Circuit "A" Circuit Voltage Above Threshold
      P0C6913 Generator Position Sensor Circuit "B" Circuit Open
      P0C6916 Generator Position Sensor Circuit "B" Circuit Voltage Below Threshold
      P0C6917 Generator Position Sensor Circuit "B" Circuit Voltage Above Threshold
      P0D2D16 Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Below Threshold
      P0D2D17 Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold
      P0DFA62 Generator Phase U-V-W Current Sensor Signal Compare Failure
      P0E0012 Generator Phase U Current Sensor Circuit Short to Battery
      P0E0014 Generator Phase U Current Sensor Circuit Short to Ground or Open
      P0E0028 Generator Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
      P0E0412 Generator Phase V Current Sensor Circuit Short to Battery
      P0E0414 Generator Phase V Current Sensor Circuit Short to Ground or Open
      P0E0428 Generator Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
      P0E0812 Generator Phase W Current Sensor Circuit Short to Battery
      P0E0814 Generator Phase W Current Sensor Circuit Short to Ground or Open
      P0E0828 Generator Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
      P0E3116 DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Below Threshold
      P0E3117 DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Above Threshold
      P0E5111 DC/DC Converter Current Sensor Circuit Short to Ground
      P0E5115 DC/DC Converter Current Sensor Circuit Short to Battery or Open
      P0E512A DC/DC Converter Current Sensor Signal Stuck In Range
      P1CAC49 Generator Position Sensor Internal Electronic Failure
      P1CAD49 Drive Motor "A" Position Sensor Internal Electronic Failure
      P1CAF38 Generator Position Sensor REF Signal Cycle Malfunction Signal Frequency Incorrect
      P1CB038 Drive Motor "A" Position Sensor REF Signal Frequency Incorrect
      Hybrid control system P0C7600 Hybrid/EV Battery System Discharge Time Too Long
      P0D2D1C Drive Motor "A" Inverter after Boosting Voltage Sensor Circuit Voltage Out of Range
      P0E311C Drive Motor "A" Inverter before Boosting Voltage Sensor Circuit Voltage Out of Range
      P1C2D62 Drive Motor "A" Inverter before Boosting Voltage Sensor Signal Compare Failure
      System malfunction Motor generator control system P0A7873 Drive Motor "A" Inverter Actuator Stuck Closed
      P0A7A73 Generator Inverter Actuator Stuck Closed
      P0A9000 Drive Motor "A" Performance
      P0A9200 Hybrid Generator Performance

      Tech Tips


      • P1CA51D may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM) Click here

    A

  2. CHECK DIAGNOSIS RELATED INFORMATION


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Motor Generator / Utility / Diagnosis Related Information.


      Powertrain > Motor Generator > Utility
      Tester Display
      Diagnosis Related Information

    4. Read the diagnosis related information.

      Result
      Result Proceed to
      P0A9200 is output A
      Other than above B

    5. Turn the power switch off.


    A

    GO TO DTC CHART (P0A9200) Click here

    B

  3. CHECK FREEZE FRAME DATA AND DIAGNOSIS RELATED INFORMATION


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Motor Generator / Utility / Diagnosis Related Information.


      Powertrain > Motor Generator > Utility
      Tester Display
      Diagnosis Related Information

    4. Enter the following menus: Powertrain / Motor Generator / Trouble Codes.


      Powertrain > Motor Generator > Trouble Codes

    5. Read the diagnosis related information and freeze frame data of DTC P1CA51D.

      Result
      Result Proceed to
      DTC P31241F or P312487 is listed in Diagnosis Related Information. A
      DTC P31241F and P312487 are not listed in Diagnosis Related Information and the value of freeze frame data item Emergency Shutdown Signal is ON. B
      Other than above C

    6. Turn the power switch off.


    A

    GO TO DTC CHART (P312487) Click here

    B

    GO TO DTC CHART (P321E9F) Click here

    C

  4. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    Result
    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    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. A005MZX

      Check the connection condition of the low voltage connectors of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and the connector for water and foreign matter.

      Click here

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the claws of the lock levers are engaged and that the connector cannot be pulled off.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

      Tech Tips

      When connecting the connector, connect it with the lock levers raised. Rotate each lock lever downward and make sure that the connector is securely connected. When a lock lever is fully lowered, a click will be heard as its claw engages. After the click is heard, pull up on the connector to confirm that it is securely connected.


    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  5. CHECK SHUT DOWN SIGNAL CIRCUIT

    Click here

    Result
    Proceed to
    NEXT

    NEXT

  6. CHECK GENERATOR HIGH-VOLTAGE CIRCUIT

    Click here

    Tech Tips

    If the "Generator High-voltage Circuit" inspection results are normal, perform the next step.

    Result
    Proceed to
    NEXT

    NEXT

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here