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HYBRID CONTROL SYSTEM Motor Resolver Circuit

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DTC Code DTC Name
  Motor Resolver Circuit
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DESCRIPTION

The cause of this malfunction may be the motor resolver.

Check the motor resolver internal resistance and the connection condition from the inverter to the resolver.

Table 1. Related Parts Check
Area Inspection Step
Wire harness and connector between the inverter and motor resolver Check for short circuit between wire harness and +B side. 1
Resolver, wire harness, connector Check the internal resistance of resolver (including wire harness), body ground resistance, and connector connection condition. 2, 3
Resolver Check for open or short circuit in resolver. 4
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SYSTEM DESCRIPTION

A resolver is a sensor that is used to detect the position of the magnetic poles of the rotor of a motor. Knowing the position of the poles is indispensable for ensuring precise control of the motor (MG2).

Each resolver contains a stator that has an excitation coil and 2 detection coils (S, C). The gap between the stator and rotor changes as the rotor turns because the rotor is oval shaped. An alternating current with a predetermined frequency flows through the excitation coil, and detection coils S and C output alternating currents in accordance with the sensor rotor position.

The MG ECU, which is built into the inverter with converter assembly, detects the absolute position of the rotor according to the phases of detection coils S and C and the heights of their waveforms. Furthermore, the CPU calculates the amount of change in the position within a predetermined length of time, in order to use the resolver as a revolution speed sensor.

The MG ECU monitors signals output from the motor resolver and detects malfunctions.

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WIRING DIAGRAM

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CAUTION / NOTICE / HINT

This step is referenced from the procedures for each DTC.

If the inspection results below are normal, perform the next procedure for the referenced DTC.

CAUTION:

  • B004STG

    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

  • B004Y5N

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

  • B004SX1

    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.

  • B004W3JC06
    *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.

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    Tip:

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

  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

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.

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Tip:

  • If the problem symptom cannot be reproduced, performing a road test on a road on which the vehicle tends to vibrate will make it easier to reproduce the symptom.

  • If the resolver is malfunctioning, the vehicle may not drive smoothly.

  • When inspecting the connectors, if it is difficult to judge if a connector was disconnected, deformed or improperly secured, disconnect and reconnect the connector and then check for DTCs again. Check if the same DTC is output. If the same DTC is not output, improper connection of connectors is suspected.

  • As a malfunction detection threshold may be exceeded when performing the vibration or heat connector inspections, make sure to perform the following inspection to check that the DTC was not stored due to the malfunction of a part.

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PROCEDURE


  1. Click here

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER)

    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 A94*1, A78*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

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

    4. Turn the power switch on (IG).

    5. B004TPFC44
      *A for LHD
      *B for RHD
      *a

      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
      Table 2. for LHD:
      Tester Connection Condition Specified Condition
      A94-12 (MRF) - Body ground Power switch on (IG) Below 1 V
      A94-23 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A94-1 (MSN) - Body ground Power switch on (IG) Below 1 V
      A94-2 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A94-4 (MCS) - Body ground Power switch on (IG) Below 1 V
      A94-3 (MCSG) - Body ground Power switch on (IG) Below 1 V
      Table 3. for RHD:
      Tester Connection Condition Specified Condition
      A78-12 (MRF) - Body ground Power switch on (IG) Below 1 V
      A78-23 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A78-1 (MSN) - Body ground Power switch on (IG) Below 1 V
      A78-2 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A78-4 (MCS) - Body ground Power switch on (IG) Below 1 V
      A78-3 (MCSG) - Body ground Power switch on (IG) Below 1 V
      Note:

      Turning the power switch on (IG) with the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.

    8. Reconnect the A94*1, A78*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

      Result
      Proceed to
      OK
      NG

    • OKClick here
    • NG

      REPAIR OR REPLACE HARNESS OR CONNECTOR

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    CHECK MOTOR RESOLVER

    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 A94*1, A78*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. B004TPFC44
      *A for LHD
      *B for RHD
      *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 (Check for Open)
      Table 4. for LHD:
      Tester Connection Condition Specified Condition
      A94-12 (MRF) - A94-23 (MRFG) Power switch off 9.1 to 15.2 Ω
      A94-1 (MSN) - A94-2 (MSNG) Power switch off 16.4 to 28.4 Ω
      A94-4 (MCS) - A94-3 (MCSG) Power switch off 18.4 to 30.4 Ω
      Table 5. for RHD:
      Tester Connection Condition Specified Condition
      A78-12 (MRF) - A78-23 (MRFG) Power switch off 9.1 to 15.2 Ω
      A78-1 (MSN) - A78-2 (MSNG) Power switch off 16.4 to 28.4 Ω
      A78-4 (MCS) - A78-3 (MCSG) Power switch off 18.4 to 30.4 Ω
      Tip:

      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 (°F).)

      Standard Resistance (Check for Short)
      Table 6. for LHD:
      Tester Connection Condition Specified Condition
      A94-12 (MRF) or A94-23 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A94-1 (MSN) or A94-2 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A94-4 (MCS) or A94-3 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 7. for RHD:
      Tester Connection Condition Specified Condition
      A78-12 (MRF) or A78-23 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A78-1 (MSN) or A78-2 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A78-4 (MCS) or A78-3 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the A94*1, A78*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

      Result
      Proceed to
      OK
      NG

    • OK

      MOTOR RESOLVER CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

    • NGClick here
  3. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B004Y45

      Check the connection condition of the motor resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

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      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

    • AClick here
    • B

      CONNECT SECURELY

    • C

      REPAIR OR REPLACE HARNESS OR CONNECTOR

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    INSPECT HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR RESOLVER)


    1. Disconnect the D39 motor resolver connector.

    2. B004UCTC26
      *a

      Component without harness connected

      (Motor Resolver (Hybrid Vehicle Transmission Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      D39-1 (MRF) - D39-7 (MRFG) Power switch off 8.8 to 14.8 Ω
      D39-2 (MSN) - D39-6 (MSNG) Power switch off 16.2 to 28.0 Ω
      D39-3 (MCS) - D39-5 (MCSG) Power switch off 18.1 to 30.0 Ω
      Tip:

      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 (°F).)

      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      D39-1 (MRF) - Body ground and other terminals (except D39-7 (MRFG)) Power switch off 1 MΩ or higher
      D39-7 (MRFG) - Body ground and other terminals (except D39-1 (MRF)) Power switch off 1 MΩ or higher
      D39-2 (MSN) - Body ground and other terminals (except D39-6 (MSNG)) Power switch off 1 MΩ or higher
      D39-6 (MSNG) - Body ground and other terminals (except D39-2 (MSN)) Power switch off 1 MΩ or higher
      D39-3 (MCS) - Body ground and other terminals (except D39-5 (MCSG)) Power switch off 1 MΩ or higher
      D39-5 (MCSG) - Body ground and other terminals (except D39-3 (MCS)) Power switch off 1 MΩ or higher

    3. Reconnect the D39 motor resolver connector.

      Result
      Proceed to
      OK
      NG

    • OK

      REPAIR OR REPLACE HARNESS OR CONNECTOR

    • NG

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY for 2WD:

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY for AWD:

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here