HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A4B-253, P0A4C-513, P0A4D-255

DTC Code DTC Name
P0A4B-253 Generator Position Sensor Circuit
P0A4C-513 Generator Position Sensor Circuit Range / Performance
P0A4D-255 Generator Position Sensor Circuit Low

DESCRIPTION

A resolver is a sensor that is used to detect the position of the magnetic poles of the rotor of a motor generator. Knowing the position of the poles is indispensable for ensuring precise control of MG2 and MG1.

Each resolver contains a stator that has an excitation coil and 2 detection coils (S, C) Click here.

The inverter with converter assembly (MG ECU) monitors output signals from the generator resolver and detects malfunctions.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A4B 253 Interphase short in the generator resolver circuit

  • Wire harness or connector

  • Hybrid vehicle transmission assembly

  • Inverter with converter assembly
P0A4C 513 Generator resolver output is out of the normal range
P0A4D 255 Open or short in the generator resolver circuit

WIRING DIAGRAM

Refer to the wiring diagram for DTC0A3F-243 Click here.

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 disconnecting 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.

Note

Check for output DTCs again after the repair has been completed. If P0A78-286 or P0A7A-324 is output, replace the inverter with converter assembly.

Tech Tips


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

  • 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.

PROCEDURE


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

    CAUTION:

    Be sure to wear insulated gloves.

    Note

    Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector cannot be pulled out.


    1. Turn the power switch off.

    2. Remove the service plug grip Click here.

      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.

    3. Check the connection of the low voltage connector of the inverter with converter assembly.

      OK
      The connector is connected securely and there are no contact problems.

      Tech Tips

      When connecting the connector, insert it with the locking lever in the raised position. Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage. After the click is heard, pull up on the connector to confirm that it is properly connected.


    NG

    CONNECT SECURELY

    OK

  2. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)


    1. A01H1UUE04

      Disconnect the low voltage connector from the inverter with converter assembly.

    2. Turn the power switch on (IG).

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

      Standard voltage
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A79-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A79-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A79-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A79-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A79-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A88-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A88-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A88-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A88-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A88-6 (GCSG) - Body ground Power switch on (IG) Below 1 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.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. CHECK GENERATOR RESOLVER


    1. A01H1UUE04

      Turn the power switch off.

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

      Standard resistance (Check for open)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) - A79-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A79-18 (GSN) - A79-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A79-17 (GCS) - A79-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) - A88-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A88-18 (GSN) - A88-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A88-17 (GCS) - A88-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      Standard resistance (Check for short)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) or A79-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-18 (GSN) or A79-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-17 (GCS) or A79-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) or A88-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-18 (GSN) or A88-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-17 (GCS) or A88-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    NG

    Click here

    OK

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


    1. Turn the power switch on (IG).

    2. A01H1UUE03

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

      Standard voltage
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A79-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A79-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A79-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A79-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A79-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A88-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A88-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A88-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A88-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A88-27 (MCSG) - Body ground Power switch on (IG) Below 1 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.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  5. CHECK MOTOR RESOLVER


    1. Turn the power switch off.

    2. A01H1UUE03

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

      Standard resistance (Check for open)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) - A79-29 (MRFG) Power switch off 4.5 to 16.8 Ω
      A79-39 (MSN) - A79-28 (MSNG) Power switch off 9.3 to 27.8 Ω
      A79-38 (MCS) - A79-27 (MCSG) Power switch off 12.4 to 30.7 Ω
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) - A88-29 (MRFG) Power switch off 4.5 to 16.8 Ω
      A88-39 (MSN) - A88-28 (MSNG) Power switch off 9.3 to 27.8 Ω
      A88-38 (MCS) - A88-27 (MCSG) Power switch off 12.4 to 30.7 Ω
      Standard resistance (Check for short)
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) or A79-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-39 (MSN) or A79-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A79-38 (MCS) or A79-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) or A88-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-39 (MSN) or A88-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A88-38 (MCS) or A88-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    NG

    Click here

    OK

  6. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


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

      OK
      The connector is connected securely and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  7. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. 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.

      OK
      The connector is connected securely and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.

      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    CONNECT SECURELY

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  8. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


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

      OK
      The connector is connected securely and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.


    NG

    CONNECT SECURELY

    OK

  9. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)


    1. A01H1UUE04

      Disconnect the low voltage connector from the inverter with converter assembly.

    2. Turn the power switch on (IG).

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

      Standard voltage
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A79-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A79-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A79-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A79-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A79-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A88-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A88-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A88-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A88-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A88-6 (GCSG) - Body ground Power switch on (IG) Below 1 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.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  10. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. 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.

      OK
      The connector is connected securely and there are no contact problems.

      Note

      If the terminals connect poorly, are damaged, or contain water or foreign matter, repair or replace the wire harness or connector.

      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    NG

    CONNECT SECURELY

    OK

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


    1. Turn the power switch on (IG).

    2. A01H1UUE03

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

      Standard voltage
      LHD
      Tester Connection Switch Condition Specified Condition
      A79-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A79-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A79-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A79-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A79-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A79-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      RHD
      Tester Connection Switch Condition Specified Condition
      A88-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A88-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A88-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A88-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A88-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A88-27 (MCSG) - Body ground Power switch on (IG) Below 1 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.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here