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

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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.

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WIRING DIAGRAM

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

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INSPECTION PROCEDURE

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PROCEDURE

1. Click here

   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.

      Tip:

      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.

   
   
   • OKClick here
   • NGClick here
2. Click here

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

   
   
   1. 

      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.

   
   
   • OKClick here
   • NGClick here
3. Click here

   CHECK GENERATOR RESOLVER

   
   
   1. 

      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

   
   
   • OKClick here
   • NGClick here
4. Click here

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

   
   

   1. Turn the power switch on (IG).

   2. 

      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.

   
   
   • OKClick here
   • NGClick here
5. Click here

   CHECK MOTOR RESOLVER

   
   

   1. 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 A79-40 (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

   
   
   • OKClick here
   • NGClick here
6. Click here

   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.

   
   
   • OKClick here
   • NGClick here
7. Click here

   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

   
   
   • AClick here
   • BClick here
   • CClick here
8. Click here

   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.

   
   
   • OKClick here
   • NGClick here
9. Click here

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

   
   
   1. 

      Disconnect the generator resolver connector.

   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) - E62-1 (GRF) Power switch off Below 1 Ω A79-9 (GRFG) - E62-5 (GRFG) Power switch off Below 1 Ω A79-18 (GSN) - E62-2 (GSN) Power switch off Below 1 Ω A79-7 (GSNG) - E62-6 (GSNG) Power switch off Below 1 Ω A79-17 (GCS) - E62-3 (GCS) Power switch off Below 1 Ω A79-6 (GCSG) - E62-7 (GCSG) Power switch off Below 1 Ω
      RHD
      Tester Connection Switch Condition Specified Condition A88-20 (GRF) - E62-1 (GRF) Power switch off Below 1 Ω A88-9 (GRFG) - E62-5 (GRFG) Power switch off Below 1 Ω A88-18 (GSN) - E62-2 (GSN) Power switch off Below 1 Ω A88-7 (GSNG) - E62-6 (GSNG) Power switch off Below 1 Ω A88-17 (GCS) - E62-3 (GCS) Power switch off Below 1 Ω A88-6 (GCSG) - E62-7 (GCSG) Power switch off Below 1 Ω

      Standard resistance (Check for short)
      LHD
      Tester Connection Switch Condition Specified Condition A79-20 (GRF) or E62-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher A79-9 (GRFG) or E62-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A79-18 (GSN) or E62-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher A79-7 (GSNG) or E62-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A79-17 (GCS) or E62-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher A79-6 (GCSG) or E62-7 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      RHD
      Tester Connection Switch Condition Specified Condition A88-20 (GRF) or E62-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher A88-9 (GRFG) or E62-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A88-18 (GSN) or E62-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher A88-7 (GSNG) or E62-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A88-17 (GCS) or E62-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher A88-6 (GCSG) or E62-7 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tip:

      The generator resolver is not available separately. If it requires replacement, replace the hybrid vehicle transmission assembly.

   
   
   • OKClick here
   • NGClick here
10. Click here

    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.

    
    
    • OKClick here
    • NGClick here
11. Click here

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

    
    
    1. 

       Disconnect the motor resolver connector.

    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 A79-40 (MRF) - E63-1 (MRF) Power switch off Below 1 Ω A79-29 (MRFG) - E63-5 (MRFG) Power switch off Below 1 Ω A79-39 (MSN) - E63-2 (MSN) Power switch off Below 1 Ω A79-28 (MSNG) - E63-6 (MSNG) Power switch off Below 1 Ω A79-38 (MCS) - E63-3 (MCS) Power switch off Below 1 Ω A79-27 (MCSG) - E63-7 (MCSG) Power switch off Below 1 Ω
       RHD
       Tester Connection Switch Condition Specified Condition A88-40 (MRF) - E63-1 (MRF) Power switch off Below 1 Ω A88-29 (MRFG) - E63-5 (MRFG) Power switch off Below 1 Ω A88-39 (MSN) - E63-2 (MSN) Power switch off Below 1 Ω A88-28 (MSNG) - E63-6 (MSNG) Power switch off Below 1 Ω A88-38 (MCS) - E63-3 (MCS) Power switch off Below 1 Ω A88-27 (MCSG) - E63-7 (MCSG) Power switch off Below 1 Ω

       Standard resistance (Check for short)
       LHD
       Tester Connection Switch Condition Specified Condition A79-40 (MRF) or E63-1 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher A79-29 (MRFG) or E63-5 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A79-39 (MSN) or E63-2 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher A79-28 (MSNG) or E63-6 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A79-38 (MCS) or E63-3 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher A79-27 (MCSG) or E63-7 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
       RHD
       Tester Connection Switch Condition Specified Condition A88-40 (MRF) or E63-1 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher A88-29 (MRFG) or E63-5 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher A88-39 (MSN) or E63-2 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher A88-28 (MSNG) or E63-6 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher A88-38 (MCS) or E63-3 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher A88-27 (MCSG) or E63-7 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

       Tip:

       The motor resolver is not available separately. If it requires replacement, replace the hybrid vehicle transmission assembly.

    
    
    • OKClick here
    • NGClick here
12. Click here

    CONNECT SECURELY

13. Click here

    REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here

14. Click here

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here

15. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

16. Click here

    REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here