HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A40-500, P0A41-245

DTC Code DTC Name
P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
P0A41-245 Drive Motor "A" Position Sensor Circuit Low

DESCRIPTION

Refer to the description for DTC P0A3F-243 Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A40 500 Motor resolver output is out of the normal range

  • Inverter with converter assembly

  • Hybrid vehicle transmission assembly

  • Wire harness or connector
P0A41 245 Open or short in the motor resolver circuit

WIRING DIAGRAM

Refer to the wiring diagram for DTC P1CAC-200 Click here.

CAUTION / NOTICE / HINT

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 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.

  • 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

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.


    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. Check the connector connections and contact pressure of the low voltage connectors of the inverter with converter assembly Click here.

      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.

      B002BBWE01
      Text in Illustration
      *A for LHD *B for RHD
      OK
      The connectors are connected securely and there are no contact pressure 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)

    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 connector from the inverter with converter assembly.

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

    4. Turn the power switch on (IG).

    5. B002BKAE02
      Text in Illustration
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A38-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A38-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A38-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A38-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A38-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A74-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A74-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A74-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A74-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A74-6 (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.

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal.

    8. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. CHECK GENERATOR 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 connector from the inverter with converter assembly.

    3. B002BKAE02
      Text in Illustration
      *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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - A38-9 (GRFG) Power switch off 5.8 to 11.8 Ω
      A38-18 (GSN) - A38-7 (GSNG) Power switch off 11.7 to 17.7 Ω
      A38-17 (GCS) - A38-6 (GCSG) Power switch off 11.7 to 17.7 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - A74-9 (GRFG) Power switch off 5.8 to 11.8 Ω
      A74-18 (GSN) - A74-7 (GSNG) Power switch off 11.7 to 17.7 Ω
      A74-17 (GCS) - A74-6 (GCSG) Power switch off 11.7 to 17.7 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) or A38-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-18 (GSN) or A38-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-17 (GCS) or A38-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) or A74-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-18 (GSN) or A74-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-17 (GCS) or A74-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

  4. 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 connector from the inverter with converter assembly.

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

    4. Turn the power switch on (IG).

    5. B002B4ZE02
      Text in Illustration
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A38-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A38-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A38-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A38-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A38-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A74-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A74-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A74-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A74-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A74-27 (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.

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal.

    8. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  5. 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 connector from the inverter with converter assembly.

    3. B002B4ZE02
      Text in Illustration
      *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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - A38-29 (MRFG) Power switch off 6.0 to 12.0 Ω
      A38-39 (MSN) - A38-28 (MSNG) Power switch off 12.5 to 24.5 Ω
      A38-38 (MCS) - A38-27 (MCSG) Power switch off 12.5 to 24.5 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - A74-29 (MRFG) Power switch off 6.0 to 12.0 Ω
      A74-39 (MSN) - A74-28 (MSNG) Power switch off 12.5 to 24.5 Ω
      A74-38 (MCS) - A74-27 (MCSG) Power switch off 12.5 to 24.5 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) or A38-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-39 (MSN) or A38-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-38 (MCS) or A38-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) or A74-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-39 (MSN) or A74-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-38 (MCS) or A74-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Connect the inverter with converter assembly connector.


    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

  6. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B002BKT

      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 Click here.

      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. B002B4I

      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 Click here.

      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.


    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    NG

    CONNECT SECURELY

  8. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B002BKT

      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 Click here.

      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 HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR RESOLVER)


    1. Disconnect the resolver connector.

    2. B002B72C15
      *a

      Component without harness connected

      (Generator 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
      1 (GRF) - 5 (GRFG) Power switch off 5.8 to 11.8 Ω
      2 (GSN) - 6 (GSNG) Power switch off 11.7 to 17.7 Ω
      3 (GCS) - 7 (GCSG) Power switch off 11.7 to 17.7 Ω

      Tech Tips

      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
      1 (GRF) - Body ground and other terminals (except 5 (GRFG)) Power switch off 1 MΩ or higher
      5 (GRFG) - Body ground and other terminals (except 1 (GRF)) Power switch off 1 MΩ or higher
      2 (GSN) - Body ground and other terminals (except 6 (GSNG)) Power switch off 1 MΩ or higher
      6 (GSNG) - Body ground and other terminals (except 2 (GSN)) Power switch off 1 MΩ or higher
      3 (GCS) - Body ground and other terminals (except 7 (GCSG)) Power switch off 1 MΩ or higher
      7 (GCSG) - Body ground and other terminals (except 3 (GCS)) Power switch off 1 MΩ or higher

    3. Reconnect the resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

  10. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B002B4I

      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 Click here.

      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

  11. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR RESOLVER)


    1. Disconnect the resolver connector.

    2. B002B72C14
      *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
      1 (MRF) - 5 (MRFG) Power switch off 6.0 to 12.0 Ω
      2 (MSN) - 6 (MSNG) Power switch off 12.5 to 24.5 Ω
      3 (MCS) - 7 (MCSG) Power switch off 12.5 to 24.5 Ω

      Tech Tips

      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
      1 (MRF) - Body ground and other terminals (except 5 (MRFG)) Power switch off 1 MΩ or higher
      5 (MRFG) - Body ground and other terminals (except 1 (MRF)) Power switch off 1 MΩ or higher
      2 (MSN) - Body ground and other terminals (except 6 (MSNG)) Power switch off 1 MΩ or higher
      6 (MSNG) - Body ground and other terminals (except 2 (MSN)) Power switch off 1 MΩ or higher
      3 (MCS) - Body ground and other terminals (except 7 (MCSG)) Power switch off 1 MΩ or higher
      7 (MCSG) - Body ground and other terminals (except 3 (MCS)) Power switch off 1 MΩ or higher

    3. Reconnect the resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here