HYBRID CONTROL SYSTEM, Diagnostic DTC:P1CAD-168, P1CB0-795, P1CB3-796

DTC Code	DTC Name
P1CAD-168	Drive Motor "A" Position Sensor Angle Malfunction
P1CB0-795	Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
P1CB3-796	Drive Motor "A" Position Sensor REF Signal Stop Malfunction

DESCRIPTION

The MG ECU located in the inverter with converter assembly monitors its internal operation and detects malfunctions.

Tech Tips

The term "drive motor A" indicates MG2.

DTC No.	INF Code	DTC Detection Condition	Trouble Area
P1CAD	168	The difference between the resolver angle for control and estimated resolver angle exceeds the allowable value.	Inverter with converter assembly Hybrid vehicle transmission assembly Wire harness or connector
P1CB0	795	Resolver REF signal cycle error
P1CB3	796	Resolver REF signal oscillation stop error

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.

PROCEDURE

CHECK DTC OUTPUT (HYBRID CONTROL)

Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

Check if DTCs are output.

Result

Result	Proceed to
P1CAD-168, P1CB0-795 or P1CB3-796 only is output.	A
Any of the following DTCs are also output.	B

DTC No.	Relevant Diagnosis
P0A3F-243	Drive Motor "A" Position Sensor Circuit
P0A40-500	Drive Motor "A" Position Sensor Circuit Range / Performance
P0A41-245	Drive Motor "A" Position Sensor Circuit Low
P0A4B-253	Generator Position Sensor Circuit

Turn the power switch off.

GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

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.
  
  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

Text in Illustration
*A	for LHD	*B	for RHD

OK
The connectors are connected securely and there are no contact pressure problems.

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

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the connector from the inverter with converter assembly.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).

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.

Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Connect the inverter with converter assembly connector.

REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK GENERATOR RESOLVER

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the connector from the inverter with converter assembly.

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

Connect the inverter with converter assembly connector.

CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

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

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the connector from the inverter with converter assembly.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).

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.

Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Connect the inverter with converter assembly connector.

REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK MOTOR RESOLVER

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the connector from the inverter with converter assembly.

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

Connect the inverter with converter assembly connector.

CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) 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 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
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 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
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 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

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

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

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

CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR RESOLVER)

Disconnect the resolver connector.

*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

Reconnect the resolver connector.

Result

Proceed to
OK
NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY 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 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

CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MOTOR RESOLVER)

Disconnect the resolver connector.

*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

Reconnect the resolver connector.

Result

Proceed to
OK
NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here