HYBRID CONTROL SYSTEM, Diagnostic DTC:P1CAC-200, P1CAF-792, P1CB2-793

DTC Code DTC Name
P1CAC-200 Generator Position Sensor Angle Malfunction
P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction

DESCRIPTION

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

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P1CAC-200 Generator Position Sensor Angle Malfunction The difference between the resolver angle for control and estimated resolver angle exceeds the allowable value.

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction Resolver REF signal cycle error

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction Resolver REF signal oscillation stop error

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on

WIRING DIAGRAM

A0031ZEE01
*a Motor Resolver
*b Generator Resolver
*c Inverter with Converter Assembly (MG ECU)
*d Hybrid Vehicle Transaxle Assembly

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


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Result
      Result Proceed to
      P1CAC-200, P1CAF-792 or P1CB2-793 only is output, or DTCs except the ones in the table below are also output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

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

    Result
    Proceed to
    OK
    NG

    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. A01SFRS

      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 does not pull out.

      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.

      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  3. 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 B179 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. A0031ZXC08
      *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
      Tester Connection Condition Specified Condition
      B179-11 (GRF) - Body ground Power switch on (IG) Below 1 V
      B179-12 (GRFG) - Body ground Power switch on (IG) Below 1 V
      B179-7 (GSN) - Body ground Power switch on (IG) Below 1 V
      B179-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      B179-10 (GCS) - Body ground Power switch on (IG) Below 1 V
      B179-9 (GCSG) - 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.

    8. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  4. 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 B179 inverter with converter assembly connector.

    3. A0031ZXC08
      *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)
      Tester Connection Condition Specified Condition
      B179-11 (GRF) - B179-12 (GRFG) Power switch off 7.1 to 21.6 Ω
      B179-7 (GSN) - B179-8 (GSNG) Power switch off 13.7 to 34.5 Ω
      B179-10 (GCS) - B179-9 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B179-11 (GRF) or B179-12 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-7 (GSN) or B179-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-10 (GCS) or B179-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) Click here

    OK

  5. 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 B179 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. A0031ZXC07
      *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
      Tester Connection Condition Specified Condition
      B179-1 (MRF) - Body ground Power switch on (IG) Below 1 V
      B179-2 (MRFG) - Body ground Power switch on (IG) Below 1 V
      B179-3 (MSN) - Body ground Power switch on (IG) Below 1 V
      B179-4 (MSNG) - Body ground Power switch on (IG) Below 1 V
      B179-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      B179-5 (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.

    8. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. 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 B179 inverter with converter assembly connector.

    3. A0031ZXC07
      *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)
      Tester Connection Condition Specified Condition
      B179-1 (MRF) - B179-2 (MRFG) Power switch off 7.1 to 21.6 Ω
      B179-3 (MSN) - B179-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      B179-6 (MCS) - B179-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B179-1 (MRF) or B179-2 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-3 (MSN) or B179-4 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B179-6 (MCS) or B179-5 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the B179 inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) Click here

    OK

  7. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A003237

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  8. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A0031Y3

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CONNECT SECURELY

  9. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A0031Y3

      Check the connection of the motor resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  10. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)


    1. A0031Y3N01

      Disconnect the B168 motor resolver connector.

    2. A00324EC01
      *a

      Component without harness connected

      (Motor Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      B168-3 (MRF) - B168-6 (MRFG) Power switch off 7.1 to 21.6 Ω
      B168-1 (MSN) - B168-4 (MSNG) Power switch off 13.7 to 34.5 Ω
      B168-2 (MCS) - B168-5 (MCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B168-3 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-6 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-1 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-4 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-2 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      B168-5 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

      The motor resolver is not available as a supply part. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Reconnect the B168 motor resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

  11. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A003237

      Check the connection of the generator resolver connector.

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  12. INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)


    1. A003237N01

      Disconnect the B166 generator resolver connector.

    2. A00328TC03
      *a

      Component without harness connected

      (Generator Resolver (Hybrid Vehicle Transaxle Assembly))

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      B166-1 (GRF) - B166-5 (GRFG) Power switch off 7.1 to 21.6 Ω
      B166-2 (GSN) - B166-6 (GSNG) Power switch off 13.7 to 34.5 Ω
      B166-3 (GCS) - B166-7 (GCSG) Power switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      B166-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      B166-7 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

      The generator resolver is not available as a supply part. If it requires replacement, replace the hybrid vehicle transaxle assembly.

    3. Reconnect the B166 generator resolver connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    NG

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here