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

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Info Added 2017-08-02

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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
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DESCRIPTION

A resolver is a sensor that is used to detect the position of the magnetic poles 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). The gap between the stator and rotor changes as the rotor turns because the rotor is oval shaped. An alternating current with a predetermined frequency flows through the excitation coil, and detection coils S and C output alternating currents in accordance with the sensor rotor position.

The MG ECU located in the inverter with converter assembly detects the absolute position of the rotor according to the phases of detection coils S and C and the heights of their waveforms. Furthermore, the CPU calculates the amount of change in the position within a predetermined length of time, in order to use the resolver as a speed sensor.

The MG ECU monitors signals output from the motor resolver and detects malfunctions.

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

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Wire harness or connector
P0A4C 513 Generator resolver output is out of the normal range
P0A4D 255 Open or short in the generator resolver circuit
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WIRING DIAGRAM

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

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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).

    Tip:

    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.

Tip:

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.

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PROCEDURE


  1. 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. A00046KE03

      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.
      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.


  2. Click here

    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 D3 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. B001VF3E02

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      D3-1 (GRF) - Body ground Power switch on (IG) Below 1 V
      D3-7 (GRFG) - Body ground Power switch on (IG) Below 1 V
      D3-2 (GSN) - Body ground Power switch on (IG) Below 1 V
      D3-8 (GSNG) - Body ground Power switch on (IG) Below 1 V
      D3-3 (GCS) - Body ground Power switch on (IG) Below 1 V
      D3-9 (GCSG) - Body ground Power switch on (IG) Below 1 V
      Table 1. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      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. Reconnect the D3 inverter with converter assembly connector.


    • OKClick here
    • NG

      REPAIR OR REPLACE HARNESS OR CONNECTOR

  3. Click here

    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 D3 inverter with converter assembly connector.

    3. B001VF3E02

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      D3-1 (GRF) - D3-7 (GRFG) Power switch off 4.2 to 12.5 Ω
      D3-2 (GSN) - D3-8 (GSNG) Power switch off 9.8 to 20.1 Ω
      D3-3 (GCS) - D3-9 (GCSG) Power switch off 9.8 to 20.1 Ω
      Tip:

      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
      D3-1 (GRF) or D3-7 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D3-2 (GSN) or D3-8 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D3-3 (GCS) or D3-9 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 2. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    4. Reconnect the D3 inverter with converter assembly connector.


  4. Click here

    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 D3 inverter with converter assembly connector.

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

    4. Turn the power switch on (IG).

    5. B001VCME02

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      D3-4 (MRF) - Body ground Power switch on (IG) Below 1 V
      D3-11 (MRFG) - Body ground Power switch on (IG) Below 1 V
      D3-5 (MSN) - Body ground Power switch on (IG) Below 1 V
      D3-12 (MSNG) - Body ground Power switch on (IG) Below 1 V
      D3-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      D3-13 (MCSG) - Body ground Power switch on (IG) Below 1 V
      Table 3. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      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. Reconnect the D3 inverter with converter assembly connector.


    • OKClick here
    • NG

      REPAIR OR REPLACE HARNESS OR CONNECTOR

  5. Click here

    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 D3 inverter with converter assembly connector.

    3. B001VCME02

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      D3-4 (MRF) - D3-11 (MRFG) Power switch off 4.2 to 12.5 Ω
      D3-5 (MSN) - D3-12 (MSNG) Power switch off 9.8 to 20.1 Ω
      D3-6 (MCS) - D3-13 (MCSG) Power switch off 9.8 to 20.1 Ω
      Tip:

      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
      D3-4 (MRF) or D3-11 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D3-5 (MSN) or D3-12 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D3-6 (MCS) or D3-13 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      Table 4. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    4. Reconnect the D3 inverter with converter assembly connector.


  6. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B001VD0

      Check the connection of the generator resolver connector.

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

  7. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B001VHU

      Check the connection of the motor resolver connector.

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

    • OK

      REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)

    • NG

      CONNECT SECURELY

  8. Click here

    CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. B001VD0

      Check the connection of the generator resolver connector.

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

  9. Click here

    INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)


    1. B001VD0E08

      Disconnect the D12 generator resolver connector.

    2. B001VHYC01
      *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
      D12-1 (GRF) - D12-6 (GRFG) Power switch off 5.8 to 11.8 Ω
      D12-2 (GSN) - D12-7 (GSNG) Power switch off 11.7 to 17.7 Ω
      D12-3 (GCS) - D12-8 (GCSG) Power switch off 11.7 to 17.7 Ω
      Tip:

      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
      D12-1 (GRF) - Body ground and other terminals (except 6 (GRFG)) Power switch off 1 MΩ or higher
      D12-6 (GRFG) - Body ground and other terminals (except 1 (GRF)) Power switch off 1 MΩ or higher
      D12-2 (GSN) - Body ground and other terminals (except 7 (GSNG)) Power switch off 1 MΩ or higher
      D12-7 (GSNG) - Body ground and other terminals (except 2 (GSN)) Power switch off 1 MΩ or higher
      D12-3 (GCS) - Body ground and other terminals (except 8 (GCSG)) Power switch off 1 MΩ or higher
      D12-8 (GCSG) - Body ground and other terminals (except 3 (GCS)) Power switch off 1 MΩ or higher
      Tip:

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

    3. Reconnect the D12 generator resolver connector.


    • OK

      REPAIR OR REPLACE HARNESS OR CONNECTOR

    • NG

      REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)

  10. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. B001VHU

      Check the connection of the motor resolver connector.

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

  11. Click here

    INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)


    1. B001VHUE03

      Disconnect the D11 motor resolver connector.

    2. B001VC9C05
      *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
      Tester Connection Condition Specified Condition
      D11-1 (MRF) - D11-4 (MRFG) Power switch off 5.8 to 11.8 Ω
      D11-2 (MSN) - D11-5 (MSNG) Power switch off 11.7 to 17.7 Ω
      D11-3 (MCS) - D11-6 (MCSG) Power switch off 11.7 to 17.7 Ω
      Tip:

      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
      D11-1 (MRF) - Body ground and other terminals (except 4 (MRFG)) Power switch off 1 MΩ or higher
      D11-4 (MRFG) - Body ground and other terminals (except 1 (MRF)) Power switch off 1 MΩ or higher
      D11-2 (MSN) - Body ground and other terminals (except 5 (MSNG)) Power switch off 1 MΩ or higher
      D11-5 (MSNG) - Body ground and other terminals (except 2 (MSN)) Power switch off 1 MΩ or higher
      D11-3 (MCS) - Body ground and other terminals (except 6 (MCSG)) Power switch off 1 MΩ or higher
      D11-6 (MCSG) - Body ground and other terminals (except 3 (MCS)) Power switch off 1 MΩ or higher
      Tip:

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

    3. Reconnect the D11 motor resolver connector.


    • OK

      REPAIR OR REPLACE HARNESS OR CONNECTOR

    • NG

      REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (Click here)