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

DESCRIPTION

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

WIRING DIAGRAM

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

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   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.

      Result
      Result Proceed to P1CAD-168, P1CB0-795 or P1CB3-796 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
      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

   5. Turn the power switch off.

   
   
   • AClick here
   • B

     GO TO DTC CHART (HYBRID CONTROL SYSTEM) (Click here)

2. 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 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.

   
   
   • OKClick here
   • NG

     CONNECT SECURELY

3. 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. 

      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

4. 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. 

      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.

   
   
   • OKClick here
   • NGClick here
5. 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. 

      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

6. 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. 

      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.

   
   
   • OKClick here
   • NGClick here
7. Click here

   CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

   
   
   1. 

      Check the connection of the generator resolver connector.

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

   
   
   • OKClick here
   • NG

     CONNECT SECURELY

8. Click here

   CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

   
   
   1. 

      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

9. Click here

   CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)

   
   
   1. 

      Check the connection of the generator resolver connector.

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

   
   
   • OKClick here
   • NG

     CONNECT SECURELY

10. Click here

    INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR RESOLVER)

    
    
    1. 

       Disconnect the D12 generator resolver connector.

    2. 

       *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)

11. Click here

    CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)

    
    
    1. 

       Check the connection of the motor resolver connector.

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

    
    
    • OKClick here
    • NG

      CONNECT SECURELY

12. Click here

    INSPECT HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR RESOLVER)

    
    
    1. 

       Disconnect the D11 motor resolver connector.

    2. 

       *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)