HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A40-504

DTC Code DTC Name
P0A40-504 Drive Motor "A" Position Sensor Circuit Range / Performance

DESCRIPTION

For a description of the inverter Click here.

If an overvoltage occurs in the motor inverter or generator inverter, the MG ECU detects it and transmits this information to the hybrid vehicle control ECU.

Tech Tips

The term "drive motor A" indicates MG2.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A40 504

Motor inverter overvoltage signal detection (overvoltage due to hybrid vehicle transmission assembly malfunction)

Overvoltage is detected after boosting.*

(1 trip detection logic)

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Wire harness or connector

Related Data List
DTC No. Data List
P0A40-504 VH-Voltage after Boosting

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 ignition 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.

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


  1. With the vehicle engine stopped, the ignition switch to ON (READY) and the shift lever in P, depress the accelerator pedal to start the engine.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      Only P0A40-504 is output, or DTCs other than the ones in the table below are also output. A
      Any of the following DTCs including pending DTCs are also output. B
      DTC No. Relevant Diagnosis
      P06B0-163 Sensor Power Supply "A" Circuit/Open
      P06D6-511 Sensor Reference Voltage "F" Circuit/Open
      P06E6-164 Sensor Power Supply "C" Circuit/Open
      P0A1A-151, 166, 517, 658, 791, 809 Generator Control Module
      P0A1B-198, 505, 554, 786, 794, 806 Drive Motor "A" Control Module
      P0A1D (all INF codes)*1 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500, 506, 556, 808 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513, 518, 811 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A78-287, 555, 807 Drive Motor "A" Inverter Performance
      P0A7A-325, 810 Generator Inverter Performance
      P0A93-346 Inverter Cooling System Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0BEA-290 Drive Motor "A" Phase V Current Sensor Circuit Range/Performance
      P0BEE-298 Drive Motor "A" Phase W Current Sensor Circuit Range/Performance
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0D2E-565, 586 Drive Motor "A" Inverter Voltage Sensor Circuit Range/Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Performance
      P0E05-328 Generator Phase V Current Sensor Circuit Range/Performance
      P0E09-336 Generator Phase W Current Sensor Circuit Range/Performance
      P0E32-585 DC/DC Converter Voltage Sensor "A" Range/Performance
      P0E33-589 DC/DC Converter Voltage Sensor "A" Low
      P0E34-590 DC/DC Converter Voltage Sensor "A" High
      P1C2A-155 Generator A/D Converter Circuit
      P1C2B-192 Drive Motor "A" A/D Converter Circuit
      P1C2D-587 Hybrid Battery Voltage / DC/DC Converter Voltage Correlation
      P1C3C-294 Drive Motor "A" Phase V Current Sensor Correlation
      P1C3D-302 Drive Motor "A" Phase W Current Sensor Correlation
      P1C3E-333 Generator Phase V Current Sensor Correlation
      P1C3F-341 Generator Phase W Current Sensor Correlation
      P1C4A-288 Drive Motor "A" Phase V Current Sensor Sub Circuit Range/Performance
      P1C4F-296 Drive Motor "A" Phase W Current Sensor Sub Circuit Range/Performance
      P1C54-326 Generator Phase V Current Sensor Sub Circuit Range/Performance
      P1C59-334 Generator Phase W Current Sensor Sub Circuit Range/Performance
      P1C6D-501 Drive Motor "A" Phase V Current Sensor Offset Range/Performance
      P1C6E-502 Drive Motor "A" Phase W Current Sensor Offset Range/Performance
      P1C71-515 Generator Phase V Current Sensor Offset Range/Performance
      P1C72-516 Generator Phase W Current Sensor Offset Range/Performance
      P1C73-512 Sensor Standard Voltage "F" Circuit/Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P3004-803 High Voltage Power Resource
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      P314A-828 Inverter Coolant Pump Speed Signal

      Tech Tips


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • P0A40-504 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the ignition switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A004GGV

      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.


    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

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

    4. Turn the ignition switch to ON (IG).

    5. A004F6DE02
      Text in Illustration
      *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 Switch Condition Specified Condition
      C28-11 (GRF) - Body ground Ignition switch ON (IG) Below 1 V
      C28-12 (GRFG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-7 (GSN) - Body ground Ignition switch ON (IG) Below 1 V
      C28-8 (GSNG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-10 (GCS) - Body ground Ignition switch ON (IG) Below 1 V
      C28-9 (GCSG) - Body ground Ignition switch ON (IG) Below 1 V

      Note

      Turning the ignition switch to 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 ignition 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

  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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

    3. A004F6DE02
      Text in Illustration
      *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 Switch Condition Specified Condition
      C28-11 (GRF) - C28-12 (GRFG) Ignition switch off 7.1 to 21.6 Ω
      C28-7 (GSN) - C28-8 (GSNG) Ignition switch off 13.7 to 34.5 Ω
      C28-10 (GCS) - C28-9 (GCSG) Ignition switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      C28-11 (GRF) or C28-12 (GRFG) - Body ground and other terminals Ignition switch off 1 MΩ or higher
      C28-7 (GSN) or C28-8 (GSNG) - Body ground and other terminals Ignition switch off 1 MΩ or higher
      C28-10 (GCS) or C28-9 (GCSG) - Body ground and other terminals Ignition 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

  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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

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

    4. Turn the ignition switch to ON (IG).

    5. A004E74E02
      Text in Illustration
      *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 Switch Condition Specified Condition
      C28-1 (MRF) - Body ground Ignition switch ON (IG) Below 1 V
      C28-2 (MRFG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-3 (MSN) - Body ground Ignition switch ON (IG) Below 1 V
      C28-4 (MSNG) - Body ground Ignition switch ON (IG) Below 1 V
      C28-6 (MCS) - Body ground Ignition switch ON (IG) Below 1 V
      C28-5 (MCSG) - Body ground Ignition switch ON (IG) Below 1 V

      Note

      Turning the ignition switch to 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 ignition 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

  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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the inverter with converter assembly connector.

    3. A004E74E02
      Text in Illustration
      *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 Switch Condition Specified Condition
      C28-1 (MRF) - C28-2 (MRFG) Ignition switch off 7.1 to 21.6 Ω
      C28-3 (MSN) - C28-4 (MSNG) Ignition switch off 13.7 to 34.5 Ω
      C28-6 (MCS) - C28-5 (MCSG) Ignition switch off 12.8 to 32.4 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      C28-1 (MRF) or C28-2 (MRFG) - Body ground and other terminals Ignition switch off 1 MΩ or higher
      C28-3 (MSN) or C28-4 (MSNG) - Body ground and other terminals Ignition switch off 1 MΩ or higher
      C28-6 (MCS) or C28-5 (MCSG) - Body ground and other terminals Ignition 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

  7. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A004G3E

      Check the connection of the generator resolver connector.

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

    NG

    CONNECT SECURELY

    OK

  8. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A004G5V

      Check the connection of the motor resolver connector.

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

    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CONNECT SECURELY

  9. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A004G3E

      Check the connection of the generator resolver connector.

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

    NG

    CONNECT SECURELY

    OK

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


    1. A004G3E

      Disconnect the resolver connector.

    2. A004EDMC15
      *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 (Check for Open)
      Tester Connection Condition Specified Condition
      C24-1 (GRF) - C24-5 (GRFG) Ignition switch off 9.5 to 15.5 Ω
      C24-2 (GSN) - C24-6 (GSNG) Ignition switch off 15.0 to 27.0 Ω
      C24-3 (GCS) - C24-7 (GCSG) Ignition switch off 14.0 to 26.0 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
      C24-1 (GRF) - Body ground and other terminals (except C24-5 (GRFG)) Power switch off 1 MΩ or higher
      C24-5 (GRFG) - Body ground and other terminals (except C24-1 (GRF)) Power switch off 1 MΩ or higher
      C24-2 (GSN) - Body ground and other terminals (except C24-6 (GSNG)) Power switch off 1 MΩ or higher
      C24-6 (GSNG) - Body ground and other terminals (except C24-2 (GSN)) Power switch off 1 MΩ or higher
      C24-3 (GCS) - Body ground and other terminals (except C24-7 (GCSG)) Power switch off 1 MΩ or higher
      C24-7 (GCSG) - Body ground and other terminals (except C24-3 (GCS)) Power switch off 1 MΩ or higher

    3. Reconnect the resolver connector.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  11. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A004G5V

      Check the connection of the motor resolver connector.

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

    NG

    CONNECT SECURELY

    OK

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


    1. A004G5V

      Disconnect the resolver connector.

    2. A004EWLC05
      *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
      C26-3 (MRF) - C26-6 (MRFG) Ignition switch off 9.5 to 15.5 Ω
      C26-1 (MSN) - C26-4 (MSNG) Ignition switch off 15.0 to 27.0 Ω
      C26-2 (MCS) - C26-5 (MCSG) Ignition switch off 14.0 to 26.0 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
      C26-3 (MRF) - Body ground and other terminals (except C26-6 (MRFG)) Power switch off 1 MΩ or higher
      C26-6 (MRFG) - Body ground and other terminals (except C26-3 (MRF)) Power switch off 1 MΩ or higher
      C26-1 (MSN) - Body ground and other terminals (except C26-4 (MSNG)) Power switch off 1 MΩ or higher
      C26-4 (MSNG) - Body ground and other terminals (except C26-1 (MSN)) Power switch off 1 MΩ or higher
      C26-2 (MCS) - Body ground and other terminals (except C26-5 (MCSG)) Power switch off 1 MΩ or higher
      C26-5 (MCSG) - Body ground and other terminals (except C26-2 (MCS)) Power switch off 1 MΩ or higher

    3. Reconnect the resolver connector.


    OK

    REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR