HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A4C-518, P0A4C-811

DTC Code	DTC Name
P0A4C-518	Generator Position Sensor Circuit Range / Performance
P0A4C-811	Generator Position Sensor Circuit Range / Performance

DESCRIPTION

For a description of the inverter Click here.

If an abnormal amount of current flows through the generator inverter, the MG ECU detects it and sends a signal to inform the hybrid vehicle control ECU of the malfunction.

DTC No.	INF Code	DTC Detection Condition	Trouble Area
P0A4C	518	Generator inverter fail signal detection (hybrid vehicle transaxle assembly malfunction) Overcurrent occurs in the generator inverter.* (1 trip detection logic)	Inverter with converter assembly Hybrid vehicle transaxle assembly Wire harness or connector
811	Abnormal generator inverter current (overcurrent) detection (hybrid vehicle transaxle assembly malfunction) (1 trip detection logic)

DTC No.

INF Code

DTC Detection Condition

Trouble Area

P0A4C

518

Generator inverter fail signal detection (hybrid vehicle transaxle assembly malfunction)

Overcurrent occurs in the generator inverter.*

(1 trip detection logic)

Inverter with converter assembly
Hybrid vehicle transaxle assembly
Wire harness or connector

811

Abnormal generator inverter current (overcurrent) detection (hybrid vehicle transaxle assembly malfunction)

(1 trip detection logic)

*: The hybrid vehicle transaxle assembly may be suspected as a main cause of the malfunction.

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.

Turn the ignition switch to ON (READY) and wait for 5 seconds or more.
Drive the vehicle for approximately 10 minutes mainly using the engine.

PROCEDURE

CHECK DTC OUTPUT (HYBRID CONTROL)

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

Check if DTCs are output.

Result

Result	Proceed to
P0A7A-203 is not output.	A
P0A7A-203 is also output.	B

Note

If P0A7A-203 is output, troubleshoot it first. After completing the troubleshooting for P0A7A-203, return to perform troubleshooting for this DTC.
Parts repaired or replaced during troubleshooting for P0A7A-203 do not need to be re-inspected in this diagnosis procedure.

Turn the ignition switch off.

GO TO DTC CHART (P0A7A-203) Click here

CHECK DTC OUTPUT (HYBRID CONTROL)

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

Check if DTCs are output.

Tech Tips

If P0A7A-203 was not output in step 1 of this diagnosis procedure, check Table 1 below.
If P0A7A-203 was output in step 1 of this diagnosis procedure, repair that DTC first, then check Table 2 below.

Result

Result	Proceed to
Only P0A4C-518 or 811 is output or DTCs other than the ones in the table below are also output.	A
Any of the following DTCs are also output.	B

Table 1
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, 658, 791	Generator Control Module
P0A1B-198, 786, 794	Drive Motor "A" Control Module
P0A1D (all INF codes)*1	Hybrid Powertrain Control Module
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
P0A4C-513	Generator Position Sensor Circuit Range/Performance
P0A4D-255	Generator Position Sensor Circuit Low
P0BEA-290	Drive Motor "A" Phase V Current Sensor Circuit Range/Performance
P0BEE-298	Drive Motor "A" Phase W Current Sensor Circuit Range / Performance
P0C76-523	Hybrid Battery System Discharge Time Too Long
P0D2E-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
P3133-659	Communication Error from Generator to Drive Motor "A"
P3134-661	Communication Error from Drive Motor "A" to Generator

Table 2
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, 658, 791	Generator Control Module
P0A1B-198, 786, 794	Drive Motor "A" Control Module
P0A1D (all INF codes)*1	Hybrid Powertrain Control Module
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
P0A4C-513	Generator Position Sensor Circuit Range/Performance
P0A4D-255	Generator Position Sensor Circuit Low
P0BEA-290	Drive Motor "A" Phase V Current Sensor Circuit Range/Performance
P0BEE-298	Drive Motor "A" Phase W Current Sensor Circuit Range / Performance
P0C76-523	Hybrid Battery System Discharge Time Too Long
P0D2E-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
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
P1C6D-501	Drive Motor "A" Phase V Current Sensor Offset Range/Performance
P1C6E-502	Drive Motor "A" 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
P3133-659	Communication Error from Generator to Drive Motor "A"
P3134-661	Communication Error from Drive Motor "A" to Generator

Tech Tips

*1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
P0A4C-518 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.

Turn the ignition 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 ignition switch to 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.
  
  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

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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.
Disconnect the inverter with converter assembly connector.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the ignition switch to ON (IG).

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.

Turn the ignition 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.
Disconnect the inverter with converter assembly connector.

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

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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.
Disconnect the inverter with converter assembly connector.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the ignition switch to ON (IG).

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

Turn the ignition 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.
Disconnect the inverter with converter assembly connector.

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

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 of the generator resolver connector.
  
  OK
  
  The connector is connected securely and there are no contact problems.
NG
CONNECT SECURELY

OK
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
REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

NG
CONNECT SECURELY
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.
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 HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER)

Disconnect the resolver connector.

*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

Reconnect the resolver connector.

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

REPAIR OR REPLACE HARNESS OR CONNECTOR

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.
NG
CONNECT SECURELY

OK

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

Disconnect the resolver connector.

*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

Reconnect the resolver connector.

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Click here

REPAIR OR REPLACE HARNESS OR CONNECTOR