СИСТЕМА УПРАВЛЕНИЯ ГИБРИДНОЙ СИСТЕМОЙ, Diagnostic DTC:P0A40-500, P0A41-245

DTC Code DTC Name
P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
P0A41-245 Drive Motor "A" Position Sensor Circuit Low

DESCRIPTION

Refer to the description for DTC P0A3F-243 Click here.

DTC No. DTC Detection Condition Trouble Area
P0A40-500

Motor resolver signal is out of the normal range (amplitude is too large or too small).

(1 trip detection logic)


  • Inverter with converter assembly

  • Hybrid vehicle transmission assembly

  • Wire harness or connector

P0A41-245

Open or short in the motor resolver circuit

Motor resolver signal is out of the normal range (amplitude is extremely small).

(1 trip detection logic)

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A1A-200 Click here.

INSPECTION PROCEDURE

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.

  • 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.

Tech Tips


  • 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.

  • If the resolver is malfunctioning, the vehicle may not drive smoothly.

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


    1. Turn the power switch on (IG) and wait for 5 seconds or more.

    2. Turn the power switch on (READY) with the shift lever in P and wait for 5 seconds or more.

    3. Depress the accelerator pedal of the vehicle with the engine stopped and the shift lever in P to start the engine.

    4. Keep the engine running for 5 seconds or more.

    5. Drive the vehicle forward with the shift lever in D for 5 m or more.

    6. Drive the vehicle backward with the shift lever in R for 5 m or more.

PROCEDURE


  1. 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 connection condition of the low voltage connector of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter Click here.

      A01FRYME01
      Text in Illustration
      *A for LHD *B for RHD

      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 connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

      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.


    B
    C
    A
  2. 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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

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

    4. Turn the power switch on (IG).

    5. A01FQOWE17
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A38-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A38-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A38-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A38-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A38-6 (GCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - Body ground Power switch on (IG) Below 1 V
      A74-9 (GRFG) - Body ground Power switch on (IG) Below 1 V
      A74-18 (GSN) - Body ground Power switch on (IG) Below 1 V
      A74-7 (GSNG) - Body ground Power switch on (IG) Below 1 V
      A74-17 (GCS) - Body ground Power switch on (IG) Below 1 V
      A74-6 (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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG
    OK
  3. 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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. A01FQOWE17
      Text in Illustration
      *A for LHD
      *B for RHD
      *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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - A38-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A38-18 (GSN) - A38-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A38-17 (GCS) - A38-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - A74-9 (GRFG) Power switch off 4.2 to 12.5 Ω
      A74-18 (GSN) - A74-7 (GSNG) Power switch off 9.8 to 20.1 Ω
      A74-17 (GCS) - A74-6 (GCSG) Power switch off 9.8 to 20.1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) or A38-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-18 (GSN) or A38-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-17 (GCS) or A38-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) or A74-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-18 (GSN) or A74-7 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-17 (GCS) or A74-6 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
    4. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG
    OK
  4. 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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

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

    4. Turn the power switch on (IG).

    5. A01FQOWE18
      Text in Illustration
      *A for LHD
      *B for RHD
      *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
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A38-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A38-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A38-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A38-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A38-27 (MCSG) - Body ground Power switch on (IG) Below 1 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - Body ground Power switch on (IG) Below 1 V
      A74-29 (MRFG) - Body ground Power switch on (IG) Below 1 V
      A74-39 (MSN) - Body ground Power switch on (IG) Below 1 V
      A74-28 (MSNG) - Body ground Power switch on (IG) Below 1 V
      A74-38 (MCS) - Body ground Power switch on (IG) Below 1 V
      A74-27 (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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG
    OK
  5. 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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. A01FQOWE18
      Text in Illustration
      *A for LHD
      *B for RHD
      *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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - A38-29 (MRFG) Power switch off 4.2 to 12.5 Ω
      A38-39 (MSN) - A38-28 (MSNG) Power switch off 9.8 to 20.1 Ω
      A38-38 (MCS) - A38-27 (MCSG) Power switch off 9.8 to 20.1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - A74-29 (MRFG) Power switch off 4.2 to 12.5 Ω
      A74-39 (MSN) - A74-28 (MSNG) Power switch off 9.8 to 20.1 Ω
      A74-38 (MCS) - A74-27 (MCSG) Power switch off 9.8 to 20.1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) or A38-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-39 (MSN) or A38-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-38 (MCS) or A38-27 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) or A74-29 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-39 (MSN) or A74-28 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-38 (MCS) or A74-27 (MCSG) - Body ground and other terminal Power switch off 1 MΩ or higher
    4. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG
    OK
  6. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. A01FS4V

      Remove the hybrid vehicle transmission assembly Click here.

    2. Check the connection condition of the generator resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B
    C
    A
  7. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. A01FT1X

      Check the connection condition of the motor resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C
    2. Install the hybrid vehicle transmission assembly.


    B
    C
    A
  8. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)


    1. Remove the hybrid vehicle transmission assembly Click here.

    2. A01FS4V

      Check the connection condition of the generator resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B
    C
    A
  9. 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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. Disconnect the F50 generator resolver connector.

    4. A01FT2DE03
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to Generator Resolver)

      *b

      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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) - F50-1 (GRF) Power switch off Below 1 Ω
      A38-9 (GRFG) - F50-5 (GRFG) Power switch off Below 1 Ω
      A38-18 (GSN) - F50-2 (GSN) Power switch off Below 1 Ω
      A38-7 (GSNG) - F50-6 (GSNG) Power switch off Below 1 Ω
      A38-17 (GCS) - F50-3 (GCS) Power switch off Below 1 Ω
      A38-6 (GCSG) - F50-7 (GCSG) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) - F50-1 (GRF) Power switch off Below 1 Ω
      A74-9 (GRFG) - F50-5 (GRFG) Power switch off Below 1 Ω
      A74-18 (GSN) - F50-2 (GSN) Power switch off Below 1 Ω
      A74-7 (GSNG) - F50-6 (GSNG) Power switch off Below 1 Ω
      A74-17 (GCS) - F50-3 (GCS) Power switch off Below 1 Ω
      A74-6 (GCSG) - F50-7 (GCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-20 (GRF) or F50-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-9 (GRFG) or F50-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-18 (GSN) or F50-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-7 (GSNG) or F50-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-17 (GCS) or F50-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-6 (GCSG) or F50-7 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-20 (GRF) or F50-1 (GRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-9 (GRFG) or F50-5 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-18 (GSN) or F50-2 (GSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-7 (GSNG) or F50-6 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-17 (GCS) or F50-3 (GCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-6 (GCSG) or F50-7 (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 transmission assembly.

    5. Reconnect the F50 generator resolver connector.

    6. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG
    OK
  10. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)


    1. Remove the hybrid vehicle transmission assembly Click here.

    2. A01FT1X

      Check the connection condition of the motor resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter Click here.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B
    C
    A
  11. 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 A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. Disconnect the F51 motor resolver connector.

    4. A01FT2DE04
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to Motor Resolver)

      *b

      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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) - F51-1 (MRF) Power switch off Below 1 Ω
      A38-29 (MRFG) - F51-5 (MRFG) Power switch off Below 1 Ω
      A38-39 (MSN) - F51-2 (MSN) Power switch off Below 1 Ω
      A38-28 (MSNG) - F51-6 (MSNG) Power switch off Below 1 Ω
      A38-38 (MCS) - F51-3 (MCS) Power switch off Below 1 Ω
      A38-27 (MCSG) - F51-7 (MCSG) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) - F51-1 (MRF) Power switch off Below 1 Ω
      A74-29 (MRFG) - F51-5 (MRFG) Power switch off Below 1 Ω
      A74-39 (MSN) - F51-2 (MSN) Power switch off Below 1 Ω
      A74-28 (MSNG) - F51-6 (MSNG) Power switch off Below 1 Ω
      A74-38 (MCS) - F51-3 (MCS) Power switch off Below 1 Ω
      A74-27 (MCSG) - F51-7 (MCSG) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A38-40 (MRF) or F51-1 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-29 (MRFG) or F51-5 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-39 (MSN) or F51-2 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-28 (MSNG) or F51-6 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-38 (MCS) or F51-3 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A38-27 (MCSG) or F51-7 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A74-40 (MRF) or F51-1 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-29 (MRFG) or F51-5 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-39 (MSN) or F51-2 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-28 (MSNG) or F51-6 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-38 (MCS) or F51-3 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      A74-27 (MCSG) or F51-7 (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 transmission assembly.

    5. Reconnect the F51 motor resolver connector.

    6. Reconnect the A38*1 or A74*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    NG
    OK