Toyota Avalon (XX50): Generator High-voltage Circuit. Generator Resolver Circuit. How To Proceed With Troubleshooting

Generator High-voltage Circuit

DESCRIPTION

The cause of this malfunction may be the generator high-voltage circuit.

Check the generator internal resistance and the connection condition of the high-voltage line between the inverter and generator to check whether there is an open or short circuit.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

This diagnostic procedure is referenced to in the diagnostic procedure of several DTCs.

If the result of this diagnostic procedure is normal, proceed as directed in the procedure for the DTC.

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, 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.

  *a	Without waiting for 10 minutes

  Click here

  HINT:

  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

NOTICE:

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

PROCEDURE

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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.

(b) Remove the inverter cover from the inverter with converter assembly.

(c) Check that the bolts for the motor cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems. Specified Condition: T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)

(d) Disconnect the motor cable from the inverter with converter assembly.

(e) Check for arc marks at the terminals for the motor cable.

(f) Reconnect the motor cable.

(g) Reinstall the inverter cover.

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

A

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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.

(b) Remove the inverter cover from the inverter with converter assembly.

(c) Disconnect the motor cable from the inverter with converter assembly.

(d) Using a milliohmmeter, measure the resistance according to the value(s) in the table below. HINT: If the generator (MG1) temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped. Standard Resistance: Tester Connection Condition Specified Condition W2-4 (W) - W2-5 (U) Power switch off 49.2 to 54.3 mΩ W2-5 (U) - W2-6 (V) Power switch off 49.2 to 54.3 mΩ W2-6 (V) - W2-4 (W) Power switch off 49.2 to 54.3 mΩ HINT: 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)

*1 Shield Ground *a Motor Cable (Inverter with Converter Assembly Side)

(e) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

(f) Reconnect the motor cable.

(g) Reinstall the inverter cover.

OK

GENERATOR HIGH-VOLTAGE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

NG

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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.

(b) Remove the inverter with converter assembly.

(c) Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems. Specified Condition: T=10 N*m (102 kgf*cm, 7 ft.*lbf)

(d) Disconnect the motor cable from the hybrid vehicle transaxle assembly.

(e) Check for arc marks at the terminals for the generator cable.

(f) Reconnect the motor cable.

(g) Reinstall the inverter with converter assembly.

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

A

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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.

(b) Remove the inverter with converter assembly.

(c) Remove the motor cable.

(d) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

NOTICE:

Wrap the terminal of the motor cable with insulating tape to prevent them from coming into contact with body ground.

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

Standard Resistance:

(f) Reinstall the motor cable.

(g) Reinstall the inverter with converter assembly.

OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

NG

REPLACE MOTOR CABLE

Generator Resolver Circuit

DESCRIPTION

The cause of this malfunction may be the generator resolver.

Check the generator resolver internal resistance and connection condition from the inverter to the resolver.

SYSTEM DESCRIPTION

A resolver is a sensor that is used to detect the position of the magnetic poles of the rotor of a generator. Knowing the position of the poles is indispensable for ensuring precise control of the generator (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, which is built into 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 revolution speed sensor.

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

WIRING DIAGRAM

CAUTION / NOTICE / HINT

This diagnostic procedure is referenced to in the diagnostic procedure of several DTCs.

If the result of this diagnostic procedure is normal, proceed as directed in the procedure for the DTC.

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, 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.

  *a	Without waiting for 10 minutes

  Click here

  HINT:

  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

NOTICE:

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

HINT:

• 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.
• When inspecting the connectors, if it is difficult to judge if a connector was disconnected, deformed or improperly secured, disconnect and reconnect the connector and then check for DTCs again. Check if the same DTC is output. If the same DTC is not output, improper connection of connectors is suspected.
• As a malfunction detection threshold may be exceeded when performing the vibration or heat connector inspections, make sure to perform the following inspection to check that the DTC was not stored due to the malfunction of a part.

PROCEDURE

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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.

(b) Disconnect the C61 inverter with converter assembly connector.

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

(d) Turn the power switch on (IG).

(e) Measure the voltage according to the value(s) in the table below. Standard Voltage: Tester Connection Condition Specified Condition C61-8 (GRF) - Body ground Power switch on (IG) Below 1 V C61-9 (GRFG) - Body ground Power switch on (IG) Below 1 V C61-10 (GSN) - Body ground Power switch on (IG) Below 1 V C61-11 (GSNG) - Body ground Power switch on (IG) Below 1 V C61-13 (GCS) - Body ground Power switch on (IG) Below 1 V C61-12 (GCSG) - Body ground Power switch on (IG) Below 1 V NOTICE: 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.

*a Front view of wire harness connector (to Inverter with Converter Assembly)

(f) Turn the power switch off.

(g) Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.

(h) Reconnect the C61 inverter with converter assembly connector.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:

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.

(b) Disconnect the C61 inverter with converter assembly connector.

(c) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition C61-8 (GRF) - C61-9 (GRFG) Power switch off 8.9 to 14.8 Ω C61-10 (GSN) - C61-11 (GSNG) Power switch off 22.6 to 34.5 Ω C61-13 (GCS) - C61-12 (GCSG) Power switch off 25.5 to 37.4 Ω HINT: 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 C61-8 (GRF) or C61-9 (GRFG) - Body ground and other terminals Power switch off 1 MΩ or higher C61-10 (GSN) or C61-11 (GSNG) - Body ground and other terminals Power switch off 1 MΩ or higher C61-13 (GCS) or C61-12 (GCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

*a Front view of wire harness connector (to Inverter with Converter Assembly)

(d) Reconnect the C61 inverter with converter assembly connector.

OK

GENERATOR RESOLVER CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

NG

(a) Check the connection condition of the 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.

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

A

(a) Disconnect the C63 resolver connector.

(b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition C63-1 (GRF) - C63-8 (GRFG) Power switch off 8.8 to 14.8 Ω C63-12 (GSN) - C63-2 (GSNG) Power switch off 22.5 to 34.4 Ω C63-7 (GCS) - C63-11 (GCSG) Power switch off 25.5 to 37.3 Ω HINT: 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 C63-1 (GRF) - Body ground and other terminals (except C63-8 (GRFG)) Power switch off 1 MΩ or higher C63-8 (GRFG) - Body ground and other terminals (except C63-1 (GRF)) Power switch off 1 MΩ or higher C63-12 (GSN) - Body ground and other terminals (except C63-2 (GSNG)) Power switch off 1 MΩ or higher C63-2 (GSNG) - Body ground and other terminals (except C63-12 (GSN)) Power switch off 1 MΩ or higher C63-7 (GCS) - Body ground and other terminals (except C63-11 (GCSG)) Power switch off 1 MΩ or higher C63-11 (GCSG) - Body ground and other terminals (except C63-7 (GCS)) Power switch off 1 MΩ or higher

*a Component without harness connected (Generator resolver (Hybrid Vehicle Transaxle Assembly))

(c) Reconnect the C63 resolver connector.

OK

REPAIR OR REPLACE HARNESS OR CONNECTOR

NG

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

How To Proceed With Troubleshooting

CAUTION / NOTICE / HINT

HINT:

• *: Use the Techstream
• Use the following procedure to troubleshoot the hybrid control system.

PROCEDURE

NEXT

NEXT

HINT:

If the display on the tester indicates a communication error, inspect the DLC3.

NEXT

Click here

HINT:

• Make sure to save freeze frame data because the data is necessary for performing simulation tests.
• For the hybrid control system, there are many DTCs, many of which can be stored due to a single malfunction. As a result, in some of the diagnosis procedures an instruction is provided to check for other DTCs. By following the diagnosis path based on the combination of output DTCs, it is possible to narrow down the problem early and avoid unnecessary diagnosis.

NEXT

Click here

NEXT

NEXT

HINT:

If the hybrid system does not start, perform steps 9 and 11 first.

Malfunction occurs.

GO TO STEP 10

Malfunction does not occur.

NEXT

Click here

DTCs are not output.

GO TO STEP 16

DTCs are output.

Click here

NEXT

Malfunction confirmed.

GO TO STEP 13

Malfunction not confirmed.

Click here

NEXT

NEXT

NEXT

NEXT

END

Malfunctioning parts confirmed.

GO TO STEP 18

Malfunctioning parts not confirmed.

NEXT

GO TO STEP 11

NEXT

GO TO STEP 13