Toyota Avalon (XX50): Generator Temperature Sensor Voltage Out of Range (P0A361C,P0A361F). Generator Temperature Sensor Circuit Short to Ground (P0A3611,P0A3615). Hybrid/EV Battery Cooling Fan 1 Control Circuit High (P0A81

Generator Temperature Sensor Voltage Out of Range (P0A361C,P0A361F)

DTC SUMMARY

MALFUNCTION DESCRIPTION

These DTCs are stored when the generator temperature sensor output is abnormal. The cause of this malfunction may be one of the following:

• Hybrid vehicle control ECU internal malfunction

• Internal generator temperature sensor malfunction
• Open or short in generator temperature sensor

• The connectors are not connected properly
• Foreign matter or water on the connector terminals
• Open or short in wire harness

HINT:

If any of these DTCs are stored, the generator temperature sensor is malfunctioning and the self-protection function may not operate. Therefore under certain high load driving condition, the temperature of the generator (MG1) becomes high. If the self-protection function does not operate, the generator (MG1) may malfunction and cause the vehicle to enter fail-safe mode.

DESCRIPTION

Refer to the description for DTC P0A3611.

Click here

MONITOR DESCRIPTION

If the hybrid vehicle control ECU detects a malfunction of the generator temperature sensor, it will illuminate the MIL and store a DTC.

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

CONFIRMATION DRIVING PATTERN

HINT:

• After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

  Click here

• When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

  Click here

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream on.
3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
4. Turn the power switch off.
5. Leave the vehicle as is for 5 hours or more and then check the values of the Data List items "Generator Temperature", "Motor Temperature" and "Inverter Coolant Water Temperature".[*1]
6. Turn the power switch on (IG) and turn the Techstream on.[*2]

   HINT:

   [*1] to [*2]: Normal judgment procedure.

   The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. Check the DTC judgment result.

   HINT:

   • If the judgment result shows NORMAL, the system is normal.
   • If the judgment result shows ABNORMAL, the system has a malfunction.
   • If the judgment result shows INCOMPLETE or N/A, perform the normal judgment procedure again.

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream on.
3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
4. Turn the power switch off and wait for 2 minutes or more.
5. Turn the power switch on (IG) and turn the Techstream on.
6. With power switch on (IG) and wait for 5 seconds or more.[*1]

   HINT:

   [*1] : Normal judgment procedure.

   The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. Check the DTC judgment result.

   HINT:

   • If the judgment result shows NORMAL, the system is normal.
   • If the judgment result shows ABNORMAL, the system has a malfunction.
   • If the judgment result shows INCOMPLETE or N/A, perform the normal judgment procedure again.

PROCEDURE

(a) Connect the Techstream to the DLC3.

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

(c) Enter the following menus: Powertrain / Engine / Trouble Codes.

(d) Check for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (SFI SYSTEM)

A

Click here

OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

NG

CONNECT SECURELY

Generator Temperature Sensor Circuit Short to Ground (P0A3611,P0A3615)

DTC SUMMARY

MALFUNCTION DESCRIPTION

These DTCs are stored when the generator temperature sensor output is abnormal. The cause of this malfunction may be one of the following:

• Hybrid vehicle control ECU internal malfunction

• Internal generator temperature sensor malfunction
• Open or short in generator temperature sensor

• The connectors are not connected properly
• Foreign matter or water on the connector terminals
• Open or short in wire harness

HINT:

If any of these DTCs are stored, the generator temperature sensor is malfunctioning and the self-protection function may not operate. Therefore under certain high load driving condition, the temperature of the generator (MG1) becomes high. If the self-protection function does not operate, the generator (MG1) may malfunction and cause the vehicle to enter fail-safe mode.

DESCRIPTION

The resistance of the thermistor built into the generator temperature sensor changes in accordance with changes in generator (MG1) temperature. The lower the generator (MG1) temperature, the higher the thermistor resistance. Conversely, the higher the generator (MG1) temperature, the lower the resistance.

HINT:

After confirming that DTC P0A3611 or P0A3615 is output, use the Techstream to check "Generator Temperature" in the Data List.

MONITOR DESCRIPTION

If the hybrid vehicle control ECU detects a malfunction of the generator temperature sensor, it will illuminate the MIL and store a DTC.

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

CONFIRMATION DRIVING PATTERN

HINT:

• After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

  Click here

• When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

  Click here

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream on.
3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
4. Turn the power switch off and wait for 2 minutes or more.
5. Turn the power switch on (IG) and turn the Techstream on.
6. With power switch on (IG) and wait for 5 seconds or more.[*1]

   HINT:

   [*1] : Normal judgment procedure.

   The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. Check the DTC judgment result.

   HINT:

   • If the judgment result shows NORMAL, the system is normal.
   • If the judgment result shows ABNORMAL, the system has a malfunction.
   • If the judgment result shows INCOMPLETE or N/A, perform the normal judgment procedure again.

WIRING DIAGRAM

PROCEDURE

Click here

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

A

(a) Check the connection condition of the generator temperature sensor 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) Connect the Techstream to the DLC3.

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

(c) Enter the following menus: Powertrain / Hybrid Control / Data List / Generator Temperature.

(d) Read the Data List.

(e) Turn the power switch off.

B

GO TO STEP 6

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

A

(a) Disconnect the C62 generator temperature sensor connector.

(b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition C62-5 (GMT) - C62-4 (GMTG) Power switch off 0.3338 to 1487 kΩ

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

(c) Reconnect the C62 generator temperature sensor connector.

NG

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK

(a) Connect terminals 26 (GMT) and 27 (GMTG) of the A23 hybrid vehicle control ECU connector.

*a Component with harness connected (Hybrid Vehicle Control ECU)

(b) Connect the Techstream to the DLC3.

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

(d) Enter the following menus: Powertrain / Hybrid Control / Data List / Generator Temperature.

(e) Read the Data List.

OK:

(f) Turn the power switch off.

OK

REPAIR OR REPLACE HARNESS OR CONNECTOR

NG

REPLACE HYBRID VEHICLE CONTROL ECU

(a) Disconnect the C62 generator temperature sensor connector.

(b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition C62-5 (GMT) - C62-4 (GMTG) Power switch off 0.3338 to 1487 kΩ

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

(c) Reconnect the C62 generator temperature sensor connector.

NG

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

OK

(a) Disconnect the C62 generator temperature sensor connector.

(b) Disconnect the A23 hybrid vehicle control ECU connector.

(c) Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for Open): Tester Connection Condition Specified Condition C62-5 (GMT) - A23-26 (GMT) Power switch off Below 1 Ω C62-4 (GMTG) - A23-27 (GMTG) Power switch off Below 1 Ω Standard Resistance (Check for Short): Tester Connection Condition Specified Condition C62-5 (GMT) or A23-26 (GMT) - Body ground and other terminals Power switch off 10 kΩ or higher C62-4 (GMTG) or A23-27 (GMTG) - Body ground and other terminals Power switch off 10 kΩ or higher

*a Front view of wire harness connector (to Generator Temperature Sensor) *b Rear view of wire harness connector (to Hybrid Vehicle Control ECU)

(d) Reconnect the A23 hybrid vehicle control ECU connector.

(e) Reconnect the C62 generator temperature sensor connector.

OK

REPLACE HYBRID VEHICLE CONTROL ECU

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

Hybrid/EV Battery Cooling Fan 1 Control Circuit High (P0A8100,P0A8115)

DESCRIPTION

Refer to the description for DTC P0A8111.

Click here

The following items can be helpful when performing repairs:

• Hybrid Battery Temperature 1 to 3
• BATT Voltage

HINT:

• "Hybrid Battery Cooling Fan 1 Frequency" is detected when the battery cooling blower assembly is operating and its value changes in proportion to the battery cooling blower assembly speed.
• If the battery cooling blower assembly speed is excessively high, this DTC is stored.

MONITOR DESCRIPTION

If the hybrid vehicle control ECU detects that the speed of the battery cooling blower assembly is higher than the target speed, it will illuminate the MIL and store a DTC.

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

CONFIRMATION DRIVING PATTERN

HINT:

• After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

  Click here

• When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

  Click here

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream on.
3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
4. Turn the power switch off and wait for 2 minutes or more.
5. Turn the power switch on (IG) and turn the Techstream on.
6. Enter the following menus: Powertrain / Hybrid Control / Active Test / Control the Hybrid Battery Cooling Fan.[*1]
7. Select fan mode 6 and operate the battery cooling blower assembly and wait for 60 seconds or more.[*2]

   HINT:

   • Operation of the battery cooling blower assembly can be confirmed by checking if air is sucked into the air intake port of the intake duct or by operation sounds.
   • [*1] to [*2]: Normal judgment procedure.

     The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

8. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
9. Check the DTC judgment result.

   HINT:

   • If the judgment result shows NORMAL, the system is normal.
   • If the judgment result shows ABNORMAL, the system has a malfunction.
   • If the judgment result shows INCOMPLETE or N/A, perform the normal judgment procedure again.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A8111.

Click here

CAUTION / NOTICE / HINT

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.

  Click here

  HINT:

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

  

  *a	Without waiting for 10 minutes

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

(a) Connect the Techstream to the DLC3.

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

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

Click here

OK

REPLACE BATTERY COOLING BLOWER ASSEMBLY

NG

REPLACE BATTERY VOLTAGE SENSOR