Toyota Avalon (XX50): Drive Motor "A" Position Sensor Internal Electronic Failure (P1CAD49,P1C651F,P1CB038). DC/DC Converter Voltage Sensor "A"(VL) Stuck On (P1CB59E). Drive Motor "A" Inverter Voltage Sensor(VH) Stuck On (

Drive Motor "A" Position Sensor Internal Electronic Failure (P1CAD49,P1C651F,P1CB038)

DESCRIPTION

The motor generator control ECU (MG ECU) , which is built into the inverter with converter assembly, monitors its internal operation and detects malfunctions.

HINT:

Although the DTC titles generator control module, these DTCs relate to the motor control module.

MONITOR DESCRIPTION

The motor generator control ECU performs diagnostic tests to verify proper operation of internal ECU systems. In one of those tests, the motor generator control ECU checks for an R/D (Resolver/ Digital converter) malfunction involving the motor resolver. If the motor generator control ECU detects an R/D converter error, it will conclude that there is an internal malfunction involving the motor resolver. The motor generator control ECU will illuminate the MIL and set 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]

   *: Lightly wiggle the connectors and wire harnesses up and down and right and left.

7. Turn the power switch on (READY) and wait for 5 seconds or more. [*2]
8. Depress the accelerator pedal of the vehicle with the engine stopped and the shift lever in P to start the engine. [*3]
9. Keep the engine running for 5 seconds or more. [*4]
10. Drive the vehicle forward with the shift lever in D for 5 m (16 ft.) or more. [*5]
11. Drive the vehicle backward with the shift lever in R for 5 m (16 ft.) or more. [*6]

    HINT:

    [*1] to [*6]: Normal judgment procedure.

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

12. Enter the following menus: Powertrain / Motor Generator / Utility / All Readiness.
13. 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 P1CAC49.

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

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

(a) Connect the Techstream to the DLC3.

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

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

(d) Check for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)

A

Click here

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

A

Click here

NEXT

Click here

HINT:

If the "Motor Resolver Circuit" inspection results are normal, perform the next step.

NEXT

REPLACE INVERTER WITH CONVERTER ASSEMBLY

DC/DC Converter Voltage Sensor "A"(VL) Stuck On (P1CB59E)

DTC SUMMARY

MALFUNCTION DESCRIPTION

If an overvoltage malfunction occurs in the boost converter, the motor generator control ECU (MG ECU) detects the malfunction and stores this DTC. The cause of this malfunction may be one of the following:

• Inverter with converter assembly internal circuit malfunction
• Malfunction in ECU that controls the inverter

DESCRIPTION

For a description of the boost converter.

Click here

MONITOR DESCRIPTION

If the boost converter detects a circuit malfunction, it will transmit a boost converter overvoltage signal to the motor generator control ECU. Upon receiving this signal, the motor generator control ECU will illuminate the MIL and set 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 the power switch on (IG) and wait for 5 seconds or more. [*1]
7. Turn the power switch on (READY) and wait for 5 seconds or more. [*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.

8. Enter the following menus: Powertrain / Motor Generator / 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.

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

Click here

A

REPLACE INVERTER WITH CONVERTER ASSEMBLY

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

Drive Motor "A" Inverter Voltage Sensor(VH) Stuck On (P1CB69E)

DTC SUMMARY

MALFUNCTION DESCRIPTION

If an overvoltage malfunction occurs in the motor inverter and generator inverter, the motor generator control ECU (MG ECU) detects the malfunction and stores this DTC. The cause of this malfunction may be one of the following:

• Inverter with converter assembly internal circuit malfunction
• Malfunction in ECU that controls the inverter

DESCRIPTION

For a description of the inverter.

Click here

MONITOR DESCRIPTION

If the motor inverter detects a circuit malfunction, it will transmit a motor inverter overvoltage signal to the motor generator control ECU. Upon receiving this signal, the motor generator control ECU will illuminate the MIL and set 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 wait for 5 seconds or more. [*1]
6. Turn the power switch on (READY) and wait for 5 seconds or more. [*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 / Motor Generator / 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.

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

Click here

A

REPLACE INVERTER WITH CONVERTER ASSEMBLY

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR