Lexus ES: Diagnosis System

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / Hybrid / Battery Control / Motor Generator Control System (for Lithium-ion Battery) / Diagnosis System

DIAGNOSIS SYSTEM

DESCRIPTION

(a) The motor generator control ECU (MG ECU) (inverter with converter assembly) has a self-diagnosis system. If the motor generator control ECU (MG ECU), motor generator system or a component is not working properly, the ECU records the conditions that relate to the fault. The ECU also illuminates the master warning light in the combination meter assembly and provides other appropriate messages on the multi-information display, such as the HV system warning message, HV battery warning message or discharge warning message.

HINT:

The master warning light will illuminate if the motor generator control system is malfunctioning and will blink when in inspection mode.

When troubleshooting OBD II (On-Board Diagnostics) vehicles, the Techstream (complying with SAE J1978) must be connected to the DLC3 (Data Link Connector 3) of the vehicle. Various data in the vehicle motor generator control ECU can then be read.
OBD II regulations require that the vehicle's on-board computer illuminates the MIL (Malfunction Indicator Lamp) on the instrument panel when the computer detects a malfunction in:
1. The emission control system components.
2. The powertrain control components (which affect vehicle emissions).
3. The computer itself.
  In addition, the applicable DTCs prescribed by SAE J2012 are recorded in the motor generator control ECU memory. If the malfunction does not recur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the motor generator control ECU memory.
To check for DTCs, connect the Techstream to the DLC3. The Techstream displays DTCs, freeze frame data, and a variety of hybrid control system data. The DTCs and freeze frame data can be cleared with the Techstream. In order to enhance the OBD function on vehicles and develop the off-board diagnosis system, Controller Area Network (CAN) communication is used in this system. CAN is a network which uses a pair of data transmission lines spanning multiple computers and sensors. It allows for high speed communications between the systems and simplification of the wire harness connections.

2 TRIP DETECTION LOGIC

Following is the description for storage of DTC using "2 trip detection logic".

When a malfunction is first detected, the malfunction is temporarily stored in the motor generator control ECU memory (1st trip). If the same malfunction is detected during the next drive cycle, the MIL is illuminated (2nd trip).

FREEZE FRAME DATA

The motor generator control ECU records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was moving or stationary, whether the engine was warmed up or not, as well as other data recorded at the time of a malfunction.

AUXILIARY BATTERY VOLTAGE

Standard Voltage:

Switch Condition	Specified Condition
Power switch on (IG)	11 to 14 V

If voltage is below 11 V, recharge or replace the auxiliary battery.
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

MIL (Malfunction Indicator Lamp)

(a) The MIL is illuminated when the power switch is first turned on (IG), before the READY indicator illuminates.

(b) When the READY indicator illuminates, the MIL should turn off. If the MIL remains illuminated, the diagnosis system has detected a malfunction or abnormality in a system.

HINT:

If the MIL is not illuminated when the power switch is first turned on (IG), check the MIL circuit.

for SFI System: Click here

RELEVANT SYSTEMS CHECK

The inspection areas and outline of the inspection for each circuit are listed below.

Inspection Details of Relevant Systems

System to be Inspected	Malfunction Possibility	Inspection Content
Motor Resolver Circuit	Motor resolver signal	Open or short circuit in the motor resolver, connectors or cables
Motor High-voltage Circuit	Motor (MG2) output	Open or short circuit in the motor (MG2), connectors or cables
Generator Resolver Circuit	Generator resolver signal	Open or short circuit in the generator resolver, connectors or cables
Generator High-voltage Circuit	Generator (MG1) output	Open or short circuit in the generator (MG1), connectors or cables
Inverter Low-voltage Circuit	Power supply voltage from +B or communication between hybrid vehicle control ECU and motor generator control ECU	Open or short circuit in communication line between hybrid vehicle control ECU and motor generator control ECU Open or short circuit in the +B or ground lines Fuse is blown
HV Battery High-voltage Line Circuit	High voltage power supply from HV battery	Open or short circuit in the system main relay, connectors or cables
Cooling System	Temperature abnormally high	Grille blockage Whether coolant is present Whether there is a possibility that coolant was frozen when malfunction occurs Cooling hose blockage HV radiator fan operation
Shutdown Signal Circuit	Shutdown signal	Open or short circuit in shutdown signal communication line between hybrid vehicle control ECU and motor generator ECU

DTC PRIORITY LEVEL AND TROUBLE AREAS

Each DTC diagnostic procedure for the hybrid control system consists of a combination of the various relevant system (circuit) inspections.
When multiple DTCs are output, performing each diagnostic procedure in order of priority can lead to a more accurate diagnosis.

Inspection Details of Relevant Systems

DTC No.	Detection Item	Order of Priority					Inspection Pattern
		1	2	3	4	5
		Microcomputer Malfunction	Power Source Circuit Malfunction	Communication System Malfunction	Sensor and Actuator Circuit Malfunction	System Malfunction
P033500	Crankshaft Position Sensor "A"	-	-	-	○	-	-
P033531	Crankshaft Position Sensor "A" No Signal	-	-	-	○	-	-
P034000	Camshaft Position Sensor "A" Circuit Bank 1 or Single Sensor	-	-	-	○	-	-
P034031	Camshaft Position Sensor "A" Circuit Bank 1 or Single Sensor No Signal	-	-	-	○	-	-
P062F44	Internal Control Module EEPROM Data Memory Failure	○	-	-	-	-	-
P062F46	Generator Control Module (EEPROM Learning Value) Calibration / Parameter Memory Failure	○	-	-	-	-	-
P06B01C	Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range	-	○	-	-	-	-
P06D61C	Generator Control Module Offset Power Circuit Voltage Out of Range	-	○	-	-	-	-
P0A0011	Motor Electronics Coolant Temperature Sensor Circuit Short to Ground	-	-	-	○	-	-
P0A0015	Motor Electronics Coolant Temperature Sensor Circuit Short to Battery or Open	-	-	-	○	-	-
P0A001C	Motor Electronics Coolant Temperature Sensor Circuit Voltage Out of Range	-	-	-	○	-	B
P0A0812	DC/DC Converter Status Circuit Short to Battery	-	-	-	○	-	-
P0A0814	DC/DC Converter Status Circuit Short to Ground or Open	-	-	-	○	-	-
P0A1112	DC/DC Converter Enable Circuit Short to Battery	-	-	-	○	-	-
P0A1114	DC/DC Converter Enable Circuit Short to Ground or Open	-	-	-	○	-	-
P0A1A47	Generator Control Module Watchdog / Safety μC Failure	○	-	-	-	-	-
P0A1A49	Generator Control Module Internal Electronic Failure	○	-	-	-	-	-
P0A1B1F	Generator Control Module Circuit Intermittent	○	-	-	-	-	-
P0A3F16	Drive Motor "A" Position Sensor Circuit Voltage Below Threshold	-	-	-	○	-	G
P0A3F1F	Drive Motor "A" Position Sensor Circuit Intermittent	-	-	-	○	-	G
P0A3F21	Drive Motor "A" Position Sensor Signal Amplitude < Minimum	-	-	-	○	-	G
P0A3F22	Drive Motor "A" Position Sensor Signal Amplitude > Maximum	-	-	-	○	-	G
P0A4B16	Generator Position Sensor Circuit Voltage Below Threshold	-	-	-	○	-	H
P0A4B1F	Generator Position Sensor Circuit Intermittent	-	-	-	○	-	H
P0A4B21	Generator Position Sensor Signal Amplitude < Minimum	-	-	-	○	-	H
P0A4B22	Generator Position Sensor Signal Amplitude > Maximum	-	-	-	○	-	H
P0A6012	Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Battery	-	-	-	○	-	A
P0A6014	Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Ground or Open	-	-	-	○	-	A
P0A601C	Drive Motor "A" Phase V Current (High Resolution) Circuit Voltage Out of Range	-	-	-	○	-	A
P0A601F	Drive Motor "A" Phase V Current (High Resolution) Circuit Intermittent	-	-	-	○	-	A
P0A6312	Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Battery	-	-	-	○	-	A
P0A6314	Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Ground or Open	-	-	-	○	-	A
P0A631C	Drive Motor "A" Phase W Current (High Resolution) Circuit Voltage Out of Range	-	-	-	○	-	A
P0A631F	Drive Motor "A" Phase W Current (High Resolution) Circuit Intermittent	-	-	-	○	-	A
P0A7872	Drive Motor "A" Inverter Actuator Stuck Open	-	-	-	-	○	K
P0A7873	Drive Motor "A" Inverter Actuator Stuck Closed	-	-	-	-	○	-
P0A789E	Drive Motor "A" Inverter Stuck On	-	-	-	-	○	E
P0A7A72	Generator Inverter Actuator Stuck Open	-	-	-	-	○	N
P0A7A73	Generator Inverter Actuator Stuck Closed	-	-	-	-	○	-
P0A7A9E	Generator Inverter Stuck On	-	-	-	-	○	E
P0A9000	Drive Motor "A" Performance	-	-	-	-	○	I
P0A9200	Hybrid Generator Performance	-	-	-	-	○	J
P0A949E	DC/DC Converter Stuck On	-	-	-	-	○	E
P0AED11	Drive Motor Inverter Temperature Sensor "A" Circuit Short to Ground	-	-	-	○	-	-
P0AED15	Drive Motor Inverter Temperature Sensor "A" Circuit Short to Battery or Open	-	-	-	○	-	-
P0AED1C	Drive Motor Inverter Temperature Sensor "A" Circuit Voltage Out of Range	-	-	-	○	-	B
P0BE512	Drive Motor "A" Phase U Current Sensor Circuit Short to Battery	-	-	-	○	-	A
P0BE514	Drive Motor "A" Phase U Current Sensor Circuit Short to Ground or Open	-	-	-	○	-	A
P0BE51F	Drive Motor "A" Phase U Current Sensor Circuit Intermittent	-	-	-	○	-	A
P0BE528	Drive Motor "A" Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure	-	-	-	○	-	A
P0BE912	Drive Motor "A" Phase V Current Sensor Circuit Short to Battery	-	-	-	○	-	A
P0BE914	Drive Motor "A" Phase V Current Sensor Circuit Short to Ground or Open	-	-	-	○	-	A
P0BE91F	Drive Motor "A" Phase V Current Sensor Circuit Intermittent	-	-	-	○	-	A
P0BE928	Drive Motor "A" Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure	-	-	-	○	-	A
P0BED12	Drive Motor "A" Phase W Current Sensor Circuit Short to Battery	-	-	-	○	-	A
P0BED14	Drive Motor "A" Phase W Current Sensor Circuit Short to Ground or Open	-	-	-	○	-	A
P0BED1F	Drive Motor "A" Phase W Current Sensor Circuit Intermittent	-	-	-	○	-	A
P0BED28	Drive Motor "A" Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure	-	-	-	○	-	A
P0BFD62	Drive Motor "A" Phase U-V-W Current Sensor Signal Compare Failure	-	-	-	○	-	K
P0BFF1D	Drive Motor "A" Circuit Current Out of Range	-	-	-	-	○	M
P0C1900	Drive Motor "A" Execution Torque Performance	-	-	-	-	○	M
P0C3811	DC/DC Converter Temperature Sensor "A" Circuit Short to Ground	-	-	-	○	-	-
P0C3815	DC/DC Converter Temperature Sensor "A" Circuit Short to Battery or Open	-	-	-	○	-	-
P0C381C	DC/DC Converter Temperature Sensor "A" Circuit Voltage Out of Range	-	-	-	○	-	B
P0C3D11	DC/DC Converter Temperature Sensor "B" Circuit Short to Ground	-	-	-	○	-	-
P0C3D15	DC/DC Converter Temperature Sensor "B" Circuit Short to Battery or Open	-	-	-	○	-	-
P0C3D1C	DC/DC Converter Temperature Sensor "B" Circuit Voltage Out of Range	-	-	-	○	-	B
P0C5013	Drive Motor "A" Position Sensor Circuit "A" Circuit Open	-	-	-	○	-	G
P0C5016	Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Below Threshold	-	-	-	○	-	A
P0C5017	Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Above Threshold	-	-	-	○	-	A
P0C501F	Drive Motor "A" Position Sensor Circuit "A" Circuit Intermittent	-	-	-	○	-	G
P0C5A13	Drive Motor "A" Position Sensor Circuit "B" Circuit Open	-	-	-	○	-	G
P0C5A16	Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Below Threshold	-	-	-	○	-	A
P0C5A17	Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Above Threshold	-	-	-	○	-	A
P0C5A1F	Drive Motor "A" Position Sensor Circuit "B" Circuit Intermittent	-	-	-	○	-	G
P0C6413	Generator Position Sensor Circuit "A" Circuit Open	-	-	-	○	-	H
P0C6416	Generator Position Sensor Circuit "A" Circuit Voltage Below Threshold	-	-	-	○	-	A
P0C6417	Generator Position Sensor Circuit "A" Circuit Voltage Above Threshold	-	-	-	○	-	A
P0C641F	Generator Position Sensor Circuit "A" Circuit Intermittent	-	-	-	○	-	H
P0C6913	Generator Position Sensor Circuit "B" Circuit Open	-	-	-	○	-	H
P0C6916	Generator Position Sensor Circuit "B" Circuit Voltage Below Threshold	-	-	-	○	-	A
P0C6917	Generator Position Sensor Circuit "B" Circuit Voltage Above Threshold	-	-	-	○	-	A
P0C691F	Generator Position Sensor Circuit "B" Circuit Intermittent	-	-	-	○	-	H
P0C7917	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold	-	-	-	-	○	F
P0CA300	DC/DC Converter Step Up Voltage Performance	-	-	-	-	○	A
P0D2D16	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Below Threshold	-	-	-	○	-	-
P0D2D17	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold	-	-	-	○	-	-
P0D2D1F	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Intermittent	-	-	-	○	-	-
P0D3319	DC/DC Converter Circuit Current Above Threshold	-	-	-	-	○	E
P0DFA62	Generator Phase U-V-W Current Sensor Signal Compare Failure	-	-	-	○	-	N
P0E0012	Generator Phase U Current Sensor Circuit Short to Battery	-	-	-	○	-	A
P0E0014	Generator Phase U Current Sensor Circuit Short to Ground or Open	-	-	-	○	-	A
P0E001F	Generator Phase U Current Sensor Circuit Intermittent	-	-	-	○	-	A
P0E0028	Generator Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure	-	-	-	○	-	A
P0E0412	Generator Phase V Current Sensor Circuit Short to Battery	-	-	-	○	-	A
P0E0414	Generator Phase V Current Sensor Circuit Short to Ground or Open	-	-	-	○	-	A
P0E041F	Generator Phase V Current Sensor Circuit Intermittent	-	-	-	○	-	A
P0E0428	Generator Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure	-	-	-	○	-	A
P0E0812	Generator Phase W Current Sensor Circuit Short to Battery	-	-	-	○	-	A
P0E0814	Generator Phase W Current Sensor Circuit Short to Ground or Open	-	-	-	○	-	A
P0E081F	Generator Phase W Current Sensor Circuit Intermittent	-	-	-	○	-	A
P0E0828	Generator Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure	-	-	-	○	-	A
P0E3116	DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Below Threshold	-	-	-	○	-	-
P0E3117	DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Above Threshold	-	-	-	○	-	-
P0E311F	DC/DC Converter Voltage Sensor "A" (VL) Circuit Intermittent	-	-	-	○	-	-
P0E5111	DC/DC Converter Current Sensor Circuit Short to Ground	-	-	-	○	-	-
P0E5115	DC/DC Converter Current Sensor Circuit Short to Battery or Open	-	-	-	○	-	-
P0E511F	DC/DC Converter Current Sensor Circuit Intermittent	-	-	-	○	-	-
P0E5128	DC/DC Converter Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure	-	-	-	-	○	A
P0E512A	DC/DC Converter Current Sensor Signal Stuck In Range	-	-	-	○	-	L
P0E5717	DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Above Threshold	-	-	-	-	○	F
P0E5811	DC/DC Converter Temperature Sensor 2 Circuit Short to Ground	-	-	-	○	-	-
P0E5815	DC/DC Converter Temperature Sensor 2 Circuit Short to Battery or Open	-	-	-	○	-	-
P0E581C	DC/DC Converter Temperature Sensor 2 Circuit Voltage Out of Range	-	-	-	○	-	B
P0E7100	Generator Execution Torque Performance	-	-	-	-	○	M
P1C2A1C	Generator A/D Converter Circuit Circuit Voltage Out of Range	○	-	-	-	-	-
P1C2A49	Generator A/D Converter Circuit Internal Electronic Failure	○	-	-	-	-	-
P1C2B1C	Drive Motor "A" Control Module A/D Converter Circuit Voltage Out of Range	○	-	-	-	-	-
P1C2B49	Drive Motor "A" Control Module A/D Converter Circuit Internal Electronic Failure	○	-	-	-	-	-
P1C2E46	Motor Generator ECU (EEPROM) Calibration / Parameter Memory Failure	○	-	-	-	-	-
P1C5D19	Drive Motor "A" Inverter Circuit Current Above Threshold	-	-	-	-	○	E
P1C5F19	Generator Inverter Circuit Current Above Threshold	-	-	-	-	○	E
P1C601F	Generator Control Module Position Sensor REF Power Source Circuit Intermittent	-	○	-	-	-	-
P1C621F	Generator Control Module Offset Power Circuit Intermittent	-	○	-	-	-	-
P1C641F	Generator Control Module Circuit Intermittent	○	-	-	-	-	C
P1C651F	Generator Control Module Circuit Intermittent	○	-	-	-	-	C
P1C671F	Drive Motor "A" Phase U-V-W Current Sensor Circuit Intermittent	-	-	-	○	-	K
P1C691F	Generator Phase U-V-W Current Sensor Circuit Intermittent	-	-	-	○	-	N
P1CA51D	Hybrid Generator Circuit Current Out of Range	-	-	-	-	○	M
P1CAC49	Generator Position Sensor Internal Electronic Failure	-	-	-	○	-	C
P1CAD49	Drive Motor "A" Position Sensor Internal Electronic Failure	-	-	-	○	-	C
P1CAF38	Generator Position Sensor REF Signal Cycle Malfunction Signal Frequency Incorrect	-	-	-	○	-	C
P1CB038	Drive Motor "A" Position Sensor REF Signal Frequency Incorrect	-	-	-	○	-	C
P1CB59E	DC/DC Converter Voltage Sensor "A" (VL) Stuck On	-	-	-	-	○	A
P1CB69E	Drive Motor "A" Inverter Voltage Sensor (VH) Stuck On	-	-	-	-	○	A
P1CCC96	DC/DC Converter Enable Component Internal Failure	-	-	-	-	○	-
P1CFF62	Hybrid/EV Battery Current/DC/DC Converter Current Signal Compare Failure	-	-	-	-	○	A
P31241F	Lost Communication between Drive Motor "A" and HV ECU Circuit Intermittent	-	-	○	-	-	-
P312487	Lost Communication between Drive Motor "A" and HV ECU Missing Message	-	-	○	-	-	-
P313383	Communication Error from Generator to Drive Motor "A" Value of Signal Protection Calculation Incorrect	○	-	-	-	-	-
P313386	Communication Error from Generator to Drive Motor "A" Signal Invalid	○	-	-	-	-	-
P313387	Communication Error from Generator to Drive Motor "A" Missing Message	○	-	-	-	-	-
P313483	Communication Error from Drive Motor "A" to Generator Value of Signal Protection Calculation Incorrect	○	-	-	-	-	-
P313486	Communication Error from Drive Motor "A" to Generator Signal Invalid	○	-	-	-	-	-
P313487	Communication Error from Drive Motor "A" to Generator Missing Message	○	-	-	-	-	-
P314F1F	DC/DC Converter Voltage Sensor "A" (VL) Circuit Intermittent	-	-	-	-	○	F
P31531D	DC/DC Converter Current Sensor Circuit Current Out of Range	-	-	-	-	○	F
U010087	Lost Communication With ECM/PCM "A" Missing Message	-	-	○	-	-	-
U029387	Lost Communication With Hybrid Powertrain Control Module Missing Message	-	-	○	-	-	-
U117087	Lost Communication With Brake System Control Module (ch2) Missing Message	-	-	○	-	-	-

HINT:

The "Example of Multiple DTCs being Output" below is only one example of a malfunction condition. Therefore, a determination should not be made based on this alone.

Example of Multiple DTCs being Output:

The power supply of the microcomputer decreases while the vehicle is being driven.
1. DTCs are detected and the vehicle behavior is as follows.
Detected DTCs
- P06B01C (Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range): Power source malfunction*
- P0C5016 (Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Below Threshold): Sensor and actuator circuit malfunction*
- P0A3F16 (Drive Motor "A" Position Sensor Circuit Voltage Below Threshold): Sensor and actuator circuit malfunction*
- P1CAD49 (Drive Motor "A" Position Sensor Internal Electronic Failure): Sensor and actuator circuit malfunction*
- P1CAC49 (Generator Position Sensor Internal Electronic Failure): Sensor and actuator circuit malfunction*
  - *: Check the priority level in the "DTC Order of Priority" chart above.
Vehicle Behavior
- System stopped
The inspection order of priority is: Microcomputer circuit → power source circuit → communication circuit → sensor and actuator circuit → system circuit. Therefore, check the repair procedure for P0B601C.
Follow the repair procedures and replace the inverter assembly. Finish the repair.

It is possible to check only the specified malfunctioning parts without having to check irrelevant parts.

SEE MORE:

Inspection

INSPECTION PROCEDURE 1. INSPECT CYLINDER BLOCK FOR WARPAGE (a) Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head gasket for warpage. Maximum Warpage: 0.05 mm (0.00197 in.) HINT: If the warpage is more than the maximum, replace the cylinder block

Installation

INSTALLATION CAUTION / NOTICE / HINT NOTICE: This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts. Click here PROCEDURE 1. INSTALL ENGINE BALANCER ASSEMBLY Click here 2. INSTALL STIFFENING CRANKCASE ASSEMBL

Lexus ES: Diagnosis System

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Dtc Check / Clear

Freeze Frame Data

Vehicle Behavior Chart

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Inspection

Installation