Lexus ES: Hybrid Generator Circuit Current Out of Range (P1CA51D)

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / Hybrid / Battery Control / Motor Generator Control System (for Lithium-ion Battery) / Hybrid Generator Circuit Current Out of Range (P1CA51D)

DTC SUMMARY

MALFUNCTION DESCRIPTION

This DTC indicates that current does not flow as commanded due to a generator output circuit malfunction. The cause of this malfunction may be one of the following:

Area	Main Malfunction Description
Inside of inverter	Inverter with converter assembly internal circuit malfunction
Hybrid vehicle transaxle assembly	Generator (MG1) internal malfunction (entry of foreign matter, etc.) Open or short circuit in the generator coils
Inverter low-voltage circuit	The connectors are not connected properly
Motor cable (for MG1)	Defective motor cable connection condition Open circuit or poor insulation in motor cable
Hybrid vehicle control ECU	Hybrid vehicle control ECU internal circuit malfunction

DESCRIPTION

For a description of the inverter.

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DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	Warning Indicate
P1CA51D	Hybrid Generator Circuit Current Out of Range	Generator system malfunction: If current does not flow as commanded, the generator high voltage system may be malfunctioning. Malfunction is detected when the vehicle is stopped or the engine is starting. (1 trip detection logic)	Hybrid vehicle transaxle assembly Inverter with converter assembly Wire harness or connector Hybrid vehicle control ECU	Comes on	Master Warning Light: Comes on

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P1CA51D

Hybrid Generator Circuit Current Out of Range

Generator system malfunction:

If current does not flow as commanded, the generator high voltage system may be malfunctioning.

Malfunction is detected when the vehicle is stopped or the engine is starting.

(1 trip detection logic)

Hybrid vehicle transaxle assembly
Inverter with converter assembly
Wire harness or connector
Hybrid vehicle control ECU

Comes on

Master Warning Light:

Comes on

MONITOR DESCRIPTION

The motor generator control ECU monitors the generator. If the motor generator control ECU detects a malfunction of the generator, the motor generator control ECU will illuminate the MIL and store a DTC.

MONITOR STRATEGY

Related DTCs	P1CA5 (INF P1CA51D): Generator system malfunction (No generator torque)
Required sensors/components	Generator (MG1), inverter, generator resolver
Frequency of operation	Continuous
Duration	TMC's intellectual property
MIL operation	1 driving cycle
Sequence of operation	None

TYPICAL ENABLING CONDITIONS

The monitor will run whenever the following DTCs are not stored	TMC's intellectual property
Other conditions belong to TMC's intellectual property	-

TYPICAL MALFUNCTION THRESHOLDS

TMC's intellectual property

COMPONENT OPERATING RANGE

Motor generator control ECU

DTC P1CA5 (INF P1CA51D) is not detected

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

Connect the Techstream to the DLC3.
Turn the power switch on (IG) and turn the Techstream on.
Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
Turn the power switch off and wait for 2 minutes or more.
Turn the power switch on (IG) and turn the Techstream on.
Turn the power switch on (READY) with the shift lever in P. [*1]
With the engine stopped, depress the accelerator pedal and start the engine. [*2]
Release the accelerator pedal immediately. (Start and stop the engine several times) [*3]
HINT:

[*1] to [*3]: Normal judgment procedure.

The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.
Enter the following menus: Powertrain / Motor Generator / Utility / All Readiness.
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 the Generator High-voltage Circuit.

Click here

Refer to the wiring diagram for the Shut Down Signal Circuit.

Click here

Refer to the wiring diagram for the Motor High-voltage Circuit.

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 an abnormality occurs after disconnecting and connecting the motor cable, reconfirm the cable connection condition.

PROCEDURE

1.	CHECK DTC OUTPUT

(a) Connect the Techstream to the DLC3.

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

(d) Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes Powertrain > Motor Generator > Trouble Codes

Result	Proceed to
P1CA51D only is output, or DTCs except the ones in the tables below are also output.	A
DTCs of hybrid control system in the tables below are output.	B
DTCs of motor generator control system in the tables below are output.	C

Table 1:

Malfunction Content	Relevant DTC
Insulation Malfunction	P1C7C49	Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure
	P1C7D49	Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure
	P1C7E49	Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure
	P1C7F49	Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure
System Main Relay or High Voltage Circuit Malfunction	P0AD911	Hybrid/EV Battery Positive Contactor Circuit Short to Ground
	P0AD915	Hybrid/EV Battery Positive Contactor Circuit Short to Battery or Open
	P0ADD11	Hybrid/EV Battery Negative Contactor Circuit Short to Ground
	P0ADD15	Hybrid/EV Battery Negative Contactor Circuit Short to Battery or Open
	P1C8449	High Voltage Power Resource Circuit Short during Ready ON

Table 2

Malfunction Content	System	Relevant DTC
Microcomputer malfunction	Motor generator control system	P0A1A47	Generator Control Module Watchdog / Safety μC Failure
		P0A1A49	Generator Control Module Internal Electronic Failure
		P0A1B1F	Generator Control Module Circuit Intermittent
		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
		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
	Hybrid control system	P0A1B49	Drive Motor "A" Control Module Internal Electronic Failure
Power source circuit malfunction	Motor generator control system	P06B01C	Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range
Power source circuit malfunction	Motor generator control system	P06D61C	Generator Control Module Offset Power Circuit Voltage Out of Range
Sensor and actuator circuit malfunction	Motor generator control system	P0A3F16	Drive Motor "A" Position Sensor Circuit Voltage Below Threshold
		P0A3F21	Drive Motor "A" Position Sensor Signal Amplitude < Minimum
		P0A3F22	Drive Motor "A" Position Sensor Signal Amplitude > Maximum
		P0A4B16	Generator Position Sensor Circuit Voltage Below Threshold
		P0A4B21	Generator Position Sensor Signal Amplitude < Minimum
		P0A4B22	Generator Position Sensor Signal Amplitude > Maximum
		P0A6012	Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Battery
		P0A6014	Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Ground or Open
		P0A601C	Drive Motor "A" Phase V Current (High Resolution) Circuit Voltage Out of Range
		P0A6312	Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Battery
		P0A6314	Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Ground or Open
		P0A631C	Drive Motor "A" Phase W Current (High Resolution) Circuit Voltage Out of Range
		P0BE512	Drive Motor "A" Phase U Current Sensor Circuit Short to Battery
		P0BE514	Drive Motor "A" Phase U Current Sensor Circuit Short to Ground or Open
		P0BE528	Drive Motor "A" Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
		P0BE912	Drive Motor "A" Phase V Current Sensor Circuit Short to Battery
		P0BE914	Drive Motor "A" Phase V Current Sensor Circuit Short to Ground or Open
		P0BE928	Drive Motor "A" Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
		P0BED12	Drive Motor "A" Phase W Current Sensor Circuit Short to Battery
		P0BED14	Drive Motor "A" Phase W Current Sensor Circuit Short to Ground or Open
		P0BED28	Drive Motor "A" Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
		P0BFD62	Drive Motor "A" Phase U-V-W Current Sensor Signal Compare Failure
		P0C5013	Drive Motor "A" Position Sensor Circuit "A" Circuit Open
		P0C5016	Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Below Threshold
		P0C5017	Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Above Threshold
		P0C5A13	Drive Motor "A" Position Sensor Circuit "B" Circuit Open
		P0C5A16	Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Below Threshold
		P0C5A17	Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Above Threshold
		P0C6413	Generator Position Sensor Circuit "A" Circuit Open
		P0C6416	Generator Position Sensor Circuit "A" Circuit Voltage Below Threshold
		P0C6417	Generator Position Sensor Circuit "A" Circuit Voltage Above Threshold
		P0C6913	Generator Position Sensor Circuit "B" Circuit Open
		P0C6916	Generator Position Sensor Circuit "B" Circuit Voltage Below Threshold
		P0C6917	Generator Position Sensor Circuit "B" Circuit Voltage Above Threshold
		P0D2D16	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Below Threshold
		P0D2D17	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold
		P0DFA62	Generator Phase U-V-W Current Sensor Signal Compare Failure
		P0E0012	Generator Phase U Current Sensor Circuit Short to Battery
		P0E0014	Generator Phase U Current Sensor Circuit Short to Ground or Open
		P0E0028	Generator Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
		P0E0412	Generator Phase V Current Sensor Circuit Short to Battery
		P0E0414	Generator Phase V Current Sensor Circuit Short to Ground or Open
		P0E0428	Generator Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
		P0E0812	Generator Phase W Current Sensor Circuit Short to Battery
		P0E0814	Generator Phase W Current Sensor Circuit Short to Ground or Open
Sensor and actuator circuit malfunction	Motor generator control system	P0E0828	Generator Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure
		P0E3116	DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Below Threshold
		P0E3117	DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Above Threshold
		P0E5111	DC/DC Converter Current Sensor Circuit Short to Ground
		P0E5115	DC/DC Converter Current Sensor Circuit Short to Battery or Open
		P0E512A	DC/DC Converter Current Sensor Signal Stuck In Range
		P1CAC49	Generator Position Sensor Internal Electronic Failure
		P1CAD49	Drive Motor "A" Position Sensor Internal Electronic Failure
		P1CAF38	Generator Position Sensor REF Signal Cycle Malfunction Signal Frequency Incorrect
		P1CB038	Drive Motor "A" Position Sensor REF Signal Frequency Incorrect
	Hybrid control system	P0C7600	Hybrid/EV Battery System Discharge Time Too Long
		P0D2D1C	Drive Motor "A" Inverter after Boosting Voltage Sensor Circuit Voltage Out of Range
		P0E311C	Drive Motor "A" Inverter before Boosting Voltage Sensor Circuit Voltage Out of Range
		P1C2D62	Drive Motor "A" Inverter before Boosting Voltage Sensor Signal Compare Failure
System malfunction	Motor generator control system	P0A7873	Drive Motor "A" Inverter Actuator Stuck Closed
		P0A7A73	Generator Inverter Actuator Stuck Closed
		P0A9000	Drive Motor "A" Performance
		P0A9200	Hybrid Generator Performance
		P1C5D19	Drive Motor "A" Inverter Circuit Current Above Threshold

HINT:

P1CA51D may be output as a result of the malfunction indicated by the DTCs above.
1. The chart above is listed in inspection order of priority.
2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

(e) Turn the power switch off.

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)

2.	CHECK DIAGNOSIS RELATED INFORMATION

(a) Connect the Techstream to the DLC3.

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

Powertrain > Motor Generator > Utility

Tester Display
Diagnosis Related Information

(d) Read the diagnosis related information.

Result	Proceed to
P0A9200 is output	A
Other than above	B

(e) Turn the power switch off.

GO TO DTC CHART (P0A9200)

3.	CHECK FREEZE FRAME DATA AND DIAGNOSIS RELATED INFORMATION

(a) Connect the Techstream to the DLC3.

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

Powertrain > Motor Generator > Utility

Tester Display
Diagnosis Related Information

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

Powertrain > Motor Generator > Trouble Codes

(e) Read the diagnosis related information and freeze frame data of DTC P1CA51D.

Result	Proceed to
DTC P312487 is listed in Diagnosis Related Information.	A
DTC P312487 is not listed in Diagnosis Related Information and the value of freeze frame data item Emergency Shutdown Signal is ON.	B
Other than above	C

(f) Turn the power switch off.

GO TO DTC CHART (P312487)

GO TO DTC CHART (P321E9F)

4.	CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

Click here

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

CONNECT SECURELY

REPAIR OR REPLACE HARNESS OR CONNECTOR

5.	CHECK SHUT DOWN SIGNAL CIRCUIT

Click here

6.	CHECK GENERATOR HIGH-VOLTAGE CIRCUIT

Click here

7.	CHECK MOTOR HIGH-VOLTAGE CIRCUIT

Click here

HINT:

If the "Motor High-voltage Circuit" inspection results are normal, perform the next step.

REPLACE INVERTER WITH CONVERTER ASSEMBLY

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