Lexus ES: 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 |
|
| Inverter low-voltage circuit | The connectors are not connected properly |
| Motor cable (for MG1) |
|
| 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) |
| 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.
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-
When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.
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- 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.
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Refer to the wiring diagram for the Shut Down Signal Circuit.
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Refer to the wiring diagram for the Motor High-voltage Circuit.
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CAUTION / NOTICE / HINT
CAUTION:
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-
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.
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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.
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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).
(c) Enter the following menus: Powertrain / Hybrid Control and Motor Generator / Trouble Codes.
(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 | |
| 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 |
| 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.
- The chart above is listed in inspection order of priority.
- 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.
| B | .gif) | GO TO DTC CHART (HYBRID CONTROL SYSTEM) |
| C | | GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM) |
|
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| 2. | CHECK DIAGNOSIS RELATED INFORMATION |
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Enter the following menus: Powertrain / Motor Generator / Utility / Diagnosis Related Information.
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.
| A | | 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).
(c) Enter the following menus: Powertrain / Motor Generator / Utility / Diagnosis Related Information.
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.
| A | | GO TO DTC CHART (P312487) |
| B | | 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 |
| B | | CONNECT SECURELY |
| C | | 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.
| NEXT | | REPLACE INVERTER WITH CONVERTER ASSEMBLY |
READ NEXT:
Generator Position Sensor Internal Electronic Failure (P1CAC49,P1C641F,P1CAF38)
DESCRIPTION The motor generator control ECU (MG ECU), which is built into the inverter with converter assembly, monitors its internal operation and detects malfunctions. DTC No. Detection Item
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. DTC No. Detection Item
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
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