Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001OR0T
Model Year Start: 2020 Model: RAV4 HV Prod Date Range: [06/2020 -           ]
Title: HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): P1CAD49,P1C651F,P1CB038; Drive Motor "A" Position Sensor Internal Electronic Failure; 2020 - 2024 MY RAV4 HV [06/2020 -        ]

DTC

P1CAD49

Drive Motor "A" Position Sensor Internal Electronic Failure

DTC

P1C651F

Generator Control Module Circuit Intermittent

DTC

P1CB038

Drive Motor "A" Position Sensor REF Signal Frequency Incorrect

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

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P1C651F

Generator Control Module Circuit Intermittent

Excitation signal (REF signal) for resolver angle detection cycle malfunction detected when DTC P0C7917, P0D3319, P1C5D19, P1C5F19 or P1C5E19 is stored.

(1 trip detection logic)

  • Inverter with converter assembly
  • Hybrid vehicle transaxle assembly
  • Rear traction motor with transaxle assembly
  • Wire harness or connector

Does not come on

Master Warning:

Does not come on

P1CAD49

Drive Motor "A" Position Sensor Internal Electronic Failure

Motor resolver angle malfunction:

The difference between the resolver angle for control and estimated resolver angle exceeds the allowable limit.

(1 trip detection logic)

  • Inverter with converter assembly
  • Hybrid vehicle transaxle assembly
  • Rear traction motor with transaxle assembly
  • Wire harness or connector

Comes on

Master Warning:

Comes on

P1CB038

Drive Motor "A" Position Sensor REF Signal Frequency Incorrect

Resolver REF signal cycle malfunction:

Excitation signal (REF signal) for resolver angle detection cycle malfunction

(1 trip detection logic)

  • Inverter with converter assembly
  • Hybrid vehicle transaxle assembly
  • Rear traction motor with transaxle assembly
  • Wire harness or connector

Comes on

Master Warning:

Comes on

HINT:

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

Related Data List

DTC No.

Data List

P1CAD49

Motor Revolution

P1CB038

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

Related DTCs

P1CAD (INF P1CAD49): Drive Motor "A" Control Module R/D Processing (Drive Motor "A" Position) Performance

P1CB0 (INF P1CB038): Drive Motor "A" Position Sensor Reference Signal Performance

Required sensors/components

Motor resolver

Frequency of operation

Continuous

Duration

TMC's intellectual property

MIL operation

Immediately

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 P1CAD (INF P1CAD49) is not detected

DTC P1CB0 (INF P1CB038) 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 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): UTILITY

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

    Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): DTC CHECK / CLEAR

  1. Connect the Techstream to the DLC3.
  2. Turn the ignition switch to ON and turn the Techstream on.
  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  4. Turn the ignition switch off and wait for 2 minutes or more.
  5. Turn the ignition switch to ON and turn the Techstream on.
  6. With ignition switch ON 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 ignition switch to 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, perform the normal judgment procedure again.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P1CAC49.

Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): P1CAC49,P1C641F,P1CAF38; Generator Position Sensor Internal Electronic Failure+

CAUTION / NOTICE / HINT

CAUTION:

  • Before the following operations are conducted, take precautions to prevent electric shock by turning the ignition 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 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): PRECAUTION

    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 ignition 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 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

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

1.

CHECK DTC OUTPUT (MOTOR GENERATOR)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

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

(d) Check for DTCs.

Powertrain > Motor Generator > Trouble Codes

Result

Proceed to

P1CAD49, P1CB038 or P1C651F only is output, or DTCs except the ones in the table below are also output.

A

Any of the following DTCs are also output.

B

System

Relevant DTC

Motor generator control system

P0A3F16

Drive Motor "A" Position Sensor Circuit Voltage Below Threshold

P0A4516

Drive Motor B" Position Sensor Circuit Voltage Below Threshold

P0A4B16

Generator Position Sensor Circuit Voltage Below Threshold

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

(e) Turn the ignition switch off.

B

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)

A

2.

CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): P033500,P033531; Crankshaft Position Sensor "A"+

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

A

3.

CHECK GENERATOR RESOLVER CIRCUIT

Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): Generator Resolver Circuit

NEXT

4.

CHECK MOTOR RESOLVER CIRCUIT

Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): Motor Resolver Circuit

NEXT

5.

CHECK REAR MOTOR RESOLVER CIRCUIT

Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): Rear Motor Resolver Circuit

HINT:

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

NEXT

REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS