HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): P0C5516,P0C5517,P0C5F16,P0C5F17; Drive Motor "B" Position Sensor Circuit "A" Circuit Voltage Below Threshold; 2020 - 2024 MY RAV4 HV [06/2020

These DTCs indicate that the resolver output signal is abnormal. The cause of this malfunction may be one of the following:

If any of these DTCs is output, malfunction of the motor generator control ECU circuit board or poor connection of low-voltage connectors is suspected. It is not necessary to inspect the motor resolver.

DESCRIPTION

MONITOR DESCRIPTION

The motor generator control ECU monitors the rear motor resolver output signal. If the motor generator control ECU detects output signals that are out of the normal range or specification, it will conclude that there is a malfunction in the rear motor resolver. If a malfunction is detected, 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.
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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 ignition switch to ON and turn the Techstream on.
Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
Turn the ignition switch off and wait for 2 minutes or more.
Turn the ignition switch to ON and turn the Techstream on.
With ignition switch ON and wait for 5 seconds or more. [*1]
Turn the ignition switch to ON (READY) and wait for 5 seconds or more. [*2]
Depress the accelerator pedal of the vehicle with the engine stopped and the shift lever in P to start the engine. [*3]
Drive the vehicle forward with the shift lever in D for 5 m (16 ft.) or more. [*4]
Drive the vehicle backward with the shift lever in R for 5 m (16 ft.) or more. [*5]
HINT:

[*1] to [*5]: 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, 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 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.

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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

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.

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

Powertrain > Hybrid Control > Trouble Codes

Powertrain > Motor Generator > Trouble Codes

Table 1

Table 2

HINT:

P0C5516, P0C5517, P0C5F16 or P0C5F17 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.)

DTC SUMMARY

Internal inverter malfunction

Inverter low-voltage circuit malfunction

DESCRIPTION

MONITOR DESCRIPTION

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

CONFIRMATION DRIVING PATTERN

CAUTION / NOTICE / HINT

PROCEDURE

Powertrain > Hybrid Control > Trouble Codes

Powertrain > Motor Generator > Trouble Codes

Table 1

Table 2