Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: DC/DC Converter Current Sensor Circuit Current Out of Range (P31531D)

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / Hybrid / Battery Control / Motor Generator Control System / DC/DC Converter Current Sensor Circuit Current Out of Range (P31531D)

DTC SUMMARY

MALFUNCTION DESCRIPTION

This DTC is stored if the value of the reactor current sensor fluctuates excessively. The cause of this malfunction may be one of the following:

Area

Main Malfunction Description

Hybrid vehicle transaxle assembly
  • Open or short circuit in the motor or generator coils
  • Motor (MG2) or generator (MG1) internal malfunction (iron particles or damage from foreign objects)

Resolver

Open or short circuit in the motor resolver or generator resolver circuit
Inverter
  • Inverter internal circuit malfunction
  • Malfunction in ECU that controls the inverter
  • Malfunction in sensor for inverter control (current sensor)

HV battery high-voltage line circuit

Open in a frame wire

DESCRIPTION

For a description of the inverter.

Click here

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P31531D

DC/DC Converter Current Sensor Circuit Current Out of Range

Value of reactor current sensor fluctuates excessively

(1 trip detection logic)
  • HV battery junction block assembly
  • Inverter with converter assembly
  • Service plug grip
  • HV floor under wire
  • Hybrid vehicle control ECU
  • PCU fuse
  • Wire harness or connector
  • Hybrid vehicle transaxle assembly
  • Motor cable

Does not come on

Master Warning Light:

Comes on

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

  1. Connect the Techstream to the DLC3.
  2. Turn the power switch on (IG) and turn the Techstream on.
  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  4. Turn the power switch off and wait for 2 minutes or more.
  5. Turn the power switch on (IG) and turn the Techstream on.
  6. With power switch on (IG) and wait for 5 seconds or more.
  7. Turn the power switch on (READY) and wait for 5 seconds or more.
  8. Drive the vehicle for approximately 10 minutes mainly using the engine.
  9. Enter the following menus: Powertrain / Motor Generator / Utility / All Readiness.
  10. 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 driving pattern again.

WIRING DIAGRAM

Refer to the wiring diagram for the Generator Resolver Circuit.

Click here

Refer to the wiring diagram for the Motor Resolver Circuit.

Click here

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

Click here

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

Click here

Refer to the wiring diagram for the Inverter Low-voltage Circuit.

Click here

Refer to the wiring diagram for HV Battery High-voltage Line 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

PROCEDURE

1.

CHECK DTC OUTPUT (HYBRID CONTROL)

(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

P31531D 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

Table1:

Malfunction Content

System

Relevant DTC

Insulation Malfunction

Hybrid control system

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

Hybrid control system

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

HV Battery Malfunction

Hybrid control system

P0AFC16

Hybrid/EV Battery Sensor Module Circuit Voltage Below Threshold

P0AFC96

Hybrid/EV Battery Sensor Module Component Internal Failure

P1AC000

Hybrid/EV Battery Cell Low Voltage

P1AD01B

Hybrid/EV Battery Block Internal Resistance High

P1CBE1E

Hybrid/EV Battery Block 1 (Voltage Difference) Circuit Resistance Out of Range

P1CBF1E

Hybrid/EV Battery Block 2 (Voltage Difference) Circuit Resistance Out of Range

P1CC01E

Hybrid/EV Battery Block 3 (Voltage Difference) Circuit Resistance Out of Range

P1CC11E

Hybrid/EV Battery Block 4 (Voltage Difference) Circuit Resistance Out of Range

P1CC21E

Hybrid/EV Battery Block 5 (Voltage Difference) Circuit Resistance Out of Range

P1CC31E

Hybrid/EV Battery Block 6 (Voltage Difference) Circuit Resistance Out of Range

P1CC41E

Hybrid/EV Battery Block 7 (Voltage Difference) Circuit Resistance Out of Range

P1CC51E

Hybrid/EV Battery Block 8 (Voltage Difference) Circuit Resistance Out of Range

P1CC61E

Hybrid/EV Battery Block 9 (Voltage Difference) Circuit Resistance Out of Range

P1CC71E

Hybrid/EV Battery Block 10 (Voltage Difference) Circuit Resistance Out of Range

P1CFD1E

Hybrid/EV Battery Block 11 (Voltage Difference) Circuit Resistance Out of Range

P301100

Hybrid/EV Battery Block 1 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301200

Hybrid/EV Battery Block 2 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301300

Hybrid/EV Battery Block 3 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301400

Hybrid/EV Battery Block 4 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301500

Hybrid/EV Battery Block 5 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301600

Hybrid/EV Battery Block 6 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301700

Hybrid/EV Battery Block 7 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301800

Hybrid/EV Battery Block 8 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P301900

Hybrid/EV Battery Block 9 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P302000

Hybrid/EV Battery Block 10 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

P302100

Hybrid/EV Battery Block 11 (Internal Resistance Difference) Circuit Resistance Out of Range (Extreme)

U029A87

Lost Communication with Hybrid/EV Battery Sensor Module Missing Message
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

P06D61C

Generator Control Module Offset Power Circuit Voltage Out of Range

Communication malfunction

Motor generator control system

P312487

Lost Communication between Drive Motor "A" and HV ECU Missing Message

Hybrid control system

P312387

Lost Communication with Missing Message

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

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

P0E5128

DC/DC Converter Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure

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

P1CFF62

Hybrid/EV Battery Current/DC/DC Converter Current Signal Compare Failure

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

System Malfunction

Motor generator control system

P0A9000

Drive Motor "A" Performance

P0A9200

Hybrid Generator Performance

P0BFF1D

Drive Motor "A" Circuit Current Out of Range

P0C1900

Drive Motor "A" Execution Torque Performance

P0CA300

DC/DC Converter Step Up Voltage Performance

P0E7100

Generator Execution Torque Performance

P1CA51D

Hybrid Generator Circuit Current Out of Range

Hybrid control system

P0AA649

Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure

HINT:

  • P31531D 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.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

C

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)

A

2.

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
A

3.

CHECK GENERATOR RESOLVER CIRCUIT

Click here

NEXT

4.

CHECK MOTOR RESOLVER CIRCUIT

Click here

NEXT

5.

CHECK GENERATOR HIGH-VOLTAGE CIRCUIT

Click here

NEXT

6.

CHECK MOTOR HIGH-VOLTAGE CIRCUIT

Click here

NEXT

7.

CHECK HV BATTERY HIGH-VOLTAGE LINE CIRCUIT

Click here

NEXT

8.

CHECK INVERTER LOW-VOLTAGE CIRCUIT

Click here

HINT:

If the "Inverter Low-voltage Circuit" inspection results are normal, perform the next step.

NEXT

REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Lost Communication between Drive Motor "A" and HV ECU Circuit Intermittent (P31241F,P312487)

    Crankshaft Position Sensor "A" (P033500,P033531)

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