Hybrid Systems - HEV Sensor Calibration Procedures
Group: GENERAL INFORMATIONNumber: 11-GI-003
Date: JANUARY 2011
Model: 2011 MY SONATA, 2.4L HEV
Subject
YF HEV SENSOR CALIBRATION PROCEDURES
USING GDS
DESCRIPTION:
This bulletin provides the procedures for calibrating several of the SONATA HEV (YF) sensors using GDS, which must be carried out whenever some components such as Hybrid Power Control Unit (HPCU) or Hydraulic Power Unit (HPU) are replaced:
1. Clutch Pressure Sensor Calibration
2. Motor/HSG (Hybrid Starter Generator) Resolver Calibration
3. EWP (Electronic Water Pump) Actuation
4. Brake Pedal Travel Sensor Calibration & AHB (Active Hydraulic Booster) Pressure Sensor Calibration
1. CLUTCH PRESSURE SENSOR CALIBRATION
Purpose of the calibration
The engine clutch is installed inside the hybrid drive motor and serves to mechanically connect or disconnect the engine drive power to the transaxle. It is operated by hydraulic pressure and the oil pressure is sensed by the clutch pressure sensor (CPS), which is located beside the electric oil pump in the transaxle housing.
The clutch pressure sensor calibration must be performed to reduce shock while the engine drive power is engaged to the transaxle by eliminating deviations in the engine clutch fluid pressure that may occur under the conditions listed below.
Conditions where calibration is required
After removing and re-installing, or replacing any of the following components:
^ Hybrid drive motor (integrated into the automatic transaxle)
^ Engine Control Module (ECM)
^ Transaxle Control Module (TCM)
^ HCU (integrated into the Hybrid Power Control Unit)
^ Clutch pressure sensor (CPS)
GDS procedure to perform Clutch Pressure Calibration
2. MOTOR/HSG RESOLVER CALIBRATION
Purpose of the calibration
The resolvers mounted onto the hybrid drive motor and the hybrid starter generator (HSG) sense the position of the rotor in the motor. The rotor position sensed by the resolver is one of the most important factors used by the motor control unit (MCU) to control the motor precisely. The resolver calibration must be performed to correct the offset between the actual rotor position and the estimated rotor position that occurs in the conditions listed below. If calibration is not carried out, the actual motor torque may differ from the target value.
Conditions where calibration is required
^ After removing and re-installing or replacing the MCU (integrated into the HPCU)
^ After removing and re-installing or replacing the hybrid drive motor (integrated into the automatic transaxle)
^ After removing and re-installing or replacing the HSG
^ When DTC POC17 or P1C76 is stored and the service indicator (in the cluster) is illuminated
GDS procedure to perform Motor/HSG Calibration:
3. ELECTRIC WATER PUMP (EWP) ACTUATION
Purpose of the actuation
The electric water pump (EWP) is a device used to circulate coolant in the cooling circuit between the HSG and the HPCU. EWP actuation must be performed to bleed air from the cooling circuit in the conditions listed below. If not carried out, it may lead to deterioration in cooling performance.
For further information on the EWP actuation procedure, refer to the "Hybrid Motor Cooling System - Coolant" section of the shop manual.
Conditions where calibration is required
^ changing coolant
^ adding coolant due to a low coolant level
^ adding coolant after removing and re-installing or replacing the HSG
^ adding coolant after removing and re-installing or replacing the HPCU
^ adding coolant after removing and re-installing or replacing the coolant hose(s)
^ adding coolant after removing and re-installing or replacing the EWP
^ adding coolant after removing and re-installing or replacing the inverter radiator
GDS procedure for EWP Actuation:
4. BRAKE PEDAL TRAVEL SENSOR & AHB PRESSURE SENSOR CALIBRATION
Purpose of the calibration
The brake pedal travel and active hydraulic booster (AHB) pressure sensors measure the stroke and pressure generated at the brake pedal and the sensors must be calibrated for offset compensation in the conditions listed below. If not carried out, trouble codes C1379 or C1380 may be set.
Conditions where calibration is required
^ After removing and re-installing or replacing the brake pedal
^ After removing and re-installing or replacing the HPCU
GDS procedure for Brake Pedal Travel Sensor & AHB Pressure Sensor Calibration
Normal warranty applies.