Motor position sensor incorrectly fitted or misaligned

The rotor position sensor is physically in the wrong place — mounted off its correct alignment, refitted without being set, or moved by something.

Distinct from the calibration simply not having been run, and the difference decides the repair. A missed calibration is software: the routine has not stored an offset. This is hardware: the geometry itself is wrong, so the routine, if it runs at all, measures something outside what the manufacturer will accept.

Many resolvers are deliberately adjustable, mounted in slotted holes so the offset can be set on assembly. That adjustability is exactly what makes them easy to get wrong — a sensor removed for access and refitted "where it was" is a sensor that is approximately where it was. The other physical causes are rarer and more serious: a rotor that has moved on its shaft, or mounting hardware that has loosened.

The tell is a learning routine that completes and returns an implausible figure, rather than one that refuses. And the trap that follows is worth naming: re-running the routine until it accepts a value is the wrong response. The number is out of range for a reason, and forcing one the car will then drive on turns a marginal fit into a machine running permanently mistimed — producing less torque for more current, more heat, and worse range, for as long as it stays that way.