HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA073

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DTC SUMMARY

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1. MALFUNCTION DESCRIPTION

   The hybrid vehicle control ECU assembly detects a stuck closed malfunction of a system main relay on the positive (+) terminal side and negative (-) terminal side of the HV battery.

   The cause of this malfunction may be one of the following:

   
   
   • Inverter voltage sensor (VH) internal circuit malfunction

   • Voltage sensor (VH) malfunction

   • Motor generator control ECU (MG ECU) malfunction

   • Communication (wire harness) malfunction

   
   
   • High voltage system malfunction

   • HV battery junction block assembly malfunction

   
   
   • Low-voltage circuit (12 V) malfunction

   • Hybrid vehicle control ECU assembly malfunction

   • HV battery junction block assembly malfunction

   • Low voltage wire harness malfunction

   • Low voltage connector malfunction

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DESCRIPTION

Refer to the description for DTC P0AE411.

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This circuit uses the hybrid vehicle control ECU assembly to monitor the system main relays and stops the system if a malfunction is detected in the relays, because it may be impossible to shut off the high-voltage system if any of the relays becomes stuck.

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CONFIRMATION DRIVING PATTERN

1. Connect the GTS to the DLC3.

2. Turn the power switch on (IG) and turn the GTS 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 GTS on.

6. Turn the power switch on (READY) and wait for 2 minutes or more.

   Tip:

   According to the display on the GTS, read the Data List and monitor the values of "Hybrid Battery Voltage" and "VL-Voltage before Boosting" for 3 minutes. If the difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is always less than 100 V, the vehicle has returned to normal.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

8. Check the DTC judgment result.

   Tip:
   

   • 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 driving pattern again.

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WIRING DIAGRAM

Refer to the wiring diagram for the HV battery high-voltage line circuit.

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CAUTION / NOTICE / HINT

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PROCEDURE

1. Click here

   CHECK DTC OUTPUT (HYBRID CONTROL, MOTOR GENERATOR)

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the power switch on (IG).

   3. Enter the following menus: Powertrain / Hybrid Control and Motor Generator / Trouble Codes.

   4. Check for DTCs.

      
      
      1. Powertrain > Hybrid Control > Trouble Codes
      2. 
         
      3. 
         
      
      
      1. Powertrain > Motor Generator > Trouble Codes
      2. 
         
      3. 
         

      Result
      Result Proceed to P0AA073 only is output, or DTCs except the ones in the table 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

      Malfunction Content	System	Relevant DTC
      Microcomputer malfunction	Hybrid control system	P060647	Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
      		P060687	Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message
      		P060A47	Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure
      		P060A87	Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message
      		P0A1B49	Drive Motor "A" Control Module Internal Electronic Failure
      		P1C9E9F	Hybrid/EV System Reset Stuck Off
      	Motor generator control system	P0A1B1F	Generator Control Module Circuit Intermittent
      		P0A1A47	Generator Control Module Watchdog / Safety μC Failure
      		P0A1A49	Generator Control Module Internal Electronic Failure
      		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
      		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
      		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
      Power source circuit malfunction	Motor generator control system	P06D61C	Generator Control Module Offset Power Circuit Voltage Out of Range
      		P06B01C	Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range
      Communication system malfunction	Hybrid control system	P312387	Lost Communication with Drive Motor Control Module "A" from Hybrid/EV Control Module Missing Message
      Sensor and actuator circuit malfunction	Hybrid control system	P0AD911	Hybrid/EV Battery Positive Contactor Circuit Short to Ground
      		P0AD915	Hybrid/EV Battery Positive Contactor Circuit Short to Auxiliary Battery or Open
      		P0ADD11	Hybrid/EV Battery Negative Contactor Circuit Short to Ground
      		P0ADD15	Hybrid/EV Battery Negative Contactor Circuit Short to Auxiliary Battery or Open
      		P0AE411	Hybrid/EV Battery Precharge Contactor Circuit Short to Ground
      		P0AE415	Hybrid/EV Battery Precharge Contactor Circuit Short to Auxiliary Battery or Open
      	Motor generator control system	P0A3F16	Drive Motor "A" Position Sensor Circuit Voltage Below Threshold
      		P0A4B16	Generator Position Sensor Circuit Voltage Below Threshold
      		P0A4B21	Generator Position Sensor Signal Amplitude < Minimum
      		P0A4B22	Generator Position Sensor Signal Amplitude > Maximum
      		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
      System malfunction	Hybrid control system	P0C7600	Hybrid/EV Battery System Discharge Time Too Long
      		P0D2D1C	Drive Motor "A" Inverter Voltage Sensor Voltage Out of Range
      		P1C8349	High Voltage Power Resource Circuit Voltage Sensor after Boosting Malfunction
      	Motor generator control system	P0D2D16	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Below Threshold
      		P0D2D17	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold
      		P1CB69E	Drive Motor "A" Inverter Voltage Sensor (VH) Stuck On

      Tip:
      

      • P0AA073 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.)

   5. Turn the power switch off.

   
   
   • AClick here
   • B

     GO TO DTC CHART (HYBRID CONTROL SYSTEM)Click here

   • C

     GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)Click here

2. Click here

   CHECK FREEZE FRAME DATA (HYBRID CONTROL)

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the power switch on (IG).

   3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

   4. Read the freeze frame data of DTC P0AA073.

      
      
      1. Powertrain > Hybrid Control > Trouble Codes
      2. 
         
      3. 
         
      Note:

      As freeze frame data is stored immediately before and after a DTC is stored, make sure to only read the values for the moment the DTC was stored ("0(s)").

      Result
      Result Proceed to Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is less than 41 V. A Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is 41 V or more. B

      Tip:

      If VH-Voltage after Boosting is output even when an off command is being sent to the system main relay (positive side), P0AA073 is output. If the difference between the "VL-Voltage before Boosting" and the "VH-Voltage after Boosting" is large, it is determined that there is an inverter (VH sensor) malfunction.

   5. Turn the power switch off.

   
   
   • AClick here
   • B

     REPLACE INVERTER WITH CONVERTER ASSEMBLYClick here

3. Click here

   CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR)

   Result
   Proceed to OK NG

   
   
   1. 

      *A	for LHD
      *B	for RHD

      Check the connector connections and contact pressure of the relevant terminals for the hybrid vehicle control ECU assembly connectors.

      Click here

      OK
      The connectors are connected securely and there are no contact pressure problems.

      Result
      Proceed to OK NG

   
   
   • OKClick here

     GO TO STEP 5

   • NGClick here
4. Click here

   CONNECT SECURELY

   Result
   Proceed to NEXT

   
   
   • NEXTClick here
5. Click here

   CHECK CONNECTOR CONNECTION CONDITION (FLOOR WIRE CONNECTOR)

   Result
   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

   
   
   1. 

      Check the connection condition of the LG1 floor wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

      Click here

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.

      Result
      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

   
   
   • AClick here

     GO TO STEP 8

   • BClick here
   • CClick here
6. Click here

   CONNECT SECURELY

   Result
   Proceed to NEXT

   
   
   • NEXTClick here

     GO TO STEP 8

7. Click here

   REPAIR OR REPLACE HARNESS OR CONNECTOR

   Result
   Proceed to NEXT

   
   
   • NEXTClick here
8. Click here

   CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

   Result
   Proceed to OK NG

   CAUTION:

   Be sure to wear insulated gloves.

   
   

   1. Check that the service plug grip is not installed.

      Note:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

   2. Remove the No. 10 HV battery shield panel.

      Click here

   3. 

      Check the connector connections and contact pressure of the relevant terminals of the HV battery junction block assembly connector.

      Click here

      OK
      The connectors are connected securely and there are no contact pressure problems.

   4. Install the No. 10 HV battery shield panel.

      Result
      Proceed to OK NG

   
   
   • OKClick here

     GO TO STEP 10

   • NGClick here
9. Click here

   CONNECT SECURELY

   Result
   Proceed to NEXT

   
   
   • NEXTClick here
10. Click here

    CHECK GROUND WIRE CONNECTION CONDITION (SMR ACTIVATION LOW-VOLTAGE CIRCUIT)

    Result
    Proceed to OK NG

    
    

    1. Check the installation condition of the ground wire LG.

       OK
       The ground wire LG is securely installed.

       Result
       Proceed to OK NG

    
    
    • OKClick here

      GO TO STEP 12

    • NGClick here
11. Click here

    CONNECT SECURELY

    Result
    Proceed to NEXT

    
    
    • NEXTClick here
12. Click here

    CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - HV BATTERY JUNCTION BLOCK ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note:

       After removing the service plug grip, do not turn the power switch on (IG), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 10 HV battery shield panel.

       Click here

    3. Disconnect the e2 HV battery junction block assembly connector.

    4. Disconnect the G92 hybrid vehicle control ECU assembly connector.

    5. 

       *a	Rear view of wire harness connector (to Hybrid Vehicle Control ECU Assembly)
       *b	Front view of wire harness connector (to HV Battery Junction Block Assembly)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance (Check for Open)
       Tester Connection Condition Specified Condition G92-5 (SMRB) - e2-1 (SMRB) Power switch off Below 1 Ω G92-1 (SMRG) - e2-4 (SMRG) Power switch off Below 1 Ω G92-15 (SMRP) - e2-2 (SMRP) Power switch off Below 1 Ω

       Standard Resistance (Check for Short)
       Tester Connection Condition Specified Condition G92-5 (SMRB) or e2-1 (SMRB) - Body ground and other terminals Power switch off 10 kΩ or higher G92-1 (SMRG) or e2-4 (SMRG) - Body ground and other terminals Power switch off 10 kΩ or higher G92-15 (SMRP) or e2-2 (SMRP) - Body ground and other terminals Power switch off 10 kΩ or higher

    6. Reconnect the G92 hybrid vehicle control ECU assembly connector.

    7. Reconnect the e2 HV battery junction block assembly connector.

    8. Install the No. 10 HV battery shield panel.

       Result
       Proceed to OK NG

    
    
    • OKClick here

      GO TO STEP 14

    • NGClick here
13. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to NEXT

    
    
    • NEXTClick here
14. Click here

    CHECK HARNESS AND CONNECTOR (HV BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note:

       After removing the service plug grip, do not turn the power switch on (IG), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 10 HV battery shield panel.

       Click here

    3. Disconnect the e2 HV battery junction block assembly connector.

    4. 

       *a	Front view of wire harness connector (to HV Battery Junction Block Assembly)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Condition Specified Condition e2-3 (GND) - Body ground Power switch off Below 1 Ω

    5. Reconnect the e2 HV battery junction block assembly connector.

    6. Install the No. 10 HV battery shield panel.

       Result
       Proceed to OK NG

    
    
    • OKClick here

      GO TO STEP 16

    • NGClick here
15. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to NEXT

    
    
    • NEXTClick here
16. Click here

    INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB, SMRG, SMRP)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note:

       After removing the service plug grip, do not turn the power switch on (IG), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 10 HV battery shield panel.

       Click here

    3. Disconnect the e2 HV battery junction block assembly connector.

    4. 

       *a

       Component without harness connected (HV Battery Junction Block Assembly)

       -

       -

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance
       Tester Connection Condition Specified Condition e2-1 (SMRB) - e2-3 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 Ω e2-4 (SMRG) - e2-3 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 Ω e2-2 (SMRP) - e2-3 (GND) -40 to 80°C (-40 to 176°F) 140 to 290 Ω

    5. Reconnect the e2 HV battery junction block assembly connector.

    6. Install the No. 10 HV battery shield panel.

       Result
       Proceed to OK NG

    
    
    • OKClick here
    • NGClick here
17. Click here

    CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB, SMRG, SMRP)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Check that the service plug grip is not installed.

       Note:

       After removing the service plug grip, do not turn the power switch on (IG), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 10 HV battery shield panel.

       Click here

    3. 

       Disconnect the 2 HV floor under wire connectors from the HV battery junction block assembly.

       Note:

       Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    4. 

       *a	Service Plug Grip Removed (Service Plug Grip Connecting Terminals)
       *b	Component without harness connected (HV Battery Junction Block Assembly)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance (SMRB)
       Tester Connection Condition Specified Condition 1 - M3-1 (CBI) Power switch off 10 kΩ or higher

       Tip:
       

       • If a system main relay is stuck closed, inspect the HV battery junction block assembly without removing it from the vehicle, in order to keep the relay closed.

       • If the result of reading the freeze frame data is A, the HV battery junction block assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.

    5. 

       *a	Service Plug Grip Removed (Service Plug Grip Connecting Terminals)
       *b	Component without harness connected (HV Battery Junction Block Assembly)

       Measure the resistance according to the value(s) in the table below.

       Standard Resistance (SMRG, SMRP)
       Tester Connection Condition Specified Condition 2 - M4-1 (CEI) Power switch off 10 kΩ or higher

       Tip:
       

       • If a system main relay is stuck closed, inspect the HV battery junction block assembly without removing it from the vehicle, in order to keep the relay closed.

       • If the result of reading the freeze frame data is A, the HV battery junction block assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.

       • If the resistance is between 24.3 and 29.7 Ω, it can be determined that SMRP is stuck closed.

    6. Reconnect the 2 HV floor under wire connectors.

    7. Install the No. 10 HV battery shield panel.

       Result
       Result Judgment Proceed to OK Past malfunction A NG Present malfunction B

    
    
    • AClick here
    • BClick here
18. Click here

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

    Result
    Proceed to NEXT

    
    
    • NEXTClick here

      GO TO STEP 21

19. Click here

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

    Result
    Proceed to NEXT

    
    
    • NEXTClick here

      GO TO STEP 21

20. Click here

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

    Result
    Proceed to NEXT

    
    
    • NEXTClick here
21. Click here

    CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY (CHECK FOR NORMAL OPERATION)

    Result
    Result Proceed to Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is always less than 100 V. A Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is 100 V or more. B

    
    

    1. Install the service plug grip.

    2. Turn the power switch on (IG).

    3. Clear the DTCs.

       Click here

    4. Turn the power switch off and wait for 30 seconds or more.

    5. Turn the power switch on (READY).

    6. Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Voltage, VL-Voltage before Boosting.

    7. According to the display on the GTS, read the Data List and monitor the values of "Hybrid Battery Voltage" and "VL-Voltage before Boosting" for 3 minutes.

       
       
       1. Powertrain > Hybrid Control > Data List

          Tester Display
          VL-Voltage before Boosting
          Hybrid Battery Voltage

       2. 
          
          1. 
             
       3. 
          
          10. 
              
          11. 
              

       Result
       Result Proceed to Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is always less than 100 V. A Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting" is 100 V or more. B

    8. Turn the power switch off.

    
    
    • A

      END

    • B

      REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY AND HV BATTERY JUNCTION BLOCK ASSEMBLY HYBRID VEHICLE CONTROL ECU ASSEMBLY:Click here

      REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY AND HV BATTERY JUNCTION BLOCK ASSEMBLY HV BATTERY JUNCTION BLOCK ASSEMBLY:Click here