Click here

HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AE2-161

Click here
Click here Click here
DTC Code DTC Name
P0AE2-161 Hybrid Battery Precharge Contactor Circuit Stuck Closed
Click here

DESCRIPTION

Refer to the description for DTC P0AE6-225 (Click here).

If SMRG is stuck open, P0AE0-228 will usually be set. P0AE2-161 is used to pinpoint the problem more quickly and accurately.

DTC No. INF Code DTC Detection Condition Trouble Area
P0AE2 161 When the power switch is on (READY) and the HV battery is being charged, current is detected at SMRP (SMRG is open).

  • Wire harness or connector

  • HV battery junction block

  • Hybrid vehicle control ECU

  • Electric battery fuse

  • Hybrid vehicle converter
Click here

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AE6-225 (Click here).

Click here

INSPECTION PROCEDURE

CAUTION:

  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • After disconnecting 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.

Tip:

Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

Click here

PROCEDURE


  1. Click here

    CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0AE2-161 only is output. A
      P0AE0-228 is output. B

  2. Click here

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)


    1. Check the connections of the hybrid vehicle control ECU connectors.

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

  3. Click here

    CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTORS)


    1. A01H29WE02
      A01H1YGE02

      Check the connection of the battery pack wire connectors.

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

      For the removal and installation procedures related to inspection of the connection of the battery pack wire connectors, (Click here).


  4. Click here

    CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF SMRP INSIDE HYBRID VEHICLE CONTROL ECU)


    1. Turn the power switch off.

    2. A01H29WE02

      Disconnect the No. 2 battery pack wire connector.

    3. A01GXOME09

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      nS1-11 (SMRP) - Body ground Power switch off 370 to 430 kΩ

  5. Click here

    CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 BATTERY PACK WIRE CONNECTOR)


    1. Disconnect connector E58 from the hybrid vehicle control ECU.

    2. Turn the power switch on (IG).

    3. A01GXNNE05

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

      Note:

      Turning the power switch on (IG) with the hybrid vehicle control ECU connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

      Standard voltage
      Tester Connection Switch Condition Specified Condition
      E58-4 (SMRG) - Body ground Power switch on (IG) Below 1 V

    4. Turn the power switch off.

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

      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      E58-4 (SMRG) - zR3-4 (SMRG) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      E58-4 (SMRG) or zR3-4 (SMRG) - Body ground and other terminals Power switch off 10 kΩ or higher

  6. Click here

    CHECK HV BATTERY JUNCTION BLOCK (HIGH-VOLTAGE CONNECTOR CONNECTION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Remove the service plug grip. (Click here)

      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.

    3. A01GZRTE02

      Check the connections of the high-voltage connectors for the hybrid vehicle converter that are connected to the HV battery junction block.

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

  7. Click here

    CHECK HV BATTERY JUNCTION BLOCK (ELECTRIC BATTERY FUSE)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A01H1ARE02

      Check if there is an open circuit in the electric battery fuse that is installed in the HV battery junction block.

      OK
      There is no open circuit in the fuse.

    3. Check that the bolts for the electric battery fuse are tightened to the specified torque.

      Specified Condition
      T=4.5 N*m {46 kgf*cm, 40 in.*lbf}
      Note:

      Be sure to use a torque wrench to check the tightening torque.


  8. Click here

    CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY JUNCTION BLOCK CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. 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.

    3. A01GW2B

      Check the connection of the low voltage connector that drives the relay of the HV battery junction block.

      OK
      The connector is connected securely and there are no contact problems.
      Tip:

      For the removal and installation procedures related to inspection of the connection of the connector that drives the relay of the HV battery junction block, (Click here).


  9. Click here

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL CONVERTER CONNECTOR)

    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. A01H1W0
      A01H1FE

      Check the connection of the low voltage connector of the hybrid vehicle converter.

      OK
      The connector is connected securely and there are no contact problems.

  10. Click here

    CHECK HARNESS AND CONNECTOR (NO. 1 BATTERY PACK WIRE CONNECTOR - HV BATTERY JUNCTION BLOCK)

    CAUTION:

    Be sure to wear insulated gloves.


    1. A01H0KKE04

      Check that the service plug grip is not installed.

    2. Disconnect the low voltage connector that drives the relay of the HV battery junction block.

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

      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      zR3-4 (SMRG) - z38-1 (SMRG) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      zR3-4 (SMRG) or z38-1 (SMRG) - Body ground and other terminals Power switch off 10 kΩ or higher

  11. Click here

    CHECK HARNESS AND CONNECTOR (NO. 2 BATTERY PACK WIRE CONNECTOR - HYBRID VEHICLE CONVERTER)

    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. A01GXEHE10

      Disconnect the low voltage connector from the hybrid vehicle converter.

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

      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      nS1-11 (SMRP) - z82-10 (SMRP) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      nS1-11 (SMRP) or z82-10 (SMRP) - Body ground and other terminals Power switch off 10 kΩ or higher

  12. Click here

    INSPECT HV BATTERY JUNCTION BLOCK (SMRG)

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. Disconnect the HV battery junction block from the vehicle (Click here).

    3. A01GZI8E06

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

      Standard resistance
      Tester Connection Condition Specified Condition
      g3-1 - z34-1 Auxiliary battery voltage is not applied between terminals z38-1 (SMRG) and z38-2 (GND). 10 kΩ or higher
      g3-1 - z34-1 Auxiliary battery voltage is applied between terminals z38-1 (SMRG) and z38-2 (GND). Below 1 Ω

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

      Standard resistance
      Tester Connection Condition Specified Condition
      z38-1 (SMRG) - z38-2 (GND)

      -35 to 80°C

      (-31 to 176° F)

      		 18.8 to 32.1 Ω

  13. Click here

    CHECK HV CONVERTER


    1. A01GYK7

      Check that the ground bolts for the hybrid vehicle converter are tightened to the specified torque and that there are no contact problems.

      Specified Condition
      T= 7.5 N*m {76 kgf*cm, 66 in.*lbf}

  14. Click here

    CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 2 BATTERY PACK WIRE CONNECTOR)


    1. Turn the power switch off.

    2. Disconnect connector A76 from the hybrid vehicle control ECU.

    3. Turn the power switch on (IG).

    4. A01H0VYE10

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

      Tip:

      Turning the power switch on (IG) with the service plug grip removed causes an interlock switch system DTC (P0A0D-350) to be set.

      Standard voltage
      Tester Connection Switch Condition Specified Condition
      A76-25 (SMRP) - Body ground Power switch on (IG) Below 1 V

    5. Turn the power switch off.

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

      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      A76-25 (SMRP) - nS1-11 (SMRP) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      A76-25 (SMRP) or nS1-11 (SMRP) - Body ground and other terminals Power switch off 10 kΩ or higher

  15. Click here

    REPLACE HV CONVERTERClick here

  16. Click here

    REPLACE HV BATTERY JUNCTION BLOCKClick here

  17. Click here

    CONNECT SECURELY

  18. Click here

    GO TO DTC CHART (P0AE0-228)Click here

  19. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  20. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  21. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  22. Click here

    REPLACE HYBRID VEHICLE CONTROL ECUClick here

  23. Click here

    REPLACE ELECTRIC BATTERY FUSEClick here