HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA1-231

DTC Code DTC Name
P0AA1-231 Hybrid Battery Positive Contactor Circuit Stuck Closed

DESCRIPTION

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

DTC No. INF Code DTC Detection Condition Trouble Area
P0AA1 231 SMRB on the HV battery positive side is stuck closed.

  • Hybrid battery junction block assembly

  • Inverter with converter assembly

  • Power management control ECU

  • Wire harness and connector

WIRING DIAGRAM

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

CAUTION / NOTICE / HINT

CAUTION:


  • When troubleshooting P0AA1-231, be sure to wrap the tools with electrical tape. (It is very dangerous if high voltage is shorted to ground through the tools.)

  • 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 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.

    Tech Tips


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

    • If P0AA1-231 is stored, the hybrid system cannot be turned on.

Note


  • 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.

  • If the DTCs are cleared or the cable is disconnected and reconnected to the negative (-) auxiliary battery terminal before performing repairs, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY).

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / DTC.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P0AA1-231 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A-151, 155, 156, 200, 658, 659, 791, 792, 793 Generator Control Module
      P0A1B-163, 164, 168, 193, 511, 512, 661, 786, 794, 795, 796 Drive Motor "A" Control Module
      P0A1D-148 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0A78-266, 267, 586 Drive Motor "A" Inverter Performance
      P0A94-442 DC / DC Converter Performance
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P2511-149 ECM/PCM Power Relay Sensor Circuit Intermittent
      P3004-132 Power Cable Malfunction
      P324E-788 MG-ECU Power Relay Intermittent Circuit
      U0110 (all INF codes)*1 Lost Communication with Drive Motor Control Module

      Tech Tips


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • P0AA1-231 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. CHECK FREEZE FRAME DATA (HYBRID CONTROL)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / DTC.

    4. Read the freeze frame data of DTC P0AA1-231.

      Result
      Result Proceed to
      VL-Voltage before Boosting is less than 60 V. A
      VL-Voltage before Boosting is 60 V or more. B

    5. Turn the power switch off.


    A

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    B

  3. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)


    1. Check the connector connections and contact pressure of the relevant terminals for the power management control ECU connectors.

      B001M45E01
      Text in Illustration
      *A for LHD *B for RHD
      OK
      The connectors are connected securely and there are no contact pressure problems.

    OK

    CHECK CONNECTOR CONNECTION CONDITION (NO. 2 FLOOR WIRE CONNECTOR) Click here

    NG

  4. CONNECT SECURELY


    NEXT

  5. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 FLOOR WIRE CONNECTOR)


    1. Check the connector connections and contact pressure of the relevant terminals of the HQ1 No. 2 floor wire connector Click here.

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

    OK

    CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV BATTERY PACK WIRE CONNECTOR) Click here

    NG

  6. CONNECT SECURELY


    NEXT

  7. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV BATTERY PACK WIRE 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. Check the connection condition of the Qi1 No. 2 HV battery pack wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water and foreign matter.


        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

    A

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR) Click here

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    B

  8. CONNECT SECURELY


    NEXT

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR) Click here

  9. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  10. CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 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. Remove the upper hybrid battery cover sub-assembly.

    3. B001MAO

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

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

    4. Install the upper hybrid battery cover sub-assembly.


    OK

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

    NG

  11. CONNECT SECURELY


    NEXT

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


    1. Check the installation condition of the Q2 ground wire.

      OK
      The Q2 ground wire is securely installed.

    OK

    CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY) Click here

    NG

  13. CONNECT SECURELY


    NEXT

  14. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - HYBRID 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 (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

    3. Disconnect connector i3 from the hybrid battery junction block assembly.

    4. Disconnect connector H3 from the power management control ECU.

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

      B001M3ME07
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Power Management Control ECU)
      *b

      Rear view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)
      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      H3-4 (SMRB) - i3-4 (SMRB) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      H3-4 (SMRB) and i3-4 (SMRB) - Body ground and other terminals Power switch off 10 kΩ or higher

    6. Connect the power management control ECU connector.

    7. Connect the hybrid battery junction block assembly connector.

    8. Install the upper hybrid battery cover sub-assembly.


    OK

    CHECK HARNESS AND CONNECTOR (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY- BODY GROUND) Click here

    NG

  15. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  16. CHECK HARNESS AND CONNECTOR (HYBRID 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 (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

    3. Disconnect connector i3 from the hybrid battery junction block assembly.

    4. B001KUDE01
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      i3-2 (GND) - Body ground Power switch off Below 1 Ω

    5. Connect the hybrid battery junction block assembly connector.

    6. Install the upper hybrid battery cover sub-assembly.


    OK

    INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB) Click here

    NG

  17. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  18. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    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 upper hybrid battery cover sub-assembly.

    3. Disconnect connector i3 from the hybrid battery junction block assembly.

    4. B001LLJE01
      Text in Illustration
      *1 Hybrid Battery Junction Block Assembly

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      i3-4 (SMRB) - i3-2 (GND) -40 to 80°C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Connect the hybrid battery junction block assembly connector.

    6. Install the upper hybrid battery cover sub-assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  19. CHECK HYBRID 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 (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the upper hybrid battery cover sub-assembly.

    3. Disconnect the high voltage cable connectors from the hybrid battery junction block assembly.

    4. B001MP0E02
      Text in Illustration
      *1 Hybrid Battery Junction Block Assembly

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      S4-1 (CBI) - f2-1 (+) Power switch off 10 kΩ or higher

      Tech Tips


      • If a system main relay is stuck closed, inspect the hybrid 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 B, the hybrid battery junction block assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.

    5. Connect the high voltage cable connectors.

    6. Install the upper hybrid battery cover sub-assembly.


    OK
    NG

  20. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here


    NEXT

  21. CHECK POWER MANAGEMENT CONTROL ECU (CHECK FOR NORMAL OPERATION)


    1. Install the service plug grip.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the power switch on (IG).

    4. Clear the DTCs Click here.

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

    6. Turn the power switch on (READY).

    7. Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource VB, VL-Voltage before Boosting.

    8. According to the display on the intelligent tester, read the Data List and monitor the values of "Power Resource VB" and "VL-Voltage before Boosting" for 3 minutes.

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

    9. Turn the power switch off.


    A

    END

    B

    REPLACE POWER MANAGEMENT CONTROL ECU AND HYBRID BATTERY JUNCTION BLOCK ASSEMBLY