HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AE2-161

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

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

WIRING DIAGRAM

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

A000Y0HE11

CAUTION / NOTICE / HINT

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.

Tech Tips

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

PROCEDURE


  1. 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

    B

    GO TO DTC CHART (P0AE0-228) Click here

    A

  2. 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.

    NG

    CONNECT SECURELY

    OK

  3. CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTORS)


    1. A000U40E02
      *1 No. 1 Battery Pack Wire Connector
      *2 B Side
      *3 A Side
      A000YI9E02
      *1 No. 2 Battery Pack Wire Connector
      *2 A Side
      *3 B Side

      Check the connection of the battery pack wire connectors.

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

      Tech Tips

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


    NG

    CONNECT SECURELY

    OK

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


    1. Turn the power switch off.

    2. A000YI9E02
      *1 No. 2 Battery Pack Wire Connector
      *2 A Side
      *3 B Side

      Disconnect the No. 2 battery pack wire connector.

    3. A000XNIE02
      *1 No. 2 Battery Pack Wire Connector
      *2 nS1
      *3 A Side
      *4 B Side

      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

    NG

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

    OK

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

      A000YE9E02

      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

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. 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. A000V3YE02
      *1 HV Battery Junction Block

      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.

    NG

    CONNECT SECURELY

    OK

  7. 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. A000UJNE02
      *1 HV Battery Junction Block

      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.


    NG

    REPLACE ELECTRIC BATTERY FUSE Click here

    OK

  8. 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. A000TOM

      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.

      Tech Tips

      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.


    NG

    CONNECT SECURELY

    OK

  9. 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. A000WGT
      A000VXL

      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.

    NG

    CONNECT SECURELY

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


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

      A000ZDEE01

    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

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  11. 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. Disconnect the low voltage connector from the hybrid vehicle converter.

      A000TQ0E03

    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

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  12. 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. A000UTDE01
      *1 HV Battery Junction Block

      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

    NG

    REPLACE HV BATTERY JUNCTION BLOCK Click here

    OK

  13. CHECK HV CONVERTER


    1. A000WDL

      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}

    OK

    REPLACE HV CONVERTER Click here

    NG

    CONNECT SECURELY

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

      A000VBEE03

      Tech Tips

      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

    OK

    REPLACE HYBRID VEHICLE CONTROL ECU Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR