HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AE2-773

DTC Code DTC Name
P0AE2-773 Hybrid Battery Precharge Contactor Circuit Stuck Closed

DESCRIPTION

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

DTC No. INF Code DTC Detection Condition Trouble Area
P0AE2 773 SMRP on the HV battery positive side stuck closed

  • Hybrid battery junction block assembly

  • Inverter with converter assembly

WIRING DIAGRAM

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

CAUTION / NOTICE / HINT

CAUTION:


  • When performing P0AE2-773 troubleshooting, use either a tool wrapped with vinyl insulation tape or a insulated tool. (It is extremely dangerous when a high-voltage charge passes through a non-insulated tool causing a short.)

  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, turn the ignition switch off and 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.

Note

After turning the ignition 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.

Tech Tips

After the repair, clear the DTCs, perform the following procedure and check that the same DTC (including pending DTC) is not output.


  1. Turn the ignition switch off and wait for 30 seconds or more.

  2. Turn the ignition switch to ON (READY) and wait for 30 seconds or more.

  3. Turn the ignition switch off and wait for 60 seconds or more.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      Only P0AE2-773 is output or P0AE2-773 and DTCs other than the ones in the table below are also output. A
      Any of the following DTCs including pending 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
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0AA4-232 Hybrid Battery Negative Contactor Circuit Stuck Closed
      P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P2511-149 HV CPU Power Relay Sense Circuit Intermittent No Continuity
      P3004-132 High Voltage Power Resource
      P324E-788 MG-ECU Power Relay Intermittent Circuit
      U0110 (all INF codes)*1 Lost Communication with Drive Motor Control Module "A"

      Tech Tips


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

      • P0AE2-773 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 ignition switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. CHECK FREEZE FRAME DATA (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON (IG).

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

    4. Read the freeze frame data of DTC P0AE2-773.

      Note

      In this step, read only the values of "0(s)", which means the moment the DTC has been confirmed, although other information before and after the moment is also displayed when reading the freeze frame data.

      Result
      Result Proceed to
      Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is less than 76 V. A
      Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is 76 V or more. B

      Tech Tips

      If VH-Voltage after Boosting is output even when an off command is being sent to the system main relay (positive side), P0AE2-773 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 ignition switch off.


    B

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    A

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


    1. A01V0I0E01
      Text in Illustration
      *A for LHD
      *B for RHD

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

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

    OK

    CHECK CONNECTOR CONNECTION CONDITION (FLOOR WIRE CONNECTOR) Click here

    NG

  4. CONNECT SECURELY


    NEXT

  5. CHECK CONNECTOR CONNECTION CONDITION (FLOOR WIRE CONNECTOR)


    1. A004FF3E02

      Check the connector connections and contact pressure of the relevant terminals for the KF4 floor wire connector.

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

    OK

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

    NG

  6. CONNECT SECURELY


    NEXT

  7. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly.

      Click here

    3. A004FCW

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

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

    4. Install the No. 2 hybrid battery shield sub-assembly.


    OK

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

    NG

  8. CONNECT SECURELY


    NEXT

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


    1. Check the installation condition of the ground wires F1, F2, F3, F4, F5 and K4.

      OK
      The ground wires F1, F2, F3, F4, F5 and K4 are securely installed.

    OK

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

    NG

  10. CONNECT SECURELY


    NEXT

  11. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly.

      Click here

    3. Disconnect the hybrid battery junction block assembly connector.

    4. Disconnect the power management control ECU connector.

    5. A004EARC19
      *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)

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      F55-3 (SMRP) - K33-4 (SMRP) Ignition switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      F55-3 (SMRP) and K33-4 (SMRP) - Body ground and other terminals Ignition switch off 10 kΩ or higher

    6. Reconnect the power management control ECU connector.

    7. Reconnect the hybrid battery junction block assembly connector.

    8. Install the No. 2 hybrid battery shield sub-assembly.


    OK

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

    NG

  12. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  13. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly.

      Click here

    3. Disconnect the hybrid battery junction block assembly connector.

    4. A004FM2C19
      *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 Condition Specified Condition
      K33-2 (GND) - Body ground Ignition switch off Below 1 Ω

    5. Reconnect the hybrid battery junction block assembly connector.

    6. Install the No. 2 hybrid battery shield sub-assembly.


    OK

    INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP) Click here

    NG

  14. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  15. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly.

      Click here

    3. Disconnect the hybrid battery junction block assembly connector.

    4. A004F4MC25
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      K33-4 (SMRP) - K33-2 (GND) -40 to 80°C (-40 to 176°F) 112 to 274 Ω

    5. Reconnect the hybrid battery junction block assembly connector.

    6. Install the No. 2 hybrid battery shield sub-assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  16. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    3. A004GEAE02

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      L3-1 (CEI) - Y1-1 (-) Ignition 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 A, the hybrid battery junction block assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.

    4. Install the No. 2 hybrid battery shield sub-assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  17. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here


    NEXT

    CHECK POWER MANAGEMENT CONTROL ECU (CHECK FOR NORMAL OPERATION) Click here

  18. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here


    NEXT

    CHECK POWER MANAGEMENT CONTROL ECU (CHECK FOR NORMAL OPERATION) Click here

  19. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here


    NEXT

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

    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

    1. Install the service plug grip.

    2. Turn the ignition switch to ON (IG).

    3. Clear the DTCs.

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

    5. Turn the ignition switch to ON (READY).

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

    7. According to the display on the GTS, 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

    8. Turn the ignition switch off.


    A

    END

    B

    REPLACE POWER MANAGEMENT CONTROL ECU AND HYBRID BATTERY JUNCTION BLOCK ASSEMBLY POWER MANAGEMENT CONTROL ECU: Click here
    REPLACE POWER MANAGEMENT CONTROL ECU AND HYBRID BATTERY JUNCTION BLOCK ASSEMBLY HYBRID BATTERY JUNCTION BLOCK ASSEMBLY: Click here