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

System main relay stuck closed error (HV battery positive (+) terminal side)

(1 trip detection logic)

  • Hybrid battery junction block assembly

  • Inverter with converter assembly
Related Data List
DTC No. Data List
P0AA1-231

  • Power Resource VB

  • VH-Voltage after Boosting

The following items can be helpful when performing repairs:


WIRING DIAGRAM

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

CAUTION / NOTICE / HINT

CAUTION:


  • When performing P0AA1-231 troubleshooting, use either a tool wrapped with vinyl insulation tape or an 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, 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.

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

Tech Tips


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

  • After the repair, clear the DTCs and perform the following procedure to check that DTCs are 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 30 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 P0AA1-231 is output or P0AA1-231 and DTCs other than the ones in the table below are also output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P06B0-163 Sensor Power Supply "A" Circuit/Open
      P06D6-511 Sensor Reference Voltage "F" Circuit/Open
      P06E6-164 Sensor Power Supply "C" Circuit/Open
      P0A1A-151, 658, 791 Generator Control Module
      P0A1B-786, 794 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
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-586 Drive Motor "A" Inverter Voltage Sensor Circuit Range/Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Performance
      P1C2A-155 Generator A/D Converter Circuit
      P1C73-512 Sensor Standard Voltage "F" Circuit/Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P2511-149 HV CPU Power Relay Sense Circuit Intermittent No Continuity
      P3004-132 High Voltage Power Resource
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      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.

      • 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 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 P0AA1-231.

      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), P0AA1-231 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 (HYBRID VEHICLE CONTROL ECU CONNECTOR)


    1. A01V0I0E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Check the connector connections and contact pressure of the relevant terminals for the hybrid vehicle 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. A004FF3E03

      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 (HYBRID VEHICLE CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY) Click here

    NG

  10. CONNECT SECURELY


    NEXT

  11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE 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 hybrid vehicle control ECU connector.

    5. A004G98C04
      *a

      Rear view of wire harness connector

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

    6. Reconnect the hybrid vehicle 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. A004FM2C21
      *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 (SMRB) Click here

    NG

  14. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  15. 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 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. A004F4MC26
      *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
      K33-1 (SMRB) - K33-2 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 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 (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 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. A004F10E01

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      L4-1 (CBI) - A-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 HYBRID VEHICLE CONTROL ECU (CHECK FOR NORMAL OPERATION) Click here

  18. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here


    NEXT

    CHECK HYBRID VEHICLE CONTROL ECU (CHECK FOR NORMAL OPERATION) Click here

  19. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here


    NEXT

  20. CHECK HYBRID VEHICLE CONTROL ECU (CHECK FOR NORMAL OPERATION)


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