PLUG-IN CHARGE CONTROL SYSTEM, Diagnostic DTC:P0D4D-405

DTC Code DTC Name
P0D4D-405 On-Board Charger Output Voltage Sensor Circuit Range / Performance

DESCRIPTION

Refer to the description for DTC P0D4D-404 Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P0D4D 405 VCHG voltage is too large when the vehicle is not being plug-in charged (charge relay is open).

  • Plugin charge control ECU assembly

  • Hybrid battery junction block assembly

  • Electric vehicle charger assembly

  • Wire harness or connector
Related Data List
DTC No. INF Code Data List
P0D4D 405

  • Charger Output Voltage

  • Power Resource VB (HYBRID CONTROL SYSTEM )

  • Charging Control Status

  • CHRB Status

  • CHRG Status

  • CHRB Control Status

  • CHRG Control Status

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0D20-422 Click here.

Refer to the wiring diagram for DTC P0D4E-416 Click here.

INSPECTION PROCEDURE

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly or electric vehicle charger assembly, turn the power switch off. Also, 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 and electric vehicle charger assembly.

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.

Tech Tips

After the repair, turn the power switch on (READY), wait for 15 minutes or more, and check that DTCs are not output.

PROCEDURE


  1. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY (VCHG SENSOR OUTPUT VOLTAGE)

    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 z12 plugin charge control ECU assembly connector.

    3. Connect the cable to the negative (-) auxiliary battery terminal.

    4. Turn the power switch on (IG).

    5. A0042E1E03
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Plugin Charge control ECU assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      z12-25 (VCHG) - z12-21 (CGND) Power switch on (IG) 1.5 to 2.5 V

      Tech Tips

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

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal.

    8. Reconnect the z12 plugin charge control ECU assembly connector.


    NG

    Click here

    OK

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

  2. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRB CIRCUIT))


    1. Turn the power switch on (IG).

    2. A004180E13
      Text in Illustration
      *a

      Component with harness connected

      (Plugin Charge Control ECU Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      S21-4 (CHRB) - Body ground Power switch on (IG) Below 1 V

    3. Turn the power switch off.


    NG

    Click here

    OK

  3. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRG CIRCUIT))


    1. Turn the power switch on (IG).

    2. A004180E14
      Text in Illustration
      *a

      Component with harness connected

      (Plugin Charge Control ECU Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      S21-15 (CHRG) - Body ground Power switch on (IG) Below 1 V

    3. Turn the power switch off.


    NG

    Click here

    OK

  4. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (CHRB)

    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 No. 2 hybrid vehicle battery shield panel Click here.

    3. A0041SRE02
      Text in Illustration
      *a

      Component with 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
      T4-1 (CBI) - a3-6 (DCHB) Power switch off 10 kΩ or higher

      Tech Tips

      If a charge relay is stuck closed, inspect the hybrid battery junction block assembly without removing it from the vehicle, in order to keep the relay closed.

    4. Install the No. 2 hybrid vehicle battery shield panel.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  5. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (CHRG)

    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 No. 2 hybrid vehicle battery shield panel Click here.

    3. A0043XHE02
      Text in Illustration
      *a

      Component with 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
      T3-1 (CEI) - a3-3 (DCHG) Power switch off 10 kΩ or higher

      Tech Tips

      If a charge relay is stuck closed, inspect the hybrid battery junction block assembly without removing it from the vehicle, in order to keep the relay closed.

    4. Install the No. 2 hybrid vehicle battery shield panel.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

  6. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRB CIRCUIT))


    1. Disconnect the S21 plugin charge control ECU assembly connector.

    2. Turn the power switch on (IG).

    3. A00438BE12
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Plugin Charge Control ECU Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      S21-4 (CHRB) - Body ground Power switch on (IG) Below 1 V

      Note

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

    4. Turn the power switch off.

    5. Reconnect the S21 plugin charge control ECU assembly connector.


    NG

    Click here

    OK

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

  7. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRB CIRCUIT))

    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 No. 2 hybrid vehicle battery shield panel Click here.

    3. A0040Q7E02

      Disconnect the co1 battery pack wire connector.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A0041N7E01
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Battery Pack Wire Connector)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      co1-4 (CHRB) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the battery pack wire connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.

    8. Disconnect the cable from the negative (-) auxiliary battery terminal.

    9. Reconnect the co1 battery pack wire connector.

    10. Install the No. 2 hybrid vehicle battery shield panel.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRB CIRCUIT))

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 Click here.

    3. A00407JE02

      Disconnect the o9 hybrid battery junction block assembly connector.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A0040C5E01
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      o9-5 (CHRB) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the hybrid battery junction block assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.

    8. Disconnect the cable from the negative (-) auxiliary battery terminal.

    9. Reconnect the o9 hybrid battery junction block assembly connector.

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


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

  9. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRG CIRCUIT))


    1. Disconnect the S21 plugin charge control ECU assembly connector.

    2. Turn the power switch on (IG).

    3. A00438BE13
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Plugin Charge Control ECU Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      S21-15 (CHRG) - Body ground Power switch on (IG) Below 1 V

      Note

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

    4. Turn the power switch off.

    5. Reconnect the S21 plugin charge control ECU assembly connector.


    NG

    Click here

    OK

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

  10. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRG CIRCUIT))

    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 No. 2 hybrid vehicle battery shield panel Click here.

    3. A0040Q7E02

      Disconnect the co1 battery pack wire connector.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A0041N7E02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Battery Pack Wire Connector)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      co1-6 (CHRG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the battery pack wire connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.

    8. Disconnect the cable from the negative (-) auxiliary battery terminal.

    9. Reconnect the co1 battery pack wire connector.

    10. Install the No. 2 hybrid vehicle battery shield panel.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  11. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRG CIRCUIT))

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 Click here.

    3. A00407JE02

      Disconnect the o9 hybrid battery junction block assembly connector.

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. A0040C5E02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      o9-3 (CHRG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the hybrid battery junction block assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    7. Turn the power switch off.

    8. Disconnect the cable from the negative (-) auxiliary battery terminal.

    9. Reconnect the o9 hybrid battery junction block assembly connector.

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


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here