PLUG-IN CHARGE CONTROL SYSTEM, Diagnostic DTC:P0D52-406

DTC Code DTC Name
P0D52-406 On-Board Charger Output Current Sensor Circuit Range / Performance

DESCRIPTION

An ICHG sensor (DC output current sensor) is located inside the electric vehicle charger assembly. It detects output current to the DC high-voltage circuit and sends a signal to the plugin charge control ECU assembly.

The plugin charge control ECU assembly monitors the electric vehicle charger assembly to ensure it is operating normally based on signals from the ICHG sensor.

The plugin charge control ECU assembly monitors and detects errors in the ICHG sensor signal line.

A0042YME01
DTC No. INF Code DTC Detection Condition Trouble Area
P0D52 406 The difference between the current request value and output value of the ICHG sensor (DC output current sensor) is too large while the vehicle is being plug-in charged.

  • Plugin charge control ECU assembly

  • Electric vehicle charger assembly

  • Electric vehicle charger cable

  • Electric vehicle charger wire

  • Electric vehicle fuse

  • Hybrid battery junction block assembly

  • No. 1 hybrid vehicle battery pack cable

  • No. 2 hybrid vehicle battery pack cable

  • Wire harness or connector

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AA6-526 Click here.

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

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

Refer to the wiring diagram for DTC P0D53-408 Click here.

Refer to the wiring diagram for DTC P0D5C-847 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, check that the Data List item "State of Charge (All Bat)" is 70% or less, then plug-in charge the vehicle until it completes and check that DTCs are not output.

PROCEDURE


  1. CHECK DTC OUTPUT (PLUG-IN CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Plug-in Control / Trouble Codes.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      Only P0D52-406 is output or P0D52-406 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
      P060B-134, 135, 570 Internal Control Module A/D Processing Performance
      P0D52-407 On-Board Charger Output Current Sensor Circuit Range / Performance
      P0D53-408 On-Board Charger Output Current Sensor Circuit Low
      P0D54-409 On-Board Charger Output Current Sensor Circuit High

      Tech Tips

      P0D52-406 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 (PLUG-IN CHARGE CONTROL SYSTEM) Click here

    A

  2. CHECK PLUGIN CHARGE CONTROL ECU ASSEMBLY (ICHG SENSOR VOLTAGE)

    Note

    If the power switch is turned on (IG) during plug-in charging, the power switch will be turned off automatically after several tens of seconds.


    1. Connect the GTS to the DLC3.

    2. Start plug-in charging the vehicle.

    3. Turn the power switch on (IG).

    4. Enter the following menus: Powertrain / Plug-in Control / Data List.

    5. Select "On-Board Charger Current Sensor Voltage" in the Data List.

      Tester Display Measurement Item/Range
      On-Board Charger Current Sensor Voltage

      Output voltage of the ICHG sensor based on the amperage output from the electric vehicle charger assembly/

      Min.: 0.00 V, Max.: 79.99 V
    6. A004180E06
      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
      z12-24 (ICHG) - z12-21 (CGND) During plug-in charging

    7. While plug-in charging the vehicle, compare the Data List item "On-Board Charger Current Sensor Voltage" with actual measurement of ICHG terminal voltage.

      Result
      Result Proceed to
      Difference between "On-Board Charger Current Sensor Voltage" and actual measurement of ICHG terminal voltage is less than 1 V. A
      Difference between "On-Board Charger Current Sensor Voltage" and actual measurement of ICHG terminal voltage is 1 V or more. B

    8. Turn the power switch off.

    9. Stop plug-in charging the vehicle.


    B

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

    A

  3. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY (CHECK FOR OPEN (CGND 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. Disconnect the z12 plugin charge control ECU assembly connector.

    3. A0042E1E01
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Plugin Charge Control ECU Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      z12-21 (CGND) - Body ground Power switch off Below 1.5 Ω

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


    NG

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

    OK

  4. CHECK PLUGIN CHARGE CONTROL ECU ASSEMBLY (CHECK WAVEFORM (CHPW))


    1. Connect an oscilloscope between the plugin charge control ECU assembly terminals specified in the table below.

    2. Turn the power switch on (IG).

    3. A0041YJE05
      Text in Illustration
      *a

      Component with harness connected

      (Plugin Charge Control ECU Assembly )

      Measure the waveform.

      Item Contents
      Tester Connection z12-30 (CHPW) - S21-14 (E1)
      Equipment Setting 5 V/DIV., 50 ms/DIV.
      Condition Power switch on (IG)
      Result
      Result Proceed to
      The waveform appears as shown in the illustration. A
      The waveform differs from the one shown in the illustration. B

    4. Turn the power switch off.


    B

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

    A

  5. CHECK PLUGIN CHARGE CONTROL ECU ASSEMBLY (CHECK WAVEFORM (ILMT))


    1. Connect an oscilloscope between the plugin charge control ECU assembly terminals specified in the table below.

    2. Turn the power switch on (IG).

    3. A0041YJE04
      Text in Illustration
      *a

      Component with harness connected

      (Plugin Charge Control ECU Assembly )

      Measure the waveform.

      Item Contents
      Tester Connection z12-22 (ILMT) - S21-14 (E1)
      Equipment Setting 5 V/DIV., 50 ms/DIV.
      Condition Power switch on (IG)
      Result
      Result Proceed to
      The waveform appears as shown in the illustration. A
      The waveform differs from the one shown in the illustration. B

    4. Turn the power switch off.


    B

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

    A

  6. CHECK ELECTRIC VEHICLE CHARGER CABLE (CHARGING INLET - ELECTRIC VEHICLE CHARGER 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. A00407IE01

      Disconnect the at1 electric vehicle charger wire connector Click here.

    3. A00431FE01
      Text in Illustration
      *a

      Electric Vehicle Charger Cable

      (Charging Inlet Side)
      *b

      Electric Vehicle Charger Cable

      (Electric Vehicle Charger Wire Side)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      t1-2 (ACIC) - at1-1 (ACIC) Power switch off Below 1 Ω
      t1-1 (ACIH) - at1-2 (ACIH) Power switch off Below 1 Ω

    4. Reconnect the at1 electric vehicle charger wire connector.


    NG

    REPLACE ELECTRIC VEHICLE CHARGER CABLE Click here

    OK

  7. CHECK ELECTRIC VEHICLE CHARGER WIRE (ELECTRIC VEHICLE CHARGER WIRE CONNECTOR - ELECTRIC VEHICLE CHARGER 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. A00407IE01

      Disconnect the at1 electric vehicle charger wire connector Click here.

    3. A0042SYE01

      Disconnect the a1 electric vehicle charger assembly connector Click here.

    4. A00408AE01
      Text in Illustration
      *a

      Electric Vehicle Charger Wire

      (Electric Vehicle Charger Cable Side)
      *b

      Electric Vehicle Charger Wire

      (Electric Vehicle Charger Assembly Side)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      at1-1 (ACIC) - a1-2 (ACIC) Power switch off Below 1 Ω
      at1-2 (ACIH) - a1-1 (ACIH) Power switch off Below 1 Ω

    5. Reconnect the a1 electric vehicle charger assembly connector.

    6. Reconnect the at1 electric vehicle charger wire connector.


    NG

    REPLACE EV CHARGER WIRE Click here

    OK

  8. CHECK ELECTRIC VEHICLE CHARGER WIRE (ELECTRIC VEHICLE CHARGER ASSEMBLY - 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. A0041WVE02

      Disconnect the a2 electric vehicle charger assembly connector Click here.

    3. Remove the No. 2 hybrid vehicle battery shield panel Click here.

    4. A004377E02

      Disconnect the a3 hybrid battery junction block assembly connector.

    5. A0042JDE01
      Text in Illustration
      *a

      Electric Vehicle Charger Wire

      (Electric Vehicle Charger Assembly Side)
      *b

      Electric Vehicle Charger Wire

      (Hybrid Battery Junction Block Assembly Side)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      a2-1 (DCHB) - a3-6 (DCHB) Power switch off Below 1 Ω
      a2-2 (DCHG) - a3-3 (DCHG) Power switch off Below 1 Ω

    6. Reconnect the a3 hybrid battery junction block assembly connector.

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

    8. Reconnect the a2 electric vehicle charger assembly connector.


    NG

    REPLACE EV CHARGER WIRE Click here

    OK

  9. CHECK ELECTRIC VEHICLE FUSE

    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. 1 hybrid vehicle battery shield panel Click here.

    3. A00447K

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Electric vehicle fuse Power switch off Below 1 Ω

    4. Install the No. 1 hybrid vehicle battery shield panel.


    NG

    REPLACE ELECTRIC VEHICLE FUSE Click here

    OK

  10. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (CHRB, 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. 1 hybrid vehicle battery shield panel Click here.

    3. A0041TME08

      Disconnect the T3 and T4 hybrid battery junction block assembly terminals.

    4. A004377E02

      Disconnect the a3 hybrid battery junction block assembly connector.

    5. A0042OAE03

      Disconnect the w2 and q8 hybrid battery junction block assembly connectors.

    6. A0040Q7E02

      Disconnect the co1 battery pack wire connector.

    7. A0042VRE03
      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
      T4-1 (CBI) - a3-6 (DCHB) Auxiliary battery voltage is applied between terminals co1-4 (CHRB) - co1-5 (GND) Below 1 Ω
      T3-1 (CEI) - a3-3 (DCHG) Auxiliary battery voltage is applied between terminals co1-6 (CHRG) - co1-5 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      co1-4 (CHRB) - co1-5 (GND) -40 to 80 °C (-40 to 176°F) 112 to 274 Ω
      co1-6 (CHRG) - co1-5 (GND) -40 to 80 °C (-40 to 176°F) 112 to 274 Ω

    9. Reconnect the co1 battery pack wire connector.

    10. Reconnect the a3, w2 and q8 hybrid battery junction block assembly connectors.

    11. Install the No. 1 hybrid vehicle battery shield panel.


    NG

    Click here

    OK

  11. 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 hybrid battery junction block assembly Click here.

    3. A0044BSE03
      Text in Illustration
      *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
      w2-1 (+) - T4-1 (CBI) Auxiliary battery voltage is not applied between terminals c9-1 (SMRB) and c9-2 (GND1) 10 kΩ or higher
      w2-1 (+) - T4-1 (CBI) Auxiliary battery voltage is applied between terminals c9-1 (SMRB) and c9-2 (GND1) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      c9-1 (SMRB) - c9-2 (GND1) -40 to 80°C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  12. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

    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 hybrid battery junction block assembly Click here.

    3. A0042BOE03
      Text in Illustration
      *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
      q8-1 (-) - T3-1 (CEI) Auxiliary battery voltage is not applied between terminals o10-1 (SMRG) and o10-2 (GND0) 10 kΩ or higher
      q8-1 (-) - T3-1 (CEI) Auxiliary battery voltage is applied between terminals o10-1 (SMRG) and o10-2 (GND0) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      o10-1 (SMRG) - o10-2 (GND0) -40 to 80°C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  13. CHECK NO. 2 HYBRID VEHICLE BATTERY PACK CABLE

    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. A0044AIE02

      Disconnect the w2 hybrid battery junction block assembly connector.

    4. A00426JE02
      Text in Illustration
      *1 No. 2 Hybrid Vehicle Battery Pack Cable

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      w1-1 (+) - w2-1 (+) Power switch off Below 1 Ω

    5. Reconnect the w2 hybrid battery junction block assembly connector.

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


    NG

    REPLACE NO. 2 HYBRID VEHICLE BATTERY PACK CABLE Click here

    OK

  14. CHECK NO. 1 HYBRID VEHICLE BATTERY PACK CABLE

    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. A0041TJE02

      Disconnect the q8 hybrid battery junction block assembly connector.

    4. A00436PE02
      Text in Illustration
      *1 No. 1 Hybrid Vehicle Battery Pack Cable

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      q7-1 (-) - q8-1 (-) Power switch off Below 1 Ω

    5. Connect the hybrid battery junction block assembly connector.

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


    NG

    REPLACE NO. 1 HYBRID VEHICLE BATTERY PACK CABLE Click here

    OK

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

  15. CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY)

    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. A0040Q7E02

      Disconnect the co1 battery pack wire connector.

    4. A00407JE02

      Disconnect the o9 hybrid battery junction block assembly connector.

    5. A0041C1E05
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Battery Pack Wire Connector)
      *b

      Front 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
      co1-4 (CHRB) - o9-5 (CHRB) Power switch off Below 1 Ω
      co1-6 (CHRG) - o9-3 (CHRG) Power switch off Below 1 Ω
      co1-5 (GND) - o9-4 (GND) Power switch off Below 1 Ω

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

    7. Reconnect the co1 battery pack wire connector.

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


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here