PLUG-IN CHARGE CONTROL SYSTEM, Diagnostic DTC:P0D08-755

DTC Code DTC Name
P0D08-755 Charger Positive Relay Stuck Closed

DESCRIPTION

Refer to the description for DTC P0D20-422 Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P0D08 755 VCHG sensor (Electric vehicle charger assembly output voltage sensor) voltage is too high when plug-in charging is started even though the CHRB relay is open.

  • Plugin charge control ECU assembly

  • Hybrid battery junction block assembly

  • Wire harness or connector

  • Electric vehicle charger assembly

  • Electric vehicle charger wire
Related Data List
DTC No. INF Code Data List
P0D08 755

  • Charger Output Voltage

  • Charging Control Status

  • CHRB Status

  • CHRG Status

  • CHRB Control Status

  • CHRG Control Status

WIRING DIAGRAM


INSPECTION PROCEDURE

CAUTION:


  • When performing P0D08-755 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 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, plug-in charge the vehicle for at least 1 minute and check that the DTC is not output.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      Only P0D08-755 is output or P0D08-755 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
      P0AA6-526, 611, 612, 613, 614 Hybrid Battery Voltage System Isolation Fault

      Tech Tips

      P0D08-755 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 (P0AA6) Click here

    A

  2. 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 P0D08-755 is output or P0D08-755 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
      P0D4D-404, 405 On-Board Charger Output Voltage Sensor Circuit Range / Performance
      P0D4F-417 On-Board Charger Output Voltage Sensor Circuit High

      Tech Tips

      P0D08-755 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

  3. CHECK FREEZE FRAME DATA (CHRB STATUS, CHRB CONTROL STATUS)


    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. Read the freeze frame data of DTC P0D20-422.

    5. Compare "CHRB Status" with "CHRB Control Status".

      Result
      Result Proceed to
      CHRB Status CHRB Control Status
      ON ON A
      ON OFF B
      OFF ON

    6. Turn the power switch off.


    B

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

    A

  4. CHECK 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. A0041WVE02

      Disconnect the a2 electric vehicle charger assembly connector Click here.

    3. A0040C1E01
      Text in Illustration
      *a

      Component without harness connected

      (Electric Vehicle Charger Assembly)

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      a2-1 (DCHB) - Body ground Power switch off 10 MΩ or higher
      a2-2 (DCHG) - Body ground Power switch off 10 MΩ or higher

    4. Connect the electric vehicle charger assembly connector.


    NG

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

    OK

  5. CHECK EV CHARGER WIRE

    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. A0041B2E01

      Disconnect the a3 hybrid battery junction block assembly connector.

    4. Disconnect the shield ground from the HV battery lower cover.

    5. A0041WVE02

      Disconnect the a2 electric vehicle charger assembly connector Click here.

    6. A0042BJE02
      Text in Illustration
      *1 Shield Ground
      *a

      Electric Vehicle Charger Wire

      (Hybrid Battery Junction Block Assembly Side)

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      a3-6 (DCHB) - Body ground and shielded wire ground Power switch off 10 MΩ or higher
      a3-3 (DCHG) - Body ground and shielded wire ground Power switch off 10 MΩ or higher

    7. Connect the electric vehicle charge wire.

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


    NG

    REPLACE EV CHARGER WIRE Click here

    OK

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

    3. A004377E02

      Disconnect the a3 hybrid battery junction block assembly connector.

    4. A004004E01

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      a3-6 (DCHB) - Body ground Power switch off 10 MΩ or higher
      a3-3 (DCHG) - Body ground Power switch off 10 MΩ or higher

    5. Connect the hybrid battery junction block assembly connector.

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


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  7. 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

    CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRB CIRCUIT)) Click here

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

  8. 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

    CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT (CHRB CIRCUIT)) Click here

    OK

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here

  9. 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

  10. 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