PLUG-IN CHARGE CONTROL SYSTEM, Diagnostic DTC:P0D20-422

DTC Code DTC Name
P0D20-422 Charger Relay Stuck Open

DESCRIPTION

The charge relays are located in the hybrid battery junction block assembly inside the HV battery pack. The charge relays operate according to the command from the plugin charge control ECU assembly to connect or interrupt the high-voltage circuits between the electric vehicle charger assembly and HV battery.

When the power switch is on (READY), the circuits to the HV battery are interrupted to prevent electricity leakage from the high-voltage circuits, electrical shock and fire in case of a collision.

During plug-in charging, the SMRs are closed in the order of SMRB ON, SMRP ON, SMRG ON and SMRP OFF, then the charge relays (CHRB and CHRG) are closed.

When plug-in charging is canceled, the SMRs and charge relays are opened in this order.

This DTC is also stored if a short or open occurs in the high-voltage circuit (between the HV battery and electric vehicle charger assembly).

DTC No. INF Code DTC Detection Condition Trouble Area
P0D20 422 VCHG sensor (electric vehicle charger assembly output voltage sensor) voltage is too low when plug-in charging is started even though the charge relays (CHRB and CHRG) are closed.

  • Plugin charge control ECU assembly

  • Hybrid battery junction block assembly

  • Wire harness or connector

  • Electric vehicle fuse

  • Electric vehicle charger assembly

  • Electric vehicle charger wire
Related Data List
DTC No. INF Code Data List
P0D20 422

  • Charger Output Voltage

  • Charging Control Status

  • CHRB Status

  • CHRG Status

  • CHRB Control Status

  • CHRG Control Status

The following Data List items can be helpful when performing repairs:


WIRING DIAGRAM

A0041FTE03

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, plug-in charge the vehicle for at least 1 minute and check that the DTC is 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 P0D20-422 is output or P0D20-422 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-405 On-Board Charger Output Voltage Sensor Circuit Range / Performance
      P0D4E-416 On-Board Charger Output Voltage Sensor Circuit Low
      P0D4F-417 On-Board Charger Output Voltage Sensor Circuit High

      Tech Tips

      P0D20-422 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 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

  3. CHECK FREEZE FRAME DATA (CHRG STATUS, CHRG 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 "CHRG Status" with "CHRG Control Status".

      Result
      Result Proceed to
      CHRG Status CHRG 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 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
      Result
      Result Proceed to
      NG A
      OK B

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


    B

    CHECK EV CHARGER WIRE Click here

    A

  5. REPLACE ELECTRIC VEHICLE FUSE

    Click here


    NEXT

  6. 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. 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) - a2-2 (DCHG) Power switch off 10 kΩ or higher
      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. Connect the hybrid battery junction block assembly connector.

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

    8. Connect the electric vehicle charger assembly connector.


    NG

    REPLACE EV CHARGER WIRE Click here

    OK

  7. 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. A0041J3E02
      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
      a3-3 (DCHG) - a3-6 (DCHB) Power switch off 10 kΩ 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

  8. 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

    CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY) Click here

    OK

  9. CHECK HARNESS AND CONNECTOR (PLUGIN CHARGE CONTROL ECU ASSEMBLY - BATTERY PACK 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. Disconnect the S21 plugin charge control ECU assembly connector.

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

    4. A0040Q7E02

      Disconnect the co1 battery pack wire connector.

    5. A0040MPE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Plugin Charge Control ECU Assembly)
      *b

      Front view of wire harness connector

      (to Battery Pack Wire Connector)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S21-4 (CHRB) - co1-4 (CHRB) Power switch off Below 1 Ω
      S21-15 (CHRG) - co1-6 (CHRG) Power switch off Below 1 Ω

    6. Reconnect the co1 battery pack wire connector.

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

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


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

  10. 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