PLUG-IN CHARGE CONTROL SYSTEM, Diagnostic DTC:P321D-644

DTC Code DTC Name
P321D-644 Charging System Voltage High

DESCRIPTION

Refer to the description for DTC P0D3E-234 Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P321D 644 The charger output voltage is too high while the vehicle is being plug-in charged.

  • Electric vehicle charger wire

  • Electric vehicle charger assembly

  • Plugin charge control ECU assembly

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, 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 (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 P321D-644 is output or P321D-644 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
      P1A61-123 Hybrid Battery Cell Low Voltage Stack "B"
      P1A64-123 Hybrid Battery Cell Low Voltage Stack "C"
      P1A67-123 Hybrid Battery Cell Low Voltage Stack "D"
      P31AB-123 Hybrid Battery Cell Low Voltage

      Tech Tips

      P321D-644 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    A

  2. 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 P321D-644 is output or P321D-644 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
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P3004-131, 803 Power Cable Malfunction

      Tech Tips

      P321D-644 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 (HYBRID CONTROL SYSTEM) Click here

    A

  3. 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 P321D-644 is output or P321D-644 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
      P0D20-422 On-Board Charger Input AC Voltage Sensor Circuit High
      P0D4D-405 On-Board Charger Output Voltage Sensor Circuit Range / Performance
      P0D4F-417 On-Board Charger Output Voltage Sensor Circuit High

      Tech Tips

      P321D-644 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

  4. 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

  5. READ VALUE USING GTS (CHARGER OUTPUT VOLTAGE)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Select "Charger Output Voltage" in the Data List.

      Result
      Result Proceed to
      "Charger Output Voltage" is 40 V or more. A
      "Charger Output Voltage" is less than 40 V. B

    5. Turn the power switch off.


    B

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

    A

  6. 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) Below 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

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

    OK

    REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY Click here