HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AE2-773

DTC Code DTC Name
P0AE2-773 Hybrid Battery Precharge Contactor Circuit Stuck Closed

DESCRIPTION

Refer to the description for DTC P0AE6-225 Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P0AE2 773 SMRP on the HV battery positive side stuck closed

  • Hybrid battery junction block assembly

  • Inverter with converter assembly

  • Power management control ECU

  • Wire harness and connector

WIRING DIAGRAM

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

CAUTION / NOTICE / HINT

CAUTION:


  • When performing P0AE2-773 troubleshooting, use either a tool wrapped with vinyl insulation tape or an 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, 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.

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.

  • If the DTCs are cleared or the cable is disconnected and reconnected to the negative (-) auxiliary battery terminal before performing repairs, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY).

Tech Tips

After the repair, clear the DTCs, perform the following procedure and check that the same DTC (including pending DTC) is not output.


  1. Turn the power switch off and wait for 30 seconds or more.

  2. Turn the power switch on (READY) and wait for 30 seconds or more.

  3. Turn the power switch off and wait for 60 seconds or more.

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
      DTC P0E2-773 only is output, or 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
      P06B0-163 Sensor Power Supply "A" Circuit/Open
      P06D6-511 Sensor Reference Voltage "F" Circuit/Open
      P06E6-164 Sensor Power Supply "C" Circuit/Open
      P0A1A-151, 658, 791 Generator Control Module
      P0A1B-786, 794 Drive Motor "A" Control Module
      P0A1D-148 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range/Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Low
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range/Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0AA4-232 Hybrid Battery Negative Contactor Circuit Stuck Closed
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-586 Drive Motor "A" Inverter Voltage Sensor Circuit Range/Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Performance
      P1C2A-155 Generator A/D Converter Circuit
      P1C73-512 Sensor Standard Voltage "F" Circuit/Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P2511-149 HV CPU Power Relay Sense Circuit Intermittent No Continuity
      P3004-132 Power Cable Malfunction
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      P324E-788 MG-ECU Power Relay Intermittent Circuit
      U0110 (all INF codes)*1 Lost Communication with Drive Motor Control Module "A"

      Tech Tips


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • P0AE2-773 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

  2. CHECK FREEZE FRAME DATA (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. Read the freeze frame data of DTC P0AE2-773.

      Result
      Result Proceed to
      VL-Voltage before Boosting is 60 V or more. A
      VL-Voltage before Boosting is below 60 V. B

    5. Turn the power switch off.


    B

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    A

  3. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)


    1. Check the connector connections and contact pressure of the relevant terminals for the power management control ECU connectors Click here.

      A005DLOE01
      Text in Illustration
      *A for LHD *B for RHD
      OK
      The connectors are connected securely and there are no contact pressure problems.

    OK

    CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HYBRID BATTERY PACK WIRE CONNECTOR) Click here

    NG

  4. CONNECT SECURELY


    NEXT

  5. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HYBRID 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. Check the connection condition of the Lc1 No. 2 hybrid battery pack wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water and foreign matter.


        OK:

      • The connector is connected securely.

      • The terminals are not deformed and are connected securely.

      • No water or foreign matter in the connector.

      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    A

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR) Click here

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR Click here

    B

  6. CONNECT SECURELY


    NEXT

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR) Click here

  7. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  8. CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 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. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    3. A005EVV

      Check the connector connections and contact pressure of the relevant terminals for the hybrid battery junction block assembly connector Click here.

      OK
      The connector is connected securely and there are no contact pressure problems.

    4. Install the No. 2 hybrid battery shield sub-assembly.


    OK

    CHECK GROUND WIRE CONNECTION CONDITION (SMR ACTIVATION LOW-VOLTAGE CIRCUIT) Click here

    NG

  9. CONNECT SECURELY


    NEXT

  10. CHECK GROUND WIRE CONNECTION CONDITION (SMR ACTIVATION LOW-VOLTAGE CIRCUIT)


    1. Check the installation condition of the L3 ground wire.

      OK
      The L3 ground wire is securely installed.

    OK

    CHECK HARNESS OR CONNECTOR (POWER MANAGEMENT CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY) Click here

    NG

  11. CONNECT SECURELY


    NEXT

  12. CHECK HARNESS OR CONNECTOR (POWER MANAGEMENT CONTROL ECU - 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 battery shield sub-assembly Click here.

    3. Disconnect the c6 hybrid battery junction block assembly connector.

    4. Disconnect the L5 power management control ECU connector.

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

      A005DA9E13
      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      L5-3 (SMRP) - c6-3 (SMRP) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      L5-3 (SMRP) and c6-3 (SMRP) - Body ground and other terminals Power switch off 10 kΩ or higher
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Power Management Control ECU)
      *b

      Rear view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)

    6. Reconnect the L5 power management control ECU connector.

    7. Reconnect the c6 hybrid battery junction block assembly connector.

    8. Install the No. 2 hybrid battery shield sub-assembly.


    OK

    CHECK HARNESS AND CONNECTOR (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND) Click here

    NG

  13. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  14. CHECK HARNESS AND CONNECTOR (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)

    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 battery shield sub-assembly Click here.

    3. Disconnect the c6 hybrid battery junction block assembly connector.

    4. A0059QZE01
      Text in Illustration
      *a

      Rear 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
      c6-2 (GND) - Body ground Power switch off Below 1 Ω

    5. Reconnect the c6 hybrid battery junction block assembly connector.

    6. Install the No. 2 hybrid battery shield sub-assembly.


    OK

    INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP) Click here

    NG

  15. REPAIR OR REPLACE HARNESS OR CONNECTOR


    NEXT

  16. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP)

    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 battery shield sub-assembly Click here.

    3. Disconnect the c6 hybrid battery junction block assembly connector.

    4. A005CZ2E02
      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
      c6-3 (SMRP) - c6-2 (GND) -40 to 80 °C (-40 to 176°F) 112 to 274 Ω

    5. Reconnect the c6 hybrid battery junction block assembly connector.

    6. Install the No. 2 hybrid battery shield sub-assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  17. 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 battery shield sub-assembly Click here.

    3. Disconnect the high voltage cable connectors from the hybrid battery junction block assembly.

    4. A005BQKE01

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T5-1 (CEI) - h3-1 (-) Power switch off 10 kΩ or higher

      Tech Tips


      • If a system main relay is stuck closed, inspect the HV relay assembly without removing it from the vehicle, in order to keep the relay closed.

      • If the result of reading the freeze frame data is A, the hybrid battery junction block assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.

    5. Connect the high voltage cable connectors.

    6. Install the No. 2 hybrid battery shield sub-assembly.


    OK
    NG

  18. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here


    NEXT

  19. CHECK POWER MANAGEMENT CONTROL ECU (CHECK FOR NORMAL OPERATION)


    1. Install the service plug grip.

    2. Connect the GTS to the DLC3.

    3. Turn the power switch on (IG).

    4. Clear the DTCs Click here.

    5. Turn the power switch off and wait for 30 seconds or more.

    6. Turn the power switch on (READY).

    7. Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource VB, VL-Voltage before Boosting.

    8. According to the display on the GTS, read the Data List and monitor the values of "Power Resource VB" and "VL-Voltage before Boosting" for 3 minutes.

      Result
      Result Proceed to
      Difference between "Power Resource VB" and "VL-Voltage before Boosting" is always less than 100 V. A
      Difference between "Power Resource VB" and "VL-Voltage before Boosting" is 100 V or more. B

    9. Turn the power switch off.


    A

    END

    B

    REPLACE POWER MANAGEMENT CONTROL ECU AND HYBRID BATTERY JUNCTION BLOCK ASSEMBLY