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DTC P0AE1 (62): Bypass Contactor Malfunction

WARNING: This page is about a different car, the 2011 Honda Insight and 2010 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: This procedure includes high voltage measurements with the IMA system turned on. To avoid serious injury from electrical shocks while testing the high voltage cable, use insulated gloves, select a DC range of 150 V or more on your digital multimeter, and do not touch metal surface.
NOTE:
  • Before you troubleshoot, record all freeze data, and review the general troubleshooting information (see GENERAL TROUBLESHOOTING INFORMATION  ).
  • When the ignition switch is turned to ON (II) while the battery module switch is OFF, DTC P0AE1 (62) is detected.
  • If the DTC cannot be cleared, do the troubleshooting for DTC U1204 (55).
  1. Turn the ignition switch to ON (II).
  2. Clear the DTC with the HDS (see DTC CLEAR  ).
  3. Check the SOC in the DATA LIST with the HDS.
  4. Start the engine, and hold it between 3,500 and 4,000 rpm without load (in P or N) until the SOC increases to 70 %. If the SOC does not increase at all, go to step  7.
  5. Monitor the OBD STATUS for DTC P0A78 (32), P1570 (66), P1634 (47), and U1220 (34) in the DTCs MENU with the HDS.

    Does the screen indicate PASSED? 

    YES  -go to step 6.

    NO  -

    • If the screen indicates FAILED: Go to the indicated DTC's troubleshooting.
    • If the screen indicates NOT COMPLETED: Keep the ignition switch ON (II) until a result comes on.
  6. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 (62) indicated? 

    YES  -go to step 7.

    NO  -Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the junction board, the DC-DC converter, the MPI module, and the MCM.

  7. Turn the ignition switch to LOCK (0).
  8. Turn the battery module switch OFF (see DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR  ).
  9. Remove the IPU cover (see IPU COVER REMOVAL/INSTALLATION  ).
  10. Remove the PCU lid, the PCU busplate, and the PCU cover (see MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION  ).
  11. Reinstall the PCU busplate (see MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION  ).
  12. Check for poor connections, loose terminals, or damage at the busbars (A) and the MCM connectors (B).
    Fig 1: MCM Connectors And Bolts With Torque Specifications
    G06429809Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Are the connections and the terminals OK? 

    YES  -go to step 13.

    NO  -Repair the connections or the terminals, then go to step  40.

  13. Remove the PCU busplate (see MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION ).
  14. Turn the battery module switch ON (see TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT ).
    NOTE: Wear insulated gloves to protect yourself from electrical shock.
  15. Measure the voltage between the high voltage terminals (A).
    NOTE:
    • Use a DC range of 150 V or more on your digital multimeter.
    • Always measure the voltage at the indicated position; measuring on the adjacent terminals may cause a short.
    Fig 2: Identifying High Voltage Terminal (A)
    G00496907Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is the voltage about 0V? 

    YES  -Replace the battery module, then go to step  40.

    NO  -Note the measured voltage, and go to step 16.

  16. Clear the DTC with the HDS (see DTC CLEAR  ).
  17. Turn the ignition switch to ON (II), and listen for a clicking sound from the contactor in the junction board.

    Is there a clicking sound? 

    YES  -go to step 18.

    NO  -If you never hear the sound, go to step  29. If you hear the sound only once, after clearing the DTC, go to step 18.

  18. Clear the DTC with the HDS (see DTC CLEAR  ).
  19. Quickly measure the voltage between the high voltage terminals (A) when the ignition switch is turned to ON (II).
    NOTE:
    • Use a DC range of 150 V or more on your digital multimeter.
    • Always measure the voltage at the indicated position; measuring on the adjacent terminals may cause a short.
    • This voltage spike will only occur one time when the ignition switch is turned to ON (II). You must turn the ignition switch to LOCK (0), and wait 45 seconds for the IMA relay to shut off before doing this voltage check again.
    Fig 3: Identifying High Voltage Terminals
    G06429810Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there a momentary voltage reading? 

    YES  -go to step 20.

    NO  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  40.

  20. Turn the ignition switch to LOCK (0).
  21. Turn the battery module switch OFF (see DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR  ).
  22. Reinstall the PCU busplate (see MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION ).
  23. Remove the DC-DC converter (see DC-DC CONVERTER REMOVAL/INSTALLATION  ).
  24. Temporarily reconnect the MCM connectors.
  25. Turn the ignition switch to ON (II).
  26. Clear the DTC with the HDS (see DTC CLEAR  ).
  27. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 (62) indicated? 

    YES  -go to step 28.

    NO  -Replace the DC-DC converter (see DC-DC CONVERTER REMOVAL/INSTALLATION ), then go to step  40.

  28. Check the TOTAL VOLTAGE OF ALL IMA BATTERY MODULES in the DATA LIST with the HDS, and compare the IMA battery voltage measured at step 15.

    Is the difference of the voltage 5V or more? 

    YES  -Go to step  48.

    NO  -Replace the MPI module, then go to step  40.

  29. Turn the battery module switch OFF (see DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR  ).
  30. Turn the ignition switch to LOCK (0).
  31. Disconnect MCM connector B (24P).
  32. Measure the resistance between MCM connector terminals B6 and B15.
    Fig 4: Measuring Resistance Between MCM Connector Terminals B6 And B15
    G06429811Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there 92.7-113.3Ω? 

    YES  -go to step 33.

    NO  -

    • If the resistance is too high, go to step  36.
    • If the resistance is too low, go to step  38.
  33. Check for continuity between MCM connector terminal B6 and body ground.
    Fig 5: Checking Continuity Between MCM Connector Terminal B6 And Body Ground
    G06429812Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity? 

    YES  -go to step 34.

    NO  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION ), then go to step  40.

  34. Disconnect the junction board 12P connector (A).
    Fig 6: Identifying Junction Board 12P Connector
    G06429813Courtesy of AMERICAN HONDA MOTOR CO., INC.
  35. Check for continuity between MCM connector terminal B6 and body ground.
    Fig 7: Checking Continuity Between MCM Connector Terminal B6 And Body Ground
    G06429814Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity? 

    YES  -Repair a short in the wire between the junction board 12P connector and the MCM (B6), then go to step  40.

    NO  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  40.

  36. Disconnect the junction board 12P connector (A).
    Fig 8: Identifying Junction Board 12P Connector
    G06429815Courtesy of AMERICAN HONDA MOTOR CO., INC.
  37. Check for continuity between these terminals:
    • MCM connector terminal B6 and junction board 12P connector terminal No. 7.
    • MCM connector terminal B15 and junction board 12P connector terminal No. 2.
    Fig 9: Checking Continuity Between MCM Terminal B15 And Junction Board 12P Connector Terminal 2
    G06429816Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity? 

    YES  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  40.

    NO  -Repair an open in the wire between the junction board 12P connector and the MCM (B6, B15), then go to step  40.

  38. Disconnect the junction board 12P connector (A).
    Fig 10: Identifying Junction Board 12P Connector
    G06429817Courtesy of AMERICAN HONDA MOTOR CO., INC.
  39. Check for continuity between MCM connector terminals B6 and B15.
    Fig 11: Checking Continuity Between MCM Connector Terminals B6 And B15
    G06429818Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity? 

    YES  -Repair a short in the wire between the junction board 12P connector and the MCM (B6, B15), then go to step  40.

    NO  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  40.

  40. Turn the ignition switch to LOCK (0).
  41. Reconnect all connectors.
  42. Reinstall the PCU lid, the PCU busplate, and the PCU cover (see MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION  ).
  43. Reinstall the IPU cover (see IPU COVER REMOVAL/INSTALLATION  ), then turn the battery module switch ON (see DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR  ).
  44. Turn the ignition switch to ON (II).
  45. Clear the DTC with the HDS (see DTC CLEAR  ).
  46. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 (62) indicated? 

    YES  -Check for poor connections or loose terminals at the junction board, the DC-DC converter, the MPI module, and the MCM, then go to step  1.

    NO  -go to step 47.

  47. Monitor the OBD STATUS for DTC P0AE1 (62) in the DTCs MENU with the HDS.

    Does the screen indicate PASSED? 

    YES  -Troubleshooting is complete. If any other Pending or Confirmed DTCs were indicated in step 46, go to the indicated DTC's troubleshooting.

    NO  -If the screen indicates FAILED, check for poor connections or loose terminals at the junction board, the DC-DC converter, the MPI module, and the MCM, then go to step  1. If the screen indicates NOT COMPLETED, keep the ignition switch ON (II) until a result comes on.

  48. Reconnect all connectors.
  49. Reinstall the PCU lid, the PCU busplate, and the PCU cover (see MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION  ).
  50. Reinstall the IPU cover (see IPU COVER REMOVAL/INSTALLATION  ), then turn the battery module switch ON (see DISCONNECTING THE MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR  ).
  51. Update the MCM if it does not have the latest software (see MOTOR CONTROL MODULE (MCM) UPDATE  ), or substitute a known-good MCM (see SUBSTITUTING THE MCM  ).
  52. Turn the ignition switch to ON (II).
  53. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 (62) indicated? 

    YES  -Check for poor connections or loose terminals at the junction board, the DC-DC converter, the MPI module, and the MCM. If the MCM was updated, substitute a known-good MCM (see SUBSTITUTING THE MCM  ), and recheck. If the MCM was substituted, go to step  1.

    NO  -go to step 54.

  54. Monitor the OBD STATUS for DTC P0AE1 (62) in the DTCs MENU with the HDS.

    Does the screen indicate PASSED? 

    YES  -If the MCM was updated, troubleshooting is complete. If the MCM was substituted, replace the original MCM (see MOTOR CONTROL MODULE (MCM) REMOVAL/INSTALLATION  ). If any other Pending or Confirmed DTCs were indicated in step 53, go to the indicated DTC's troubleshooting.

    NO  -If the screen indicates FAILED, check for poor connections or loose terminals at the junction board, the DC-DC converter, the MPI module, and the MCM. If the MCM was updated, substitute a known-good MCM (see SUBSTITUTING THE MCM  ), and recheck. If the MCM was substituted, go to step  1. If the screen indicates NOT COMPLETED, keep the ignition switch ON (II) until a result comes on.

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