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Home >> Honda >> 2013 >> CR-Z Base, Automatic CVT Trans >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> IMA System >> DTC Troubleshooting >> DTC P0AE1: Bypass Contactor Malfunction

DTC P0AE1: Bypass Contactor Malfunction

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  ).
  • If the ignition switch is turned to ON (II) when the battery module switch is OFF, DTC P0AE1 is stored.
  • If the DTC cannot be cleared, do the troubleshooting for DTC U1204.
  1. Turn the ignition switch to ON (II).
  2. Clear the DTC with the HDS (see DTC CLEAR  ).
  3. Start the engine.
  4. Check the SOC in the DATA LIST with the HDS.
  5. Hold the engine speed between 3, 500 RPM and 4, 000 RPM without load (in P or N (CVT model)) (in neutral (M/T model)) until the SOC increases to 70%. If the SOC does not increase at all, go to step  8.
  6. Monitor the OBD STATUS for P0A78, P1570, P1634, and U1220 in the DTCs MENU with the HDS.

    Does the HDS indicate PASSED? 

    YES  -Go to step  7.

    NO  -

    • If the HDS indicates FAILED: Go to the INDICATED DTC'S TROUBLESHOOTING .
    • If the HDS indicates NOT COMPLETED: Keep the ignition switch ON (II) until a result is indicated.
  7. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 indicated? 

    YES  -Go to step  8.

    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.

  8. Turn the ignition switch to LOCK (0).
  9. Turn the battery module switch OFF (see TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT  ).
  10. Remove the IPU cover (see IPU COVER REMOVAL/INSTALLATION  ).
  11. Remove the PCU lid, the PCU busplate, and the PCU cover (see IPU CASE REMOVAL/INSTALLATION  ).
  12. Reinstall the PCU busplate (see IPU CASE REMOVAL/INSTALLATION  ).
  13. Check for poor connections, loose terminals, or damage at the busbars (A) and the MCM connectors (B).
    Fig 1: Busbars And MCM Connectors With Torque Specifications
    G06950394Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Are the connections and the terminals OK? 

    YES  -Go to step  14.

    NO  -Repair the connections or the terminals, then go to step  43.

  14. Clear the DTC with the HDS (see DTC CLEAR  ).
  15. 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  16.

    NO  -If you never hear the sound, go to step  26. If you hear the sound only once, after clearing the DTC, go to step  16.

  16. Clear the DTC with the HDS (see DTC CLEAR  ).
  17. Turn the ignition switch to LOCK (0).
  18. 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.
  19. Quickly measure the voltage between the high voltage terminals (A, B) 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 on the indicated position; measuring on the adjacent terminals may cause a short.
    • It's normal to read 0 V as soon as 0.21 seconds after measuring the voltage.
      Fig 2: Identifying High Voltage Terminals
      G06950395Courtesy 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  43.

  20. Turn the ignition switch to LOCK (0).
  21. Turn the battery module switch OFF (see TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT  ).
  22. Remove the DC-DC converter (see DC-DC CONVERTER REMOVAL/INSTALLATION  ).
  23. Turn the ignition switch to ON (II).
  24. Clear the DTC with the HDS (see DTC CLEAR  ).
  25. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 indicated? 

    YES  -Go to step  37.

    NO  -Replace the DC-DC converter (see DC-DC CONVERTER REMOVAL/INSTALLATION  ), then go to step  43.

  26. Turn the battery module switch OFF (see TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT  ).
  27. Turn the ignition switch to LOCK (0).
  28. Disconnect MCM connector B (24P).
  29. Measure the resistance between MCM connector terminals B2 and B9.
    Fig 3: Measuring Resistance Between MCM Connector Terminals B2 And B9
    G06950396Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there 92.7-113.3 Ω? 

    YES  -Go to step  30.

    NO  -

    • If the resistance is too high, go to step  33.
    • If the resistance is too low, go to step  35.
  30. Check for continuity between MCM connector terminal B2 and body ground.
    Fig 4: Checking Continuity Between MCM Connector Terminal B2 And Body Ground
    G06950397Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity? 

    YES  -Go to step  31.

    NO  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  43.

  31. Disconnect the junction board 12P connector (A).
    Fig 5: Identifying Junction Board 12P Connector Components Location
    G06950398Courtesy of AMERICAN HONDA MOTOR CO., INC.
  32. Check for continuity between MCM connector terminal B2 and body ground.
    Fig 6: Checking Continuity Between MCM Connector Terminal B2 And Body Ground
    G06950399Courtesy 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 (B2), then go to step  43.

    NO  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  43.

  33. Disconnect the junction board 12P connector (A).
    Fig 7: Identifying Junction Board 12P Connector Components Location
    G06950400Courtesy of AMERICAN HONDA MOTOR CO., INC.
  34. Check for continuity between these terminals:
    • MCM connector terminal B2 and junction board 12P connector terminal No. 12.
    • MCM connector terminal B9 and junction board 12P connector terminal No. 5.
      Fig 8: Checking Continuity Between MCM Connector Terminal B2 And Junction Board 12P Connector Terminal No. 12
      G06950401Courtesy of AMERICAN HONDA MOTOR CO., INC.

      Is there continuity? 

      YES  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  43.

      NO  -Repair an open in the wire between the junction board 12P connector and the MCM (B2, B9), then go to step  43.

  35. Disconnect the junction board 12P connector (A).
    Fig 9: Identifying Junction Board 12P Connector Components Location
    G06950402Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. Check for continuity between MCM connector terminals B2 and B9.
    Fig 10: Checking Continuity Between MCM Connector Terminals B2 And B9
    G06950403Courtesy 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 (B2, B9), then go to step  43.

    NO  -Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION  ), then go to step  43.

  37. Reconnect MCM connector B (24P).
  38. Turn the ignition switch to ON (II).
  39. Record the value of the IMA BATTERY MODULE 1 VOLTAGE through IMA BATTERY MODULE 7 VOLTAGE in the DATA LIST with the HDS.
  40. Turn the ignition switch to LOCK (0).
  41. Disconnect MCM connector E (31P).
  42. Compare the voltages you recorded in step  39 with the voltages you record between the MCM connector terminals listed below.
    • E21 and E31, compared to IMA BATTERY MODULE 1 VOLTAGE
    • E20 and E21, compared to IMA BATTERY MODULE 2 VOLTAGE
    • E9 and E20, compared to IMA BATTERY MODULE 3 VOLTAGE
    • E8 and E9, compared to IMA BATTERY MODULE 4 VOLTAGE
    • E12 and E13, compared to IMA BATTERY MODULE 5 VOLTAGE
    • E2 and E12, compared to IMA BATTERY MODULE 6 VOLTAGE
    • E1 and E2, compared to IMA BATTERY MODULE 7 VOLTAGE
      Fig 11: Identifying MCM Connector E (31P) Terminals Layout
      G06950404Courtesy of AMERICAN HONDA MOTOR CO., INC.

      Is there more than 1 V difference between the MCM readings and the readings from step   39 ? 

      YES  -Go to step  50.

      NO  -Go to step  43.

  43. Turn the ignition switch to LOCK (0).
  44. Reconnect all connectors.
  45. Reinstall the PCU lid, the PCU busplate, and the PCU cover (see IPU CASE REMOVAL/INSTALLATION  ).
  46. Reinstall the IPU cover (see IPU COVER REMOVAL/INSTALLATION  ), then turn the battery module switch ON (see TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT  ).
  47. Turn the ignition switch to ON (II).
  48. Clear the DTC with the HDS (see DTC CLEAR  ).
  49. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 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  -Troubleshooting is complete. If any other Pending or Confirmed DTCs are indicated, go to the indicated DTC'S TROUBLESHOOTING .

  50. Reconnect all connectors.
  51. Reinstall the PCU lid, the PCU busplate, and the PCU cover (see IPU CASE REMOVAL/INSTALLATION  ).
  52. Reinstall the IPU cover (see IPU COVER REMOVAL/INSTALLATION  ), then turn the battery module switch ON (see TURNING OFF AND ON POWER TO THE HIGH VOLTAGE CIRCUIT  ).
  53. 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  ).
  54. Turn the ignition switch to ON (II).
  55. Check for Pending or Confirmed DTCs with the HDS.

    Is DTC P0AE1 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  ), then recheck. If the MCM was substituted, go to step  1.

    NO  -If the MCM was updated, troubleshooting is complete. If the MCM was substituted, replace the original MCM (see IPU CASE REMOVAL/INSTALLATION  ). If any other Pending or Confirmed DTCs were indicated, go to the indicated DTC'S TROUBLESHOOTING .

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