DTC P0AE6-225: Hybrid Battery Precharge Contactor Control Circuit Low: Procedure

CHECK DTC OUTPUT (HV)

Connect the Techstream to the DLC3.
Turn the power switch on (IG).
Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
Check if DTCs are output.

Refer to "Proceed to" in the table below to perform each inspection.

Result

Item to inspect	P0A08-264	P0A09-265	P0A09-591	P2519-766	P0AE6-225	Proceed to
Only AMD open circuit inspection	◦	-	◦	◦	◦	A
	◦	-	-	◦	◦
	◦	-	-	-	◦
Only IGCT open circuit inspection	-	◦	◦	◦	◦	B
	-	◦	-	-	◦
	-	◦	-	◦	◦
AMD and IGCT open circuit inspections	-	-	◦	◦	◦	C
AMD and IGCT open circuit inspections	-	-	-	◦	◦	C
AMD and IGCT open circuit and SMRP system inspections	-	-	-	-	◦	D

HINT:

◦ : DTCs that are output
- : DTCs that are not output

C → See step 19

B → See step 16

A → See step 12

D: Go to next step

CHECK FRAME WIRE (AUXILIARY BATTERY POSITIVE TERMINAL AND AMD TERMINAL VOLTAGE)

Turn the power switch off.

Fig 1: Locating AMD And Auxiliary Battery Positive Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard voltage

Tester Connection	Specified Condition
Auxiliary battery positive (+) terminal and AMD terminal - Body ground	11 to 14 V

NG → See step 25

OK: Go to next step

CHECK ENGINE ROOM R/B NO. 1 (FUSIBLE LINK AND FUSE)
1. Check the fusible link (DC/DC) and the fuse (IGCT NO. 3) in the engine room R/B No. 1, and the fusible link (MAIN) that is installed at the auxiliary battery, for improper installation and for open circuits.
  
  Fig 2: Identifying Engine Room R/B No. 1 (Fusible Link And Fuse)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  They are connected securely. There are no open circuits in the fusible links or fuse.
NG → REPLACE FUSE

OK: Go to next step
CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)
1. Turn the power switch off.
2. Check the connections of the hybrid vehicle control ECU connectors.
  
  Fig 3: Checking Connector Connection Condition (HV Control ECU Connector)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  The connectors are connected securely and there are no contact problems.
NG → CONNECT SECURELY

OK: Go to next step
CHECK HYBRID VEHICLE CONVERTER (AMD TERMINAL CONNECTION CONDITION)
1. Check the connection of the AMD terminal (hybrid vehicle converter side).
  
  Fig 4: Identifying AMD Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  The terminal is connected securely and there is no contact problem.
2. Check for arc marks on the AMD terminals (hybrid vehicle converter side and vehicle wire harness side).
  Result
  
  There are no arc marks.
NG → See step 26

OK: Go to next step

CHECK TERMINAL VOLTAGE (AMD TERMINAL)

Turn the power switch off.

Fig 5: Identifying W6 Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the voltage according to the value(s) in the table below when the power switch is off.

Standard voltage

Tester Connection	Specified Condition
w6-1 - Body ground	11 to 14 V

NG → REPAIR OR REPLACE FRAME WIRE

OK: Go to next step

CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR)

Disconnect the battery pack wire connector. Refer to COMPONENTS .
Turn the power switch on (IG).

Fig 6: Locating Battery Pack Wire Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 7: Identifying Battery Pack Wire Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard voltage

Tester Connection	Specified Condition
IGCT (VN1-1) - Body ground	11 to 14 V

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HYBRID VEHICLE CONTROL ECU

Turn the power switch off.

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

Fig 8: Identifying Battery Pack Wire Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection	Specified Condition
SMRP (VN1-8) - Body ground	370 to 430 kΩ

NG → See step 11

OK: Go to next step

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR)

WARNING:

Be sure to wear insulated gloves.

Turn the power switch off and remove the service plug grip. Refer to PRECAUTION .
NOTE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.
Check that the service plug grip is not installed.

Fig 9: Identifying Hybrid Vehicle Converter & N1 Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect connector N1 from the hybrid vehicle converter.

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

Fig 10: Identifying N1 Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection	Specified Condition
IGCT (VN1-1) - IGCT (N1-1)	Below 1 Ω
SMRP (VN1-8) - SMRP (N1-4)	Below 1 Ω
SMRP (VN1-8) or SMRP (N1-4) - Body ground	10 kΩ or more
IGCT (VN1-1) or IGCT (N1-1) - Body ground	10 kΩ or more

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HYBRID VEHICLE CONTROL ECU

Connect the all connectors.
Turn the power switch on (IG).

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

Fig 11: Identifying Battery Pack Wire Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard voltage

Tester Connection	Specified Condition
SMRP (VN1-8) - Body ground	9 to 12 V

NG → See step 26

OK → See step 27

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)

Turn the power switch off.
Disconnect connector A54 from the hybrid vehicle control ECU.

Fig 12: Identifying Battery Pack Wire And Hybrid Vehicle Control ECU Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard resistance (Check for open)

Tester Connection	Specified Condition
SMRP (A54-123) - SMRP (VN1-8)	Below 1 Ω

Standard resistance (Check for short)

Tester Connection	Specified Condition
SMRP (A54-123) or SMRP (VN1-8) - Body ground	10 kΩ or more

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK → See step 27

CHECK FRAME WIRE (AUXILIARY BATTERY POSITIVE TERMINAL AND AMD TERMINAL)

Turn the power switch off.

Fig 13: Locating AMD And Auxiliary Battery Positive Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard voltage

Tester Connection	Specified Condition
AMD terminal - Body ground	11 to 14 V

NG → See step 25

OK: Go to next step

CHECK FUSIBLE LINK
1. Check the fusible link (DC/DC) in the engine room R/B No. 1 and the fusible link (MAIN) that is installed at the auxiliary battery for improper installation and for open circuits.
  
  Fig 14: Identifying Fusible Link (DC/DC) In Engine Room R/B No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  They are connected securely. There are no open circuits in the fusible links.
NG → REPLACE FUSIBLE LINK

OK: Go to next step
CHECK HYBRID VEHICLE CONVERTER (AMD TERMINAL CONNECTION CONDITION)
1. Check the connection of the AMD terminal (hybrid vehicle converter side).
  
  Fig 15: Identifying AMD Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  The terminal is connected securely and there is no contact problem.
2. Check for arc marks on the AMD terminals (hybrid vehicle converter side and vehicle wire harness side).
  Result
  
  There are no arc marks.
NG → See step 26

OK: Go to next step

CHECK TERMINAL VOLTAGE (AMD TERMINAL)

Turn the power switch off.

Fig 16: Identifying W6 Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the voltage according to the value(s) in the table below when the power switch is off.

Standard voltage

Tester Connection	Specified Condition
w6-1 - Body ground	11 to 14 V

NG → REPAIR OR REPLACE FRAME WIRE

OK → See step 26

CHECK FUSE (IGCT NO. 3)
1. Check the fuse (IGCT No. 3) in the engine room R/B No. 1 for improper installation and open circuits.
  
  Fig 17: Identifying Fuse (IGCT No. 3) In Engine Room R/B No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  The fuse is installed securely. There is no open circuit in the fuse.
NG → REPLACE FUSE (IGCT NO. 3)

OK: Go to next step

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)

Disconnect the battery pack wire connector. Refer to COMPONENTS .
Turn the power switch on (IG).

Fig 18: Locating Battery Pack Wire Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 19: Identifying Battery Pack Wire Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard voltage

Tester Connection	Specified Condition
IGCT (VN1-1) - Body ground	11 to 14 V

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR)

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.

Fig 20: Identifying Hybrid Vehicle Converter & N1 Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect connector N1 from the hybrid vehicle converter. Refer to COMPONENTS .

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

Fig 21: Identifying N1 Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection	Specified Condition
IGCT (VN1-1) - IGCT (N1-1)	Below 1 Ω
IGCT (VN1-1) or IGCT (N1-1) - Body ground	10 kΩ or more

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK → See step 26

CHECK FRAME WIRE (AUXILIARY BATTERY POSITIVE TERMINAL AND AMD TERMINAL)

Turn the power switch off.

Fig 22: Locating AMD And Auxiliary Battery Positive Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard voltage

Tester Connection	Specified Condition
AMD terminal - Body ground	11 to 14 V

NG → See step 25

OK: Go to next step

CHECK ENGINE ROOM R/B NO. 1 (FUSIBLE LINK AND FUSE)
1. Check the fusible link (DC/DC), the fuse (IGCT NO. 3) in the engine room R/B No. 1 and the fusible link (MAIN) that is installed at the auxiliary battery for improper installation and for open circuits.
  
  Fig 23: Identifying Engine Room R/B No. 1 (Fusible Link And Fuse)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  They are connected securely. There are no open circuits in the fusible links or fuse.
NG → REPLACE FUSE

OK: Go to next step
CHECK HYBRID VEHICLE CONVERTER (AMD TERMINAL CONNECTION CONDITION)
1. Check the connection of the AMD terminal (hybrid vehicle converter side).
  
  Fig 24: Identifying AMD Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Result
  
  The terminal is connected securely and there is no contact problem.
2. Check for arc marks on the AMD terminals (hybrid vehicle converter side and vehicle wire harness side).
  Result
  
  There are no arc marks.
NG → See step 26

OK: Go to next step

CHECK TERMINAL VOLTAGE (AMD TERMINAL)

Measure the voltage according to the value(s) in the table below when the power switch is off.

Standard voltage

Tester Connection	Specified Condition
w6-1 - Body ground	11 to 14 V

NG → REPAIR OR REPLACE FRAME WIRE

OK: Go to next step

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)

Disconnect the battery pack wire connector. Refer to COMPONENTS .
Turn the power switch on (IG).

Fig 26: Locating Battery Pack Wire Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 27: Identifying Battery Pack Wire Connector Terminals

Standard voltage

Tester Connection	Specified Condition
IGCT (VN1-1) - Body ground	11 to 14 V

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR)

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed. Refer to PRECAUTION .

Fig 28: Identifying Hybrid Vehicle Converter & N1 Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect connector N1 from the hybrid vehicle converter.

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

Fig 29: Identifying N1 Connector

Standard resistance

Tester Connection	Specified Condition
IGCT (VN1-1) - IGCT (N1-1)	Below 1 Ω
IGCT (VN1-1) or IGCT (N1-1) - Body ground	10 kΩ or more

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK → See step 26

CHECK AUXILIARY BATTERY

Check the connection of the auxiliary battery negative terminal.
Result

The terminal is connected securely and there is no contact problem.
Check for arc marks on the auxiliary battery negative terminal.
Result

There are no arc marks.

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

Standard resistance

Tester Connection	Specified Condition
Auxiliary battery negative terminal - Body ground	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK → REPAIR OR REPLACE FRAME WIRE

REPLACE HYBRID VEHICLE CONVERTER. Refer to COMPONENTS
REPLACE HYBRID VEHICLE CONTROL ECU. Refer to COMPONENTS