DTC P0AE2-161: Hybrid Battery Precharge Contactor Circuit Stuck Closed: Procedure

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

   Result

   Result	Proceed to
   P0AE2-161 only is output.	A
   P0AE0-228 is output.	B

B → See step   17 

A: Go to next step 

1. Check the connections of the hybrid vehicle control ECU connectors.
   Fig 1: Identifying Hybrid Vehicle Control ECU Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The connectors are connected securely and there are no contact problems.

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check the connection of the battery pack wire connector.
   Fig 2: Locating Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

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

   HINT: 

   For the removal and installation procedures related to inspection of the connection of the battery pack wire connector. Refer toREMOVAL .

NG → CONNECT SECURELY 

OK: Go to next step 

1. Turn the power switch off.
2. Disconnect the battery pack wire connector.
   Fig 3: Locating Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the resistance according to the value(s) in the table below.
   Fig 4: Identifying zR2 Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   zR2-8 (SMRP) - Body ground	Power switch off	370 to 430 kΩ

NG → See step   14 

OK: Go to next step 

1. Disconnect connector E55 from the hybrid vehicle control ECU.
2. Turn the power switch on (IG).
3. Measure the voltage according to the value(s) in the table below.
   Fig 5: Checking Harness And Connector (Hybrid Vehicle Control ECU - Battery Pack Wire Connector)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Turning the power switch on (IG) with the hybrid vehicle control ECU connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

   Standard voltage

   Tester Connection	Switch Condition	Specified Condition
   E55-4 (SMRG) - Body ground	Power switch on (IG)	Below 1 V

4. Turn the power switch off.
5. Measure the resistance according to the value(s) in the table below.

   Standard resistance (Check for open)

   Tester Connection	Switch Condition	Specified Condition
   E55-4 (SMRG) - zR2-2 (CON3)	Power switch off	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Switch Condition	Specified Condition
   E55-4 (SMRG) or zR2-2 (CON3) - Body ground and other terminals	Power switch off	10 kΩ or higher

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Turn the power switch off.
2. 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 information because this may cause a malfunction.

3. Check the connections of the high voltage connectors for the hybrid vehicle converter that are connected to the HV battery junction block.
   Fig 6: Locating HV Battery Junction Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The connectors are connected securely and there are no contact problems.

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Check if there is an open circuit in the electric battery fuse that is installed in the HV battery junction block.
   Fig 7: Checking HV Battery Junction Block (Electric Battery Fuse)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   There is no open circuit in the fuse.

3. Check that the bolts for the electric battery fuse are tightened to the specified torque.

   Specified Condition

   T=4.5 N*m {46 kgf*cm, 40 in.*lbf}

   NOTE:

   Be sure to use a torque wrench to check the tightening torque.

NG → See step   19 

OK: Go to next step 

1. Turn the power switch off.
2. 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 information because this may cause a malfunction.

3. Check the connection of the low voltage connector that drives the relay of the HV battery junction block.
   Fig 8: Locating Low Voltage Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

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

   HINT: 

   For the removal and installation procedures related to inspection of the connection of the connector that drives the relay of the HV battery junction block. Refer toREMOVAL .

NG → CONNECT SECURELY 

OK: Go to next step 

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 information because this may cause a malfunction.

2. Check the connection of the low voltage connector of the hybrid vehicle converter.
   Fig 9: Locating Low Voltage Connector Of Hybrid Vehicle Converter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

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

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the low voltage connector that drives the relay of the HV battery junction block.
   Fig 10: Locating Low Voltage Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the resistance according to the value(s) in the table below.
   Fig 11: Identifying z38 And zR2 Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance (Check for open)

   Tester Connection	Switch Condition	Specified Condition
   zR2-2 (CON3) - z38-1 (CON3)	Power switch off	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Switch Condition	Specified Condition
   zR2-2 (CON3) or z38-1 (CON3) - Body ground and other terminals	Power switch off	10 kΩ or higher

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

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 information because this may cause a malfunction.

2. Disconnect the low voltage connector from the hybrid vehicle converter.
   Fig 12: Locating Low Voltage Connector Of Hybrid Vehicle Converter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the resistance according to the value(s) in the table below.
   Fig 13: Checking Harness And Connector (Battery Pack Wire Connector - Hybrid Vehicle Converter)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance (Check for open)

   Tester Connection	Switch Condition	Specified Condition
   zR2-8 (SMRP) - z35-4 (SMRP)	Power switch off	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Switch Condition	Specified Condition
   zR2-8 (SMRP) or z35-4 (SMRP) - Body ground and other terminals	Power switch off	10 kΩ or higher

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the HV battery junction block from the vehicle. Refer to REMOVAL .
3. Measure the resistance according to the value(s) in the table below.
   Fig 14: Inspecting HV Battery Junction Block (SMRG)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Condition	Specified Condition
   g3-1 - z34-1	Auxiliary battery voltage is not applied between terminals z38-1 (CON3) and z38-2 (GND).	10 kΩ or higher
   g3-1 - z34-1	Auxiliary battery voltage is applied between terminals z38-1 (CON3) and z38-2 (GND).	Below 1 Ω

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

   Standard resistance

   Tester Connection	Condition	Specified Condition
   z38-1 (CON3) - z38-2 (GND)	-31 to 176°F (-35 to 80°C)	18.8 to 32.1 Ω

NG → See step   16 

OK: Go to next step 

1. Check that the ground bolts for the hybrid vehicle converter are tightened to the specified torque and that there are no contact problems.
   Fig 15: Locating Hybrid Vehicle Converter Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 7.5 N*m ( 76 kgf*cm, 66 in.*lbf) 

NG → CONNECT SECURELY 

OK → See step   15 

1. Turn the power switch off.
2. Disconnect connector A74 from the hybrid vehicle control ECU.
3. Turn the power switch on (IG).
4. Measure the voltage according to the value(s) in the table below.
   Fig 16: Identifying A74 And zR2 Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Turning the power switch on (IG) with the service plug grip removed causes an interlock switch system DTC (P0A0D-350) to be set.

   Standard voltage

   Tester Connection	Switch Condition	Specified Condition
   A74-25 (SMRP) - Body ground	Power switch on (IG)	Below 1 V

5. Turn the power switch off.
6. Measure the resistance according to the value(s) in the table below.

   Standard resistance (Check for open)

   Tester Connection	Switch Condition	Specified Condition
   A74-25 (SMRP) - zR2-8 (SMRP)	Power switch off	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Switch Condition	Specified Condition
   A74-25 (SMRP) or zR2-8 (SMRP) - Body ground and other terminals	Power switch off	10 kΩ or higher

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   18