DTC P0AE2-773: Hybrid Battery Precharge Contactor Circuit Stuck Closed: Procedure

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   8 

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 connection of the low voltage connector of the hybrid vehicle converter.
   Fig 5: 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.

   HINT: 

   For the removal and installation procedures related to inspection of the connection of the low voltage connector of the hybrid vehicle converter. Refer toREMOVAL .

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the low voltage connector from the hybrid vehicle converter.
   Fig 6: 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 7: 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. Turn the power switch off.
2. Check that the service plug grip is not installed.
   Fig 8: Identifying Hybrid Vehicle Converter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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. Disconnect the 3 high voltage connectors of the hybrid vehicle converter from the HV battery junction block.

   HINT: 

   For the removal and installation procedures related to the high voltage connectors of the hybrid vehicle converter. Refer toREMOVAL .

4. Measure the resistance according to the value(s) in the table below.
   Fig 9: Locating z58, z59 And z60 Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection (Tester Probe Polarity)	Switch Condition	Specified Condition
   z58-1 (CBD) (Positive Prove) - z60-1 (INR) (Negative Prove)	Power switch off	10 kΩ or higher

   HINT: 

   The polarities of the tester probes may differ depending on the tester. Use the current output probe of the tester as the positive probe for this measurement. To determine the polarity, use another voltmeter to confirm the current output probe of the tester. When measuring the output of the tester, the voltmeter positive probe indicates the tester current output probe.

NG → See step   9 

OK: Go to next step 

1. Check that the ground bolts for the hybrid vehicle converter are securely installed.
   Fig 10: Locating Hybrid Vehicle Converter Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The bolts are securely installed.

NG → CONNECT SECURELY 

OK → See step   9 

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 11: 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   10