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. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Check if DTCs are output.

   Result

   Result	Proceed to
   P0AE0-228 is not output.	A
   P0AE0-228 is also output.	B

5. Turn the power switch off.

B → See step   9 

A: Go to next step 

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 service information because this may cause a malfunction.

2. Check the connection of the hybrid vehicle converter connector.
   Fig 1: Identifying z17 Hybrid Vehicle Converter Connector

   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.
   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.

2. Check the connection of the hybrid battery junction block assembly connectors.
   Fig 2: Identifying z26, z27 & z28 Hybrid Battery Junction Block Assembly Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

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

3. Check the connection of the low voltage connector that drives the HV relay assembly.
   Fig 3: Identifying z16 HV Relay Assembly

   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.
   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.

2. Remove the hybrid battery junction block assembly. Refer toCOMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 4: Identifying z16, z13 & N3 Hybrid Battery Junction Block Assembly Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   N3-1 (CEI) - z13-1 (-)	Auxiliary battery voltage is applied between terminals z16-1 (SMRG) - z16-2 (GND)	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Component without harness connected (Hybrid Battery Junction Block Assembly)

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

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   z16-1 (SMRG) - z16-2 (GND)	-31 to 176°F (-35 to 80°C)	18.8 to 32.1Ω

5. Install the hybrid battery junction block assembly. Refer toCOMPONENTS .

NG → See step   10 

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 service information because this may cause a malfunction.

2. Measure the resistance according to the value(s) in the table below.
   Fig 5: Identifying Electric Vehicle fuse Of The HV J/B Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   Electric vehicle fuse	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Hybrid Battery Junction Block Assembly

NG → See step   11 

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 service information because this may cause a malfunction.

2. Disconnect the z17 connector from the hybrid vehicle converter.
3. Measure the resistance according to the value(s) in the table below.
   Fig 6: Identifying z17 Connector From The Hybrid Vehicle Converter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   z17-4 (SMRP) - Body ground	Power switch off	370k to 430k Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Rear view of wire harness connector (to Hybrid Vehicle Converter)

4. Connect the hybrid vehicle converter connector.

NG → See step   8 

OK → See step   12 

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 service information because this may cause a malfunction.

2. Disconnect connector A58 from the hybrid vehicle control ECU.
3. Disconnect connector z17 from the hybrid vehicle converter.
4. Turn the power switch on (IG).
5. Measure the voltage according to the value(s) in the table below.
   Fig 7: Identifying A58 From The Hybrid Vehicle Control ECU & z17 From The Hybrid Vehicle Converter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   A58-72 (SMRP) - Body ground	Power switch on (IG)	Below 1 V

   TEXT IN ILLUSTRATION
   
   

   *1	Front view of wire harness connector (to Hybrid Vehicle Control ECU)
   *2	Rear view of wire harness connector (to Hybrid Vehicle Converter)

   NOTE:

   Turning the power switch on (IG) with the hybrid vehicle control ECU and hybrid battery junction block assembly connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

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

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A58-72 (SMRP) - z17-4 (SMRP)	Power switch off	Below 1 Ω

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A58-72 (SMRP) and z17-4 (SMRP) - Body ground and other terminals	Power switch off	10 kΩ or higher

8. Connect the hybrid vehicle converter connector.
9. Connect the hybrid vehicle control ECU connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   13