DTC P0AE6-225: Hybrid Battery Precharge Contactor Control Circuit Low: 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.
5. 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 and SMRP system inspections	-	-	-	-	◦	D

   HINT: 

   • ◦ : DTCs that are output
   • - : DTCs that are not output
6. Turn the power switch off.

C → See step   21 

B → See step   18 

A → See step   13 

D: Go to next step 

1. Check that the bolt for the frame wire terminals are tightened to the specified torque, the frame wire terminals are connected securely, and there are no contact problems.
   Fig 1: Identifying Frame Wire Terminals & Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque

   8.4 N*m {85 kgf*cm, 74 in.*lbf}

2. Check for arc marks at the bolt for the frame wire.

   Result

   Result		Proceed to
   The terminals are connected securely and there are no contact problems.	There are no arc marks.	A
   The terminals are not connected securely and there is a contact problem.	There are arc marks.	B
   The terminals are not connected securely and there is a contact problem.	There are no arc marks.	C
   The terminals are connected securely and there are no contact problems.	There are arc marks.	B

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: Go to next step 

1. Check the connection of the frame wire 1E connector.
   Fig 2: Identifying 1E Frame Wire 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. Measure the voltage according to the value(s) in the table below.
   Fig 3: Identifying 1E Frame Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   1E-1 - Body ground	Power switch off	11 to 14 V

NG → See step   29 

OK: Go to next step 

1. Disconnect the negative battery terminal.
2. Remove the IGCT No. 2 fuse from the engine room junction block assembly.
3. Measure the resistance according to the value(s) in the table below.
   Fig 4: Identifying IGCT No. 2 Fuse From Engine Room Junction Block Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   IGCT No. 2 fuse	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Junction Block Assembly
   *2	IGCT No. 2 Fuse

4. Install the IGCT No. 2 fuse.

NG → REPLACE FUSE (IGCT NO. 2) 

OK: 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 that the nuts for the AMD terminals are tightened to the specified torque, the AMD terminals are connected securely, and there are no contact problems.
   Fig 5: Identifying AMD Terminals & Bolts (A & B)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque

   Nut A 

   9.0 N*m {92 kgf*cm, 80 in.*lbf}

   Nut B 

   7.5 N*m {76 kgf*cm, 66 in.*lbf}

3. Check for arc marks at the nuts for the inverter terminal.

   Result

   Result		Proceed to
   The terminals are connected securely and there are no contact problems.	There are no arc marks.	A
   The terminals are not connected securely and there is a contact problem.	There are arc marks.	B
   The terminals are not connected securely and there is a contact problem.	There are no arc marks.	C
   The terminals are connected securely and there are no contact problems.	There are arc marks.	B

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: 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 voltage according to the value(s) in the table below.
   Fig 6: Identifying AMD Terminal & Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   AMD terminal - Body ground	Power switch off	11 to 14 V

NG → See step   32 

OK: 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. Disconnect connector z17 from the hybrid vehicle converter.
3. Turn the power switch on (IG).
4. Measure the voltage according to the value(s) in the table below.
   Fig 7: Identifying Connector z17 From The Hybrid Vehicle Converter Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   z17-1 (IGCT) - Body ground	Power switch on (IG)	11 to 14 V

   TEXT IN ILLUSTRATION
   
   

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

   NOTE:

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

5. Connect the hybrid vehicle converter connector.
6. Turn the power switch off.

NG → REPAIR OR REPLACE HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER) 

OK: Go to next step 

1. Disconnect connector z17 from the hybrid vehicle converter.
2. Measure the resistance according to the value(s) in the table below.
   Fig 8: 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	370 to 430 kΩ

   TEXT IN ILLUSTRATION
   
   

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

3. Connect the hybrid vehicle converter connector.

NG → See step   12 

OK → See step   33 

1. Disconnect connector A58 from the hybrid vehicle control ECU.
2. Disconnect connector z17 from the hybrid vehicle converter.
3. Measure the resistance according to the value(s) in the table below.
   Fig 9: Identifying A58 From The Hybrid Vehicle Control ECU & z17 From The Hybrid Vehicle Converter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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

   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)

4. Connect the hybrid vehicle converter connector.
5. Connect the hybrid vehicle control ECU connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID VEHICLE CONVERTER) 

OK → See step   34 

1. Check that the bolt for the frame wire terminals are tightened to the specified torque, the frame wire terminals are connected securely, and there are no contact problems.
   Fig 10: Identifying Frame Wire Terminals & Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque

   8.4 N*m {85 kgf*cm, 74 in.*lbf}

2. Check for arc marks at the bolt for the frame wire.

   Result

   Result		Proceed to
   The terminals are connected securely and there are no contact problems.	There are no arc marks.	A
   The terminals are not connected securely and there is a contact problem.	There are arc marks.	B
   The terminals are not connected securely and there is a contact problem.	There are no arc marks.	C
   The terminals are connected securely and there are no contact problems.	There are arc marks.	B

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: Go to next step 

1. Check the connection of the frame wire 1E connector.
   Fig 11: Identifying 1E Frame Wire 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. Measure the voltage according to the value(s) in the table below.
   Fig 12: Identifying 1E Frame Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   1E-1 - Body ground	Power switch off	11 to 14 V

NG → See step   29 

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 that the nuts for the AMD terminals are tightened to the specified torque, the AMD terminals are connected securely, and there are no contact problems.
   Fig 13: Identifying AMD Terminals & Bolts (A & B)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque

   Nut A 

   9.0 N*m {92 kgf*cm, 80 in.*lbf}

   Nut B 

   7.5 N*m {76 kgf*cm, 66 in.*lbf}

3. Check for arc marks at the nuts for the inverter terminal.

   Result

   Result		Proceed to
   The terminals are connected securely and there are no contact problems.	There are no arc marks.	A
   The terminals are not connected securely and there is a contact problem.	There are arc marks.	B
   The terminals are not connected securely and there is a contact problem.	There are no arc marks.	C
   The terminals are connected securely and there are no contact problems.	There are arc marks.	B

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: 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 voltage according to the value(s) in the table below.
   Fig 14: Identifying AMD Terminal & Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   AMD terminal - Body ground	Power switch off	11 to 14 V

NG → See step   32 

OK → See step   33 

1. Disconnect the negative battery terminal.
2. Remove the IGCT No. 2 fuse from the engine room junction block assembly.
3. Measure the resistance according to the value(s) in the table below.
   Fig 15: Identifying IGCT No. 2 Fuse From Engine Room Junction Block Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   IGCT No. 2 fuse	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Junction Block Assembly
   *2	IGCT No. 2 Fuse

4. Install the IGCT No. 2 fuse.

NG → REPLACE FUSE (IGCT NO. 2) 

OK: 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. Disconnect connector z17 from the hybrid vehicle converter.
3. Turn the power switch on (IG).
4. Measure the voltage according to the value(s) in the table below.
   Fig 16: Identifying Connector z17 From The Hybrid Vehicle Converter Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   z17-1 (IGCT) - Body ground	Power switch on (IG)	11 to 14 V

   TEXT IN ILLUSTRATION
   
   

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

   NOTE:

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

5. Connect the hybrid vehicle converter connector.
6. Turn the power switch off.

NG → REPAIR OR REPLACE HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER) 

OK → See step   33 

1. Check that the bolt for the frame wire terminals are tightened to the specified torque, the frame wire terminals are connected securely, and there are no contact problems.
   Fig 17: Identifying Frame Wire Terminals & Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque

   8.4 N*m {85 kgf*cm, 74 in.*lbf}

2. Check for arc marks at the bolt for the frame wire.

   Result

   Result		Proceed to
   The terminals are connected securely and there are no contact problems.	There are no arc marks.	A
   The terminals are not connected securely and there is a contact problem.	There are arc marks.	B
   The terminals are not connected securely and there is a contact problem.	There are no arc marks.	C
   The terminals are connected securely and there are no contact problems.	There are arc marks.	B

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: Go to next step 

1. Check the connection of the frame wire 1E connector.
   Fig 18: Identifying 1E Frame Wire 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. Measure the voltage according to the value(s) in the table below.
   Fig 19: Identifying 1E Frame Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   1E-1 - Body ground	Power switch off	11 to 14 V

NG → See step   29 

OK: Go to next step 

1. Disconnect the negative battery terminal.
2. Remove the IGCT No. 2 fuse from the engine room junction block assembly.
3. Measure the resistance according to the value(s) in the table below.
   Fig 20: Identifying IGCT No. 2 Fuse From Engine Room Junction Block Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   IGCT No. 2 fuse	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Engine Room Junction Block Assembly
   *2	IGCT No. 2 Fuse

4. Install the IGCT No. 2 fuse.

NG → REPLACE FUSE (IGCT NO. 2) 

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 that the nuts for the AMD terminals are tightened to the specified torque, the AMD terminals are connected securely, and there are no contact problems.
   Fig 21: Identifying AMD Terminals & Bolts (A & B)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque

   Nut A 

   9.0 N*m {92 kgf*cm, 80 in.*lbf}

   Nut B 

   7.5 N*m {76 kgf*cm, 66 in.*lbf}

3. Check for arc marks at the nuts for the inverter terminal.

   Result

   Result		Proceed to
   The terminals are connected securely and there are no contact problems.	There are no arc marks.	A
   The terminals are not connected securely and there is a contact problem.	There are arc marks.	B
   The terminals are not connected securely and there is a contact problem.	There are no arc marks.	C
   The terminals are connected securely and there are no contact problems.	There are arc marks.	B

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: 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 voltage according to the value(s) in the table below.
   Fig 22: Identifying AMD Terminal & Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   AMD terminal - Body ground	Power switch off	11 to 14 V

NG → See step   32 

OK: 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. Disconnect connector z17 from the hybrid vehicle converter.
3. Turn the power switch on (IG).
4. Measure the voltage according to the value(s) in the table below.
   Fig 23: Identifying Connector z17 From The Hybrid Vehicle Converter Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   z17-1 (IGCT) - Body ground	Power switch on (IG)	11 to 14 V

   TEXT IN ILLUSTRATION
   
   

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

   NOTE:

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

5. Connect the hybrid vehicle converter connector.
6. Turn the power switch off.

NG → REPAIR OR REPLACE HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER) 

OK → See step   33 

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

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   Fusible link block assembly (MAIN)	Always	Below 1 Ω

NG → REPLACE FUSIBLE LINK BLOCK ASSEMBLY (MAIN) 

OK: Go to next step 

1. Turn the power switch off.
2. Check the connection of the auxiliary battery negative terminal cable.

   OK

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

3. Check for arc marks on the auxiliary battery negative terminal cable.

   Result

   Result		Proceed to
   The terminals are connected securely and there are no contact problems.	There are no arc marks.	A
   The terminals are not connected securely and there is a contact problem.	There are arc marks.	B
   The terminals are not connected securely and there is a contact problem.	There are no arc marks.	C
   The terminals are connected securely and there are no contact problems.	There are arc marks.	B

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: Go to next step 

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

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   Auxiliary negative battery terminal - Body ground	Power switch off	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY NEGATIVE BATTERY TERMINAL - BODY GROUND) 

OK → REPAIR OR REPLACE FRAME WIRE 

1. Disconnect connector 1E from the engine room junction block assembly.
   Fig 24: Identifying 1F Connector Bolt & Connector 1E From The Engine Room Junction Block Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   1E-1 - 1F-1	Power switch off	Below 1 Ω

3. Connect the engine room junction block assembly connector.

NG → REPLACE FUSIBLE LINK (DC/DC) 

OK → REPAIR OR REPLACE FRAME WIRE