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

1. Check the connections of the hybrid vehicle control ECU connectors.

   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 No. 2 battery pack wire connector.
   Fig 1: Identifying No. 2 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 No. 2 battery pack wire connector. Refer to REMOVAL .

NG → CONNECT SECURELY 

OK: Go to next step 

1. Turn the power switch off.
2. Disconnect the No. 2 battery pack wire connector.
   Fig 2: Identifying No. 2 Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the resistance according to the value(s) in the table below.
   Fig 3: Identifying NS1 No. 2 Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   nS1-11 (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 4: Locating Hybrid Vehicle Converter Low Voltage Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 5: Locating Hybrid Vehicle Converter 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 low voltage connector of the hybrid vehicle converter. Refer to COMPONENTS .

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 6: Identifying NS1 No. 2 Battery Pack Wire Connector And Z82 Hybrid Vehicle Converter Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the low voltage connector from the hybrid vehicle converter.
3. Measure the resistance according to the value(s) in the table below.

   Standard resistance (Check for open)

   Tester Connection	Switch Condition	Specified Condition
   nS1-11 (SMRP) - z82-10 (SMRP)	Power switch off	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Switch Condition	Specified Condition
   nS1-11 (SMRP) or z82-10 (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 7: Locating Hybrid Vehicle Converter High-Voltage Connectors

   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 to COMPONENTS .

4. Measure the resistance according to the value(s) in the table below.
   Fig 8: Locating Z60, Z59 And Z58 Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection (Tester Probe Polarity)	Switch Condition	Specified Condition
   z58-1 (CBD) (Positive probe) - z60-1 (INR) (Negative Probe)	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 9: Identifying Hybrid Vehicle Converter Ground 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 10: Identifying NS1 No. 2 Battery Pack Wire Connector And A74 Hybrid Vehicle Control ECU Connectors

   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) - nS1-11 (SMRP)	Power switch off	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Switch Condition	Specified Condition
   A74-25 (SMRP) or nS1-11 (SMRP) - Body ground and other terminals	Power switch off	10 kΩ or higher

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   10