DTC P0D07-73: Hybrid/EV Battery Charging System Positive/Negative Contactor Actuator Stuck Closed [08/2023 - ]: Procedure

Pre-procedure1

1. None.

   Procedure1

2. Check for DTCs.

   Powertrain > Hybrid Control > Trouble Codes 

   Powertrain > HV Battery > Trouble Codes 

   Powertrain > Plug-in Control > Trouble Codes 

   Result

   Result	Proceed to
   P0D07-73 only is output, or DTCs except the ones in the table below are also output.	A
   DTCs of hybrid control system in the tables below are output.	B
   DTCs of hybrid battery system in the tables below are output.	C
   DTCs of plug-in charge control system in the tables below are output.	D

   Malfunction Content	System	Relevant DTC
   Microcomputer malfunction	Hybrid control system	P0606-47	Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
   		P0606-87	Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message
   		P060A-47	Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure
   		P060A-87	Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message
   		P1C9E-9F	Hybrid/EV System Reset Stuck Off
   	Plug-in charge control system	P060B-49	Plug-in Control Module A/D Processing Internal Electronic Failure
   		P0E5E-87	Plug-in Control Module Processor from Hybrid/EV Battery Charger Control Module Processor Missing Message
   		P1C1F-49	Hybrid/EV Battery Charger Control Module A/D Processing Internal Electronic Failure
   Communication system malfunction	Hybrid control system	P0A1F-94	Hybrid/EV Battery Energy Control Module Unexpected Operation
   		U0111-87	Lost Communication with Hybrid/EV Battery Energy Control Module "A" Missing Message
   		U019B-87	Lost Communication with Hybrid/EV Battery Charger Control Module Missing Message
   	Plug-in charge control system	U1150-87	Lost Communication with Hybrid Powertrain Control Module (Hybrid/EV Battery Local Bus) Missing Message
   Sensor and actuator circuit malfunction	Hybrid battery system	P0D0A-11	Hybrid/EV Battery Charging System Positive Contactor Control Circuit Short to Ground
   		P0D0A-15	Hybrid/EV Battery Charging System Positive Contactor Control Circuit Short to Auxiliary Battery or Open
   		P0D11-11	Hybrid/EV Battery Charging System Negative Contactor Control Circuit Short to Ground
   		P0D11-15	Hybrid/EV Battery Charging System Negative Contactor Control Circuit Short to Auxiliary Battery or Open
   		P0E6D-11	Hybrid/EV Battery Charging System Precharge Contactor Control Circuit Short to Ground
   		P0E6D-15	Hybrid/EV Battery Charging System Precharge Contactor Control Circuit Short to Auxiliary Battery or Open
   	Plug-in charge control system	P0D4C-12	Hybrid/EV Battery Charger Hybrid/EV Battery Input Voltage Sensor Circuit Short to Auxiliary Battery
   		P0D4C-14	Hybrid/EV Battery Charger Hybrid/EV Battery Input Voltage Sensor Circuit Short to Ground or Open
   System malfunction	Hybrid control system	P0D4C-1C	Hybrid/EV Battery Charger Hybrid/EV Battery Input Voltage Sensor Voltage Out of Range
   		P0D5E-00	Hybrid/EV Battery Charger Hybrid/EV System Discharge Time Too Long

   HINT: 

   • P0D07-73 may be output as a result of the malfunction indicated by the DTCs above.
     1. The chart above is listed in inspection order of priority.
     2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

   Post-procedure1

3. Turn the ignition switch off.

Result: 

B 

GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2023 - 10/2024]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2024 - ] 

Result: 

C 

GO TO DTC CHART (HYBRID BATTERY SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2023 - ] 

Result: 

D 

GO TO DTC CHART (PLUG-IN CHARGE CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2023 - ] 

Result: 

A 

See step  2

See step  3

Result

Result: 

OK 

See step  4

Result: 

NG 

See step  3

Result

Result: 

NEXT 

See step  4

Refer to PROCEDURE - Step 11

Result

Result: 

OK 

See step  6

Result: 

NG 

See step  5

Result

Result: 

NEXT 

See step  6

See step  7

Result

Result: 

OK 

See step  8

Result: 

NG 

See step  7

Result

Result: 

NEXT 

See step  8

See step  9

Result

Result: 

OK 

See step  10

Result: 

NG 

See step  9

Result

Result: 

NEXT 

See step  10

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the battery ECU assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Disconnect the No. 2 traction battery device box assembly connectors.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Procedure1

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

   Standard Resistance (Check for Open)

   Tester Connection	Condition	Specified Condition
   o6-6 (CHRG) - o17-3 (CHRG)	Ignition switch off	Below 1 Ω
   o6-7 (CHRP) - o17-2 (CHRP)	Ignition switch off	Below 1 Ω

   Standard Resistance (Check for Short)

   Tester Connection	Condition	Specified Condition
   o6-6 (CHRG) and o17-3 (CHRG) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   o6-7 (CHRP) and o17-2 (CHRP) - Body ground and other terminals	Ignition switch off	10 kΩ or higher

   Result

   Proceed to
   OK
   NG

   Post-procedure1

5. Reconnect the No. 2 traction battery device box assembly connectors.
6. Reconnect the battery ECU assembly connector.

Result: 

OK 

See step  12

Result: 

NG 

See step  11

Result

Result: 

NEXT 

See step  12

See step  11

Result

Result: 

OK 

See step  14

Result: 

NG 

See step  13

Result

Result: 

NEXT 

See step  14

See step  13

Result

Result: 

NG 

See step  19

Result: 

OK 

See step  15

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the No. 2 traction battery device box assembly connectors.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Procedure1

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (No. 2 Traction Battery Device Box Assembly)

   -

   -

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   o17-3 (CHRG) - o17-5 (GND8)	-40 to 80°C (-40 to 176°F)	20.6 to 40.8 Ω
   o17-2 (CHRP) - o17-5 (GND8)	-40 to 80°C (-40 to 176°F)	140 to 290 Ω

   Result

   Proceed to
   OK
   NG

   Post-procedure1

4. Reconnect the No. 2 traction battery device box assembly connectors.

Result: 

NG 

See step  20

Result: 

OK 

See step  16

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the electric vehicle charger assembly connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A

   for 3.3 kW Type

   *B

   for 6.6 kW Type

   Procedure1

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for 3.3 kW Type	*B	for 6.6 kW Type
   *a	Component without harness connected (Electric Vehicle Charger Assembly)	-

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   1 (DCHB) (Positive (+) probe) - 2 (DCHG) (Negative (-) probe)	Ignition switch off	Below 700 kΩ

   NOTE:

   Read the resistance after the value has stabilized.

   Result

   Proceed to
   OK
   NG

   Post-procedure1

4. Reconnect the electric vehicle charger assembly connector.

Result: 

NG 

See step  21

Result: 

OK 

See step  17

See step  14

Result

Result: 

B 

See step  22

Result: 

A 

See step  18

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

See step  23

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

See step  26

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

See step  26

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

END 

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

See step  23

Pre-procedure1

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

2. Disconnect the HV battery high voltage connector from the No. 2 traction battery device box assembly.
   NOTE:

   Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Procedure1

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Component without harness connected (No. 2 Traction Battery Device Box Assembly)

   -

   -

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   o2-1 (DCHG) - z25-1 (-)	Ignition switch off	10 kΩ or higher

   HINT: 

   • If a charge relay is stuck closed, inspect the No. 2 traction battery device box assembly without removing it from the vehicle, in order to keep the relay closed.
   • If the resistance is between 28.5 and 31.5 Ω, charge relay CHRP can be judged as stuck on.

   Result

   Result	Judgment	Proceed to
   OK	Past malfunction	A
   NG	Present malfunction	B

   Post-procedure1

4. Reconnect the HV battery high voltage connector from the No. 2 traction battery device box assembly.

Result: 

B 

See step  25

Result: 

A 

See step  24

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

See step  26

HINT: 

Refer to REMOVAL [08/2023 - ]

Result

Result: 

NEXT 

See step  26

See step  18

Result

Result: 

A 

END 

Result: 

B 

REPLACE BATTERY ECU ASSEMBLY AND NO. 2 TRACTION BATTERY DEVICE BOX ASSEMBLY 

• Battery ECU assembly:

  Refer to REMOVAL [08/2023 - ]

• No. 2 Traction battery device box assembly:

  Refer to REMOVAL [08/2023 - ]