DTC P0AA0-00: Hybrid/EV Battery Positive Contactor Circuit Stuck Closed [12/2023 - ]: Procedure

Pre-procedure1

• None.

• Check for DTCs.

  Powertrain > Hybrid Control > Trouble Codes 

  Powertrain > Motor Generator > Trouble Codes 

  Powertrain > HV Battery > Trouble Codes 

  Result

  Result	Proceed to
  P0AA0-00 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 motor generator control system in the tables below are output.	C

  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
  		P0A1B-49	Drive Motor "A" Control Module Internal Electronic Failure
  		P1C9E-9F	Hybrid/EV System Reset Stuck Off
  	Motor generator control system	P0A1B-1F	Generator Control Module Circuit Intermittent
  		P0A1A-47	Generator Control Module Watchdog / Safety MC Failure
  		P0A1A-49	Generator Control Module Internal Electronic Failure
  		P1C2A-1C	Generator A/D Converter Circuit Circuit Voltage Out of Range
  		P1C2A-49	Generator A/D Converter Circuit Internal Electronic Failure
  		P1C2B-1C	Drive Motor "A" Control Module A/D Converter Circuit Voltage Out of Range
  		P1C2B-49	Drive Motor "A" Control Module A/D Converter Circuit Internal Electronic Failure
  		P1CAC-49	Generator Position Sensor Internal Electronic Failure
  		P1CAD-49	Drive Motor "A" Position Sensor Internal Electronic Failure
  		P1CAF-38	Generator Position Sensor REF Signal Cycle Malfunction Signal Frequency Incorrect
  		P1CB0-38	Drive Motor "A" Position Sensor REF Signal Frequency Incorrect
  		P3133-83	Communication Error from Generator to Drive Motor "A" Value of Signal Protection Calculation Incorrect
  		P3133-86	Communication Error from Generator to Drive Motor "A" Signal Invalid
  		P3133-87	Communication Error from Generator to Drive Motor "A" Missing Message
  Power source circuit malfunction	Motor generator control system	P06D6-1C	Generator Control Module Offset Power Circuit Voltage Out of Range
  		P06B0-1C	Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range
  Communication system malfunction	Hybrid control system	U0110-87	Lost Communication with Drive Motor Control Module "A" Missing Message
  Sensor and actuator circuit malfunction	Hybrid control system	P0AD9-11	Hybrid/EV Battery Positive Contactor Circuit Short to Ground
  		P0AD9-15	Hybrid/EV Battery Positive Contactor Circuit Short to Auxiliary Battery or Open
  		P0ADD-11	Hybrid/EV Battery Negative Contactor Circuit Short to Ground
  		P0ADD-15	Hybrid/EV Battery Negative Contactor Circuit Short to Auxiliary Battery or Open
  		P0AE4-11	Hybrid/EV Battery Precharge Contactor Circuit Short to Ground
  		P0AE4-15	Hybrid/EV Battery Precharge Contactor Circuit Short to Auxiliary Battery or Open
  	Motor generator control system	P0A3F-16	Drive Motor "A" Position Sensor Circuit Voltage Below Threshold
  		P0A4B-16	Generator Position Sensor Circuit Voltage Below Threshold
  		P0A4B-21	Generator Position Sensor Signal Amplitude < Minimum
  		P0A4B-22	Generator Position Sensor Signal Amplitude > Maximum
  		P0C50-13	Drive Motor "A" Position Sensor Circuit "A" Circuit Open
  		P0C50-16	Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Below Threshold
  		P0C50-17	Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Above Threshold
  		P0C5A-13	Drive Motor "A" Position Sensor Circuit "B" Circuit Open
  		P0C5A-16	Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Below Threshold
  		P0C5A-17	Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Above Threshold
  		P0C64-13	Generator Position Sensor Circuit "A" Circuit Open
  		P0C64-16	Generator Position Sensor Circuit "A" Circuit Voltage Below Threshold
  		P0C64-17	Generator Position Sensor Circuit "A" Circuit Voltage Above Threshold
  		P0C69-13	Generator Position Sensor Circuit "B" Circuit Open
  		P0C69-16	Generator Position Sensor Circuit "B" Circuit Voltage Below Threshold
  		P0C69-17	Generator Position Sensor Circuit "B" Circuit Voltage Above Threshold
  System malfunction	Hybrid control system	P0D2D-1C	Drive Motor "A" Inverter Voltage Sensor Voltage Out of Range
  		P1C83-49	High Voltage Power Resource Circuit Voltage Sensor after Boosting Malfunction
  		P0C76-00	Hybrid/EV Battery System Discharge Time Too Long
  	Motor generator control system	P0D2D-16	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Below Threshold
  		P0D2D-17	Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold
  		P1CB6-9E	Drive Motor "A" Inverter Voltage Sensor (VH) Stuck On

  HINT: 

  • P0AA0-00 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

• Turn the ignition switch off.

Result: 

B 

GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [12/2023 - ] 

Result: 

C 

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [12/2023 - ] 

Result: 

A 

See step  2

Pre-procedure1

• None.

• Read the freeze frame data of DTC P0AA0-00.

  Powertrain > Hybrid Control > DTC(P0AA0-00) > Freeze Frame Data 

  Tester Display
  VL-Voltage before Boosting
  VH-Voltage after Boosting

  NOTE:

  As freeze frame data is stored immediately before and after a DTC is stored, make sure to only read the values for the moment the DTC was stored ("0(s)").

  Result

  Result	Proceed to
  Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is less than 76 V.	A
  Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is 76 V or more.	B

  HINT: 

  If VH-Voltage after Boosting is output even when an off command is being sent to the system main relay (positive side), P0AA0-00 is output. If the difference between the "VL-Voltage before Boosting" and the "VH-Voltage after Boosting" is large, it is determined that there is an inverter (VH sensor) malfunction.

Post-procedure1

• Turn the ignition switch off.

Result: 

B 

REPLACE HYBRID MOTOR CONTROL INVERTER ASSEMBLY. Refer to  REMOVAL [12/2023 - ] 

Result: 

A 

See step  3

Refer to PROCEDURE - Step 1

Result

Result: 

OK 

See step  5

Result: 

NG 

See step  4

Result

Result: 

NEXT 

See step  5

1. Check the connection condition of the No. 2 floor wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

   HINT: 

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [09/2023 - ]

   OK

   - The connector is connected securely.

   - The terminals are not deformed and are connected securely.

   - No water or foreign matter in the connector.

   Result

   Result	Proceed to
   OK	A
   NG (The connector is not connected securely.)	B
   NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

Result: 

A 

See step  8

Result: 

C 

See step  7

Result: 

B 

See step  6

Result

Result: 

NEXT 

See step  8

Result

Result: 

NEXT 

See step  8

1. Check the connection condition of the No. 2 traction battery wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

   HINT: 

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [09/2023 - ]

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   - The connector is connected securely.

   - The terminals are not deformed and are connected securely.

   - No water or foreign matter in the connector.

   Result

   Result	Proceed to
   OK	A
   NG (The connector is not connected securely.)	B
   NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

Result: 

A 

See step  11

Result: 

C 

See step  10

Result: 

B 

See step  9

Result

Result: 

NEXT 

See step  11

Result

Result: 

NEXT 

See step  11

Pre-procedure1

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

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

• Check the connector connections and contact pressure of the relevant terminals of the No. 2 traction battery device box assembly connector.

  HINT: 

  Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [09/2023 - ]

  OK

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

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  Result

  Proceed to
  OK
  NG

Post-procedure1

• None.

Result: 

OK 

See step  13

Result: 

NG 

See step  12

Result

Result: 

NEXT 

See step  13

1. Check the installation condition of the ground wire JC.

   OK

   The ground wire JC is securely installed.

   Result

   Proceed to
   OK
   NG

Result: 

OK 

See step  15

Result: 

NG 

See step  14

Result

Result: 

NEXT 

See step  15

Pre-procedure1

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

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

• Connect the SST.

  HINT: 

  Refer to Instructions for Connecting SST [12/2023 - ]

• Disconnect the No. 2 traction battery device box assembly connector.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

• Disconnect the hybrid vehicle control ECU assembly connector.

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

  Standard Resistance (Check for Open)

  Tester Connection	Condition	Specified Condition	Result
  D117-3 (SMRB) - j14-3 (SMRB)	Ignition switch off	Below 1 Ω	Ω

  Standard Resistance (Check for Short)

  Tester Connection	Condition	Specified Condition	Result
  D117-3 (SMRB) or j14-3 (SMRB) - Body ground and other terminals	Ignition switch off	10 kΩ or higher	kΩ

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Reconnect the hybrid vehicle control ECU assembly connector.
• Reconnect the No. 2 traction battery device box assembly connector.
• Disconnect the SST.

Result: 

OK 

See step  17

Result: 

NG 

See step  16

Result

Result: 

NEXT 

See step  17

Pre-procedure1

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

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

• Disconnect the No. 2 traction battery device box assembly connector.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  Standard Resistance

  Tester Connection	Condition	Specified Condition	Result
  j14-2 (GND) - Body ground	Ignition switch off	Below 1 Ω	Ω

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Reconnect the No. 2 traction battery device box assembly connector.

Result: 

OK 

See step  19

Result: 

NG 

See step  18

Result

Result: 

NEXT 

See step  19

Pre-procedure1

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

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

• Disconnect the No. 2 traction battery device box assembly connector.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

• 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	Result
  j14-3 (SMRB) - j14-2 (GND)	-40 to 80°C (-40 to 176°F)	20.6 to 40.8 Ω	Ω

  Result

  Proceed to
  OK
  NG

Post-procedure1

• Reconnect the No. 2 traction battery device box assembly connector.

Result: 

NG 

See step  22

Result: 

OK 

See step  20

Pre-procedure1

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

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

• 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

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

  Standard Resistance

  Tester Connection	Condition	Specified Condition
  f2-1 (CBI) - z26-1 (+)	Ignition switch off	10 kΩ or higher

  HINT: 

  • If a system main 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 result of reading the freeze frame data is A, the No. 2 traction battery device box assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  Result

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

Post-procedure1

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

Result: 

B 

See step  23

Result: 

A 

See step  21

HINT: 

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  24

HINT: 

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  24

HINT: 

Refer to REMOVAL [12/2023 - ]

Result

Result: 

NEXT 

See step  24

Pre-procedure1

• Install the service plug grip.
• Clear the DTCs.

  Powertrain > Hybrid Control > Clear DTCs 

• Turn the ignition switch off and wait for 2 minutes or more.
• Turn the ignition switch to ON (READY).

• According to the display on the GTS, read the Data List and monitor the values of "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" for 3 minutes.

  Powertrain > Hybrid Control > Data List 

  Tester Display
  VL-Voltage before Boosting
  Hybrid/EV Battery Voltage

  Result

  Result	Proceed to
  Difference between "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" is always less than 100 V.	A
  Difference between "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" is 100 V or more.	B

Post-procedure1

• Turn the ignition switch off.

Result: 

A 

END 

Result: 

B 

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY AND NO. 2 TRACTION BATTERY DEVICE BOX ASSEMBLY 

• Hybrid vehicle control ECU assembly:

  Refer to REMOVAL [12/2023 - ]

• No. 2 traction battery device box assembly:

  Refer to REMOVAL [12/2023 - ]