DTC P0D07-00: Hybrid/EV Battery Charging System Positive Contactor Stuck Closed: Notes

WARNING: This page is about a different variant/trim than selected.

1. -

Outline of diagnosis:

Even though the charge relay on the positive side of HV battery is turned off, the voltage in the charger does not decrease

(1 trip detection logic)

Trouble symptom:

Plug-in charging suspended

Wiring diagram:

Hybrid system Ref. to WIRING SYSTEM (CROSSTREK MODEL (HEV))>HYBRID ELECTRIC VEHICLE SYSTEM>WIRING DIAGRAM .

Courtesy of SUBARU OF AMERICA, INC.

Courtesy of SUBARU OF AMERICA, INC.

CAUTION: Before performing diagnosis, refer to "CAUTION" in "General Description". Ref. to P-HEV HYBRID POWERTRAIN CONTROL (DIAGNOSTICS)>GENERAL DESCRIPTION>CAUTION .

Courtesy of SUBARU OF AMERICA, INC.

Courtesy of SUBARU OF AMERICA, INC.

CHECK DTC .

Read the following DTCs using Subaru Select Monitor. Ref. to P-HEV HYBRID POWERTRAIN CONTROL (DIAGNOSTICS)>DIAGNOSTIC TROUBLE CODE (DTC) . Ref. to P-HEV HIGH VOLTAGE BATTERY (DIAGNOSTICS)>DIAGNOSTIC TROUBLE CODE (DTC) . Ref. to PLUG-IN BATTERY CHARGER (DIAGNOSTICS)>DIAGNOSTIC TROUBLE CODE (DTC) .

P-HEV Hybrid Powertrain Control
P-HEV High Voltage Battery
Plug-in Battery Charger

NOTE:

Malfunction contents	System	Related DTC
Microcomputer malfunction	P-HEV Hybrid Powertrain Control	P060647	HYBRID/EV POWERTRAIN CONTROL MODULE PROCESSOR WATCHDOG/SAFETY MCU FAILURE
		P060687	HYBRID/EV POWERTRAIN CONTROL MODULE PROCESSOR TO MONITORING PROCESSOR MISSING MESSAGE
		P060A47	HYBRID/EV POWERTRAIN CONTROL MODULE MONITORING PROCESSOR WATCHDOG/SAFETY MCU FAILURE
		P060A87	HYBRID/EV POWERTRAIN CONTROL MODULE PROCESSOR FROM MONITORING PROCESSOR MISSING MESSAGE
		P1C9E9F	HYBRID/EV SYSTEM RESET STUCK OFF
	Plug-in Battery Charger	P060B49	PLUG-IN CONTROL MODULE A/D PROCESSING INTERNAL ELECTRONIC FAILURE
		P0E5E87	PLUG-IN CONTROL MODULE PROCESSOR FROM HYBRID/EV BATTERY CHARGER CONTROL MODULE PROCESSOR MISSING MESSAGE
		P1C1F49	HYBRID/EV BATTERY CHARGER CONTROL MODULE A/D PROCESSING INTERNAL ELECTRONIC FAILURE
Communication system malfunction	P-HEV Hybrid Powertrain Control	P0A1F94	HYBRID/EV BATTERY ENERGY CONTROL MODULE UNEXPECTED OPERATION
		U011187	LOST COMMUNICATION WITH HYBRID/EV BATTERY ENERGY CONTROL MODULE "A" MISSING MESSAGE
		U019B87	LOST COMMUNICATION WITH HYBRID/EV BATTERY CHARGER CONTROL MODULE MISSING MESSAGE
	Plug-in Battery Charger	U115087	LOST COMMUNICATION WITH HYBRID POWERTRAIN CONTROL MODULE (HYBRID/EV BATTERY LOCAL BUS) MISSING MESSAGE
Sensor and actuator circuit malfunction	P-HEV High Voltage Battery	P0D0A11	HYBRID/EV BATTERY CHARGING SYSTEM POSITIVE CONTACTOR CONTROL CIRCUIT SHORT TO GROUND
		P0D0A15	HYBRID/EV BATTERY CHARGING SYSTEM POSITIVE CONTACTOR CONTROL CIRCUIT SHORT TO AUXILIARY BATTERY OR OPEN
		P0D1111	HYBRID/EV BATTERY CHARGING SYSTEM NEGATIVE CONTACTOR CONTROL CIRCUIT SHORT TO GROUND
		P0D1115	HYBRID/EV BATTERY CHARGING SYSTEM NEGATIVE CONTACTOR CONTROL CIRCUIT SHORT TO AUXILIARY BATTERY OR OPEN
		P0E6D11	HYBRID/EV BATTERY CHARGING SYSTEM PRE-CHARGE CONTACTOR CONTROL CIRCUIT SHORT TO GROUND
		P0E6D15	HYBRID/EV BATTERY CHARGING SYSTEM PRE-CHARGE CONTACTOR CONTROL CIRCUIT SHORT TO AUXILIARY BATTERY OR OPEN
	Plug-in Battery Charger	P0D4C12	HYBRID/EV BATTERY CHARGER HYBRID/EV BATTERY INPUT VOLTAGE SENSOR CIRCUIT SHORT TO AUXILIARY BATTERY
	Plug-in Battery Charger	P0D4C14	HYBRID/EV BATTERY CHARGER HYBRID/EV BATTERY INPUT VOLTAGE SENSOR CIRCUIT SHORT TO GROUND OR OPEN
System malfunction	P-HEV Hybrid Powertrain Control	P0D0E73	HYBRID/EV BATTERY CHARGING SYSTEM NEGATIVE CONTACTOR CONTROL ACTUATOR STUCK CLOSED
		P0D4C1C	HYBRID/EV BATTERY CHARGER HYBRID/EV BATTERY INPUT VOLTAGE SENSOR VOLTAGE OUT OF RANGE
		P0E6A73	HYBRID/EV BATTERY CHARGING SYSTEM PRE-CHARGE CONTACTOR CONTROL ACTUATOR STUCK CLOSED

When "Only DTC P0D0700 is displayed" or "DTC other than above is displayed", go to A.

When DTCs related to [P-HEV Hybrid Powertrain Control] mentioned above are simultaneously displayed, go to B.

When DTCs related to [P-HEV High Voltage Battery] mentioned above are simultaneously displayed, go to C.

When DTCs related to [Plug-in Battery Charger] mentioned above are simultaneously displayed, go to D.

Yes :

Go to 2.
Perform the diagnosis for the simultaneously displayed DTCs.
NOTE: If more than one DTC is simultaneously displayed, perform the diagnosis in the order described in the above.
Perform the diagnosis for the simultaneously displayed DTCs.
NOTE: If more than one DTC is simultaneously displayed, perform the diagnosis in the order described in the above.
Perform the diagnosis for the simultaneously displayed DTCs.

NOTE: If more than one DTC is simultaneously displayed, perform the diagnosis in the order described in the above.

No : -

CHECK FREEZE FRAME DATA .
Read the freeze frame data value of [P-HEV Hybrid Powertrain Control] using the Subaru Select Monitor. Ref. to P-HEV HYBRID POWERTRAIN CONTROL (DIAGNOSTICS)>FREEZE FRAME DATA .

Is the difference between [Charging Voltage for Hybrid Battery] and [Hybrid Battery Voltage] less than 100 [V]?

Yes : Go to 3.

No : Replace Electric vehicle charger assembly. Ref. to HYBRID ELECTRIC VEHICLE>ELECTRIC VEHICLE CHARGER .

NOTE: When the difference between HV battery charging voltage and HV battery voltage is large, even though the charge relay (+ side) OFF command is issued, it is judged as malfunction of Electric vehicle charger assembly.
CHECK CONNECTION CONDITION OF CONNECTOR (Battery ECU assembly CONNECTOR) .
CAUTION: Make sure to wear insulated gloves and protective goggles during the work.
1. Check that the Service plug is disconnected. Ref. to HYBRID ELECTRIC VEHICLE>SERVICE PLUG .
2. Check the connecting condition of connector (HV42) in Battery ECU assembly and check the relevant terminals for contact pressure, deformation and intrusion of water or foreign matter.
Is there looseness at the connector connection, or any poor contact, deformation or intrusion of water or foreign matters at the relevant terminals?

Yes : Connect the connector securely. Or repair the poor contact of connector.

And then, Go to 4.

No : Go to 4.
CHECK CONNECTION CONDITION OF CONNECTOR (HV battery junction block CONNECTOR) .
CAUTION: Make sure to wear insulated gloves and protective goggles during the work.

Check the connecting condition of connectors (HV43), (HV45) and (HV49) in HV battery junction block and check the relevant terminals for contact pressure, deformation and intrusion of water or foreign matters.

Is there looseness at the connector connection, or any poor contact, deformation or intrusion of water or foreign matters at the relevant terminals?

Yes : Connect the connector securely. Or repair the poor contact of connector.

And then, Go to 5.

No : Go to 5.
CHECK GROUNDING POINT CONNECTION (LOW VOLTAGE CIRCUIT FOR CHR DRIVING) .
Check the connection of the grounding points (GB-9), (GB-10), (GB-14) and (GB-15) of the low voltage circuit for CHR driving.

Is the grounding point connected securely?

Yes : Go to 6.

No : Connect the grounding point securely.

And then, Go to 6.
CHECK Wire harness AND CONNECTOR (Battery ECU assembly - HV battery junction block) (OPEN CIRCUIT) .
CAUTION: Make sure to wear insulated gloves and protective goggles during the work.
1. Disconnect HV battery junction block connector (HV49).
2. Disconnect Battery ECU assembly connector (HV42).
3. Using a tester, measure the resistance between HV battery junction block connector and Battery ECU assembly connector.
  Connector & terminal
  
  (HV42) No. 52 - (HV49) No. 3:
Is the resistance less than 1 Ω?

Yes : Go to 7.

No : Repair or replace Wire harness between HV battery junction block connector and Battery ECU assembly connector.

And then, Go to 7.
CHECK Wire harness AND CONNECTOR (Battery ECU assembly - HV battery junction block) (LINE-TO-LINE SHORT) .
CAUTION: Make sure to wear insulated gloves and protective goggles during the work.

Using a tester, measure the resistance between Battery ECU assembly connector terminals.

Connector & terminal

(HV42) No. 52 - (HV42) No. 1 - 69:

Is the resistance 10 kΩ or more?

Yes : Go to 8.

No : Repair or replace Wire harness between HV battery junction block connector and Battery ECU assembly connector.

And then, Go to 8.
CHECK Wire harness AND CONNECTOR (HV battery junction block - CHASSIS GROUND) (OPEN CIRCUIT) .
CAUTION: Make sure to wear insulated gloves and protective goggles during the work.
1. Disconnect HV battery junction block connector (HV49).
2. Using a tester, measure the resistance between HV battery junction block connector and chassis ground.
  Connector & terminal
  
  (HV49) No. 2 - Chassis ground:
Is the resistance less than 1 Ω?

Yes : Go to 9.

No : Repair or replace Wire harness between HV battery junction block connector and chassis ground.

And then, Go to 9.
CHECK HV battery junction block UNIT (CHRB) .
CAUTION: Make sure to wear insulated gloves and protective goggles during the work.

Using a tester, measure the resistance between HV battery junction block connector terminals.

Connector & terminal

(HV49) No. 3 - (HV49) No. 2:

Is the resistance 20.6 - 40.8 Ω? (When -40 - 80°C (-40 - 176°F))

Yes : Go to 10.

No : Go to 11.
CHECK HV battery junction block (CHRB) .
CAUTION:
- Make sure to wear insulated gloves and protective goggles during the work.
- If CHR is welded, the welding may be peeled only by slight vibrations. Therefore, perform the inspection while installed on the vehicle.
1. Disconnect connectors (HV43) and (HV45) from HV battery junction block.
  CAUTION: Be sure to insulate the disconnected high voltage connector by wrapping it with insulating tape. To do this, wrap the insulating tape from Wire harness along to the connector.
2. Using a tester, measure the resistance between HV battery junction block connector terminals.
  Connector & terminal
  
  (HV45) No. 1 - (HV43) No. 1:
Is the resistance 10 kΩ or more?

NOTE: A resistance value of 10 kΩ or more indicates a past malfunction. A resistance value of less than 10 kΩ indicates a current malfunction.

Yes : Go to 11.

No : Go to 11.
REPLACEMENT OF HV battery junction block .
CAUTION: Make sure to wear insulated gloves and protective goggles during the work.
1. Replace HV battery junction block. Ref. to HYBRID ELECTRIC VEHICLE>RELAY AND FUSE .
2. Restore the vehicle to its original state.
3. Attach the Service plug.
4. Turn to IG ON.
5. Using the Subaru Select Monitor, perform the clear memory of [P-HEV Hybrid Powertrain Control]. Ref. to COMMON (DIAG)>CLEAR MEMORY .
6. Using the Subaru Select Monitor, display the following items in the [Data monitor] of [P-HEV Hybrid Powertrain Control], and record them. Ref. to P-HEV HYBRID POWERTRAIN CONTROL (DIAGNOSTICS)>DATA MONITOR .
  - Hybrid Battery SOC
7. Using the Subaru Select Monitor, check [Data Monitor] of [P-HEV Hybrid Powertrain Control] to see if [Hybrid Battery SOC] is less than 70%.
8. Turn to IG OFF, and wait for two minutes or more.
9. Connect Electric vehicle charger cable assembly, and charge it for three minutes or more.
10. Disconnect Electric vehicle charger cable assembly, and wait for 10 seconds or more.
11. Turn to IG ON.
12. Using the Subaru Select Monitor, display the following items in the [Data Monitor] of [P-HEV Hybrid Powertrain Control], and record them. Ref. to P-HEV HYBRID POWERTRAIN CONTROL (DIAGNOSTICS)>DATA MONITOR .
  - Hybrid Battery Voltage
  - Charging Voltage for Hybrid Battery
Is the deviation between [Hybrid Battery Voltage] and [Charging Voltage for Hybrid Battery] less than 100 [V] constantly?

Yes : There was something wrong with HV battery junction block.

Finish the diagnosis.

No : Replace Battery ECU assembly. Ref. to HYBRID ELECTRIC VEHICLE>BATTERY CONTROL MODULE .