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Home >> Toyota >> 2011 >> Camry Base, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 101 (Hybrid Vehicle Control System (P311) (Hybrid) (Diagnostic Codes (P0AA1-233 - U0424-537)) >> Hybrid Control System >> DTC P0AE6-225: Hybrid Battery Precharge Contactor Control Circuit Low >> Procedure

DTC P0AE6-225: Hybrid Battery Precharge Contactor Control Circuit Low: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Select the following menu items: 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

    A → See step   13 

    B → See step   17 

    C → See step   21 

    D: Go to next step 

  2. CHECK FRAME WIRE (AUXILIARY BATTERY POSITION TERMINAL AND AMD TERMINAL VOLTAGE) 
    1. Turn the power switch off.
      Fig 1: Identifying AMD Terminal Location
      GTY192967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below.

      Standard voltage

      Tester Connection Specified Condition
      Auxiliary battery positive (+) terminal and AMD terminal - Body ground 9 to 14 V

    NG → See step   29 

    OK: Go to next step 

  3. CHECK ENGINE ROOM R/B (FUSIBLE LINK AND FUSE) 
    1. Check the fusible link (DC/DC) and the fusible link (MAIN) that is installed at the auxiliary battery, for improper installation and for open circuits.
      Fig 2: Identifying Fusible Link (DC/DC) And The Fusible Link (MAIN) Location
      GTY292027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      They are connected securely. There are no open circuits in the fusible links or fuse.

    NG → REPLACE FUSE 

    OK: Go to next step 

  4. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR). Refer to  PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  5. CHECK HYBRID VEHICLE CONVERTER (AMD TERMINAL CONNECTION CONDITION) 
    1. Check for DTCs and save freeze frame data.
      Fig 3: Identifying AMD Terminal 1 And Terminal 2 Location
      GTY185008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the negative terminal from the auxiliary battery.
    3. Check for looseness of AMD terminals 1 and 2.

      Result 1

      AMD terminal 1 

      8.0 N*m (82 kgf*cm, 71 in.*lbf)

      AMD terminal 2 

      9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Make sure to disconnect the terminals 1 and 2 to check for arc marks.

      Result 2

      There are no arc marks.

      Result Procedure Procedure to
      Result 1 Result 2
      No looseness is present No arc marks are present Connect AMD terminals 1 and 2, connect the negative terminal to the auxiliary battery, and go to  6step 6. A
      No looseness is present Arc marks are present Repair or replace the appropriate part (nut, round terminal, hybrid vehicle converter (DC/DC converter), terminal block for AMD terminal 2). After repair or replacement, connect the negative terminal to the auxiliary battery. B
      Looseness is present No arc marks are present Connect AMD terminals 1 and 2, connect the negative terminal to the auxiliary battery. C
      Looseness is present Arc marks are present Repair or replace the appropriate part (nut, round terminal, hybrid vehicle converter (DC/DC converter), terminal block for AMD terminal 2). After repair or replacement, connect the negative terminal to the auxiliary battery. B

    B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

    C → TIGHTEN TO SPECIFIED TORQUE 

    A: Go to next step 

  6. CHECK TERMINAL VOLTAGE (AMD TERMINAL) 
    1. Turn the power switch off.
      Fig 4: Identifying H5 Connector Terminal Location
      GTY169519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below when the power switch is off.

      Standard voltage

      Tester Connection Specified Condition
      h5-1 - Body ground 9 to 14 V

    NG → REPAIR OR REPLACE FRAME WIRE 

    OK: Go to next step 

  7. CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTOR). Refer to  PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  8. CHECK HARNESS AND CONNECTOR 
    1. Disconnect the battery pack wire connector. Refer to REMOVAL .
    2. Turn the power switch on (IG).
    3. Measure the voltage according to the value(s) in the table below.
      Fig 5: Identifying Battery Pack Wire Connector Terminal Identification
      GTY171825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard voltage

      Tester Connection Specified Condition
      IGCT (On1-1) - Body ground 9 to 14 V

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  9. CHECK HYBRID VEHICLE CONTROL ECU 
    1. Turn the power switch off.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 6: Identifying ON1 Battery Pack Wire Connector Terminal Identification
      GTY192749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      SMRP (On1-8) - Body ground 370 to 430 kΩ

    NG → See step   12 

    OK: Go to next step 

  10. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR). Refer to  PROCEDURE - Step 6 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Disconnect the n4 hybrid vehicle converter (DC/DC converter) connector. Refer to REMOVAL
    3. Measure the resistance according to the value(s) in the table below.
      Fig 7: Identifying Hybrid Vehicle Converter And Battery Pack Wire Connector Terminal Identification
      GTY192891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      IGCT (On1-1) - IGCT (n4-1) Below 1 Ω
      SMRP (On1-8) - SMRP (n4-4) Below 1 Ω
      SMRP (On1-8) or SMRP (n4-4) - Body ground 10 kΩ or more
      IGCT (On1-1) or IGCT (n4-1) - Body ground 10 kΩ or more

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   30 

  12. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR) 
    1. Turn the power switch off.
    2. Disconnect the A61 hybrid vehicle control ECU connector.
      Fig 8: Identifying Hybrid Vehicle Converter And Battery Pack Wire Connector Terminal Identification
      GTY192866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance according to the value(s) in the table below.

      Standard resistance (Check for open)

      Tester Connection Specified Condition
      SMRP (A61-72) - SMRP (On1-8) Below 1 Ω

      Standard resistance (Check for short)

      Tester Connection Specified Condition
      SMRP (A61-72) or SMRP (On1-8) - Body ground 10 kΩ or higher

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   31 

  13. CHECK FRAME WIRE (AUXILIARY BATTERY POSITIVE TERMINAL AND AMD TERMINAL) 
    1. Turn the power switch off.
      Fig 9: Identifying AMD Terminal Location
      GTY192967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below.

      Standard voltage

      Tester Connection Specified Condition
      Auxiliary battery positive (+) terminal and AMD terminal - Body ground 9 to 14 V

    NG → See step   29 

    OK: Go to next step 

  14. CHECK FUSIBLE LINK 
    1. Check the fusible link (DC/DC) in the engine room R/B and the fusible link (MAIN) that is installed at the auxiliary battery for improper installation and for open circuits.
      Fig 10: Identifying Fusible Link (DC/DC) In Engine Room R/B Location
      GTY192896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      They are connected securely. There are no open circuits in the fusible links.

    NG → REPLACE FUSIBLE LINK 

    OK: Go to next step 

  15. CHECK HYBRID VEHICLE CONVERTER (AMD TERMINAL CONNECTION CONDITION) 
    1. Check for DTCs and save freeze frame data.
      Fig 11: Identifying AMD Terminal 1 And Terminal 2 Location
      GTY185008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the negative terminal from the auxiliary battery.
    3. Check for looseness of AMD terminals 1 and 2.

      Result 1

      AMD terminal 1 

      8.0 N*m (82 kgf*cm, 71 in.*lbf)

      AMD terminal 2 

      9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Make sure to disconnect the terminals 1 and 2 to check for arc marks.

      Result 2

      There are no arc marks.

      Result Procedure Procedure to
      Result 1 Result 2
      No looseness is present No arc marks are present Connect AMD terminals 1 and 2, connect the negative terminal to the auxiliary battery, and go to  16step 16. A
      No looseness is present Arc marks are present Repair or replace the appropriate part (nut, round terminal, hybrid vehicle converter (DC/DC converter), terminal block for AMD terminal 2). After repair or replacement, connect the negative terminal to the auxiliary battery. B
      Looseness is present No arc marks are present Connect AMD terminals 1 and 2, connect the negative terminal to the auxiliary battery. C
      Looseness is present Arc marks are present Repair or replace the appropriate part (nut, round terminal, hybrid vehicle converter (DC/DC converter), terminal block for AMD terminal 2). After repair or replacement, connect the negative terminal to the auxiliary battery. B

    B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

    C → TIGHTEN TO SPECIFIED TORQUE 

    A: Go to next step 

  16. CHECK TERMINAL VOLTAGE (AMD TERMINAL) 
    1. Turn the power switch off.
      Fig 12: Identifying H5 Connector Terminal Location
      GTY169519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below when the power switch is off.

      Standard voltage

      Tester Connection Specified Condition
      h5-1 - Body ground 9 to 14 V

    NG → REPAIR OR REPLACE FRAME WIRE 

    OK → See step   30 

  17. CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTOR). Refer to  PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  18. CHECK HARNESS AND CONNECTOR 
    1. Disconnect the battery pack wire connector. Refer to REMOVAL .
    2. Turn the power switch on (IG).
      Fig 13: Identifying On1 Battery Pack Wire Connector Location
      GTY180714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the voltage according to the value(s) in the table below.
      Fig 14: Identifying Battery Pack Wire Connector Terminal Identification
      GTY171825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard voltage

      Tester Connection Specified Condition
      IGCT (On1-1) - Body ground 9 to 14 V

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  19. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR). Refer to  PROCEDURE - Step 6 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  20. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      Fig 15: Identifying n4 Hybrid Vehicle Converter(DC/DC Converter) Connector Location
      GTY192885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the n4 hybrid vehicle converter (DC/DC converter) connector. Refer to REMOVAL .
    3. Measure the resistance according to the value(s) in the table below.
      Fig 16: Identifying Hybrid Vehicle Converter And Battery Pack Wire Connector Terminal Identification
      GTY192892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      IGCT (On1-1) - IGCT (n4-1) Below 1 Ω
      IGCT (On1-1) or IGCT (n4-1) - Body ground 10 kΩ or more

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   30 

  21. CHECK FRAME WIRE (AUXILIARY BATTERY POSITIVE TERMINAL AND AMD TERMINAL) 
    1. Turn the power switch off.
      Fig 17: Identifying AMD Terminal Location
      GTY192967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below.

      Standard voltage

      Tester Connection Specified Condition
      Auxiliary battery positive (+) terminal and AMD terminal - Body ground 9 to 14 V

    NG → See step   29 

    OK: Go to next step 

  22. CHECK ENGINE ROOM R/B (FUSIBLE LINK AND FUSE) 
    1. Check the fusible link (DC/DC) and the fuse (IGCT No. 2) in the engine room R/B and the fusible link (MAIN) that is installed at the auxiliary battery for improper installation and for open circuits.
      Fig 18: Identifying Fusible Link (DC/DC) And Fuse (IGCT No. 2) Location
      GTY192895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      They are connected securely. There are no open circuits in the fusible links or fuse.

    NG → REPLACE FUSE 

    OK: Go to next step 

  23. CHECK HYBRID VEHICLE CONVERTER (AMD TERMINAL CONNECTION CONDITION) 
    1. Check for DTCs and save freeze frame data.
      Fig 19: Identifying AMD Terminal 1 And Terminal 2 Location
      GTY185008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the negative terminal from the auxiliary battery.
    3. Check for looseness of AMD terminals 1 and 2.

      Result 1

      AMD terminal 1 

      8.0 N*m (82 kgf*cm, 71 in.*lbf)

      AMD terminal 2 

      9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Make sure to disconnect the terminals 1 and 2 to check for arc marks.

      Result 2

      There are no arc marks.

      Result Procedure Procedure to
      Result 1 Result 2
      No looseness is present No arc marks are present Connect AMD terminals 1 and 2, connect the negative terminal to the auxiliary battery, and go to  24step 24. A
      No looseness is present Arc marks are present Repair or replace the appropriate part (nut, round terminal, hybrid vehicle converter (DC/DC converter), terminal block for AMD terminal 2). After repair or replacement, connect the negative terminal to the auxiliary battery. B
      Looseness is present No arc marks are present Connect AMD terminals 1 and 2, connect the negative terminal to the auxiliary battery. C
      Looseness is present Arc marks are present Repair or replace the appropriate part (nut, round terminal, hybrid vehicle converter (DC/DC converter), terminal block for AMD terminal 2). After repair or replacement, connect the negative terminal to the auxiliary battery. B

    B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

    C → TIGHTEN TO SPECIFIED TORQUE 

    A: Go to next step 

  24. CHECK TERMINAL VOLTAGE (AMD TERMINAL) 
    1. Turn the power switch off.
      Fig 20: Identifying H5 Connector Location
      GTY169519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below when the power switch is off.

      Standard voltage

      Tester Connection Specified Condition
      h5-1 - Body ground 9 to 14 V

    NG → REPAIR OR REPLACE FRAME WIRE 

    OK: Go to next step 

  25. CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTOR). Refer to  PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  26. CHECK HARNESS AND CONNECTOR 
    1. Disconnect the battery pack wire connector. Refer to REMOVAL .
    2. Turn the power switch on (IG).
      Fig 21: Identifying On1 Battery Pack Wire Connector Location
      GTY180714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the voltage according to the value(s) in the table below.
      Fig 22: Identifying Battery Pack Wire Connector Terminal Identification
      GTY171825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard voltage

      Tester Connection Specified Condition
      IGCT (On1-1) - Body ground 9 to 14 V

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  27. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR). Refer to  PROCEDURE - Step 6 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  28. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      Fig 23: Identifying n4 Hybrid Vehicle Converter(DC/DC Converter) Connector Location
      GTY192885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the n4 hybrid vehicle converter (DC/DC converter) connector. Refer to REMOVAL .
    3. Measure the resistance according to the value(s) in the table below.
      Fig 24: Identifying Hybrid Vehicle Converter And Battery Pack Wire Connector Terminal Identification
      GTY192893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      IGCT (On1-1) - IGCT (n4-1) Below 1 Ω
      IGCT (On1-1) or IGCT (n4-1) - Body ground 10 kΩ or more

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   30 

  29. CHECK AUXILIARY BATTERY 
    1. Check the connection of the auxiliary battery negative terminal.

      Result

      The terminal is connected securely and there is no contact problem.

    2. Check for arc marks on the auxiliary battery negative terminal.

      Result

      There are no arc marks.

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

      Standard resistance

      Tester Connection Specified Condition
      Auxiliary battery negative terminal - Body ground Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → REPAIR OR REPLACE FRAME WIRE 

  30. REPLACE HYBRID VEHICLE CONVERTER. Refer to  REMOVAL 
  31. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
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