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Home >> Toyota >> 2012 >> Highlander Limited, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 119 (Hybrid Battery System (Diagnostic Codes (P0A7F-123 - U029A-123)) (Hybrid)) >> Hybrid Battery System >> DTC P0A85-123: Hybrid Battery Pack Cooling Fan 1 Control Circuit High >> Procedure

DTC P0A85-123: Hybrid Battery Pack Cooling Fan 1 Control Circuit High: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. CHECK DTC OUTPUT (DTC P0AFC-123 IS OUTPUT) See step   1 

    B → See step   11 

    A: Go to next step 

  2. CHECK HARNESS AND CONNECTOR (VM0 VOLTAGE) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Disconnect the cable from the negative (-) battery terminal.
    2. 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 repair information because this may cause a malfunction.

    3. Remove the battery cover. Refer to REMOVAL .
    4. Remove the battery smart unit. Refer to REMOVAL .
      NOTE:

      Do not disconnect the battery smart unit connector.

    5. Connect the cable to the negative (-) battery terminal.
    6. Connect the Techstream to the DLC3.
    7. Turn the ignition switch to ON and the Techstream on.
    8. Enter the following menus: Powertrain / Hybrid Control / Active Test / Driving the Battery Cooling Fan.
    9. Select each air volume mode (1 to 6) in the "Driving the Battery Cooling Fan" active test to operate the battery cooling blower assembly.
    10. Measure the voltage according to the value(s) in the table below while the battery cooling blower is operating.
      Fig 1: Measuring Voltage In Battery Smart Unit
      GTY294814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      z21-8 (VM0) - z21-5 (GND) Ignition switch ON 10 V or less
      TEXT IN ILLUSTRATION

      *1 Component with harness connected
      (Battery Smart Unit)
      NOTE:

      If the ignition switch is turned ON with the service plug grip removed, DTC P0A0D-350 for the interlock switch system will be stored. If this DTC is output, clear the DTC using the Techstream. Refer to DTC CHECK / CLEAR .

      HINT: 

      Compare the values in each air volume mode (1 to 6).

    NG → See step   6 

    OK: Go to next step 

  3. CHECK HV BATTERY ASSEMBLY (BATTERY TEMPERATURE SENSOR) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Disconnect the cable from the negative (-) battery terminal.
    2. Check that the service plug grip is not installed.
      NOTE:

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

    3. Remove the battery cover. Refer to REMOVAL .
    4. Disconnect the z18 and z21 connectors from the battery smart unit.
    5. Measure the resistance according to the conditions and value(s) in the tables below.
      Fig 2: Checking HV Battery Assembly (Battery Temperature Sensor)
      GTY306401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TESTER CONNECTION

      Tester Connection Battery Temperature Sensor No.
      z18-7 (TB0) - z18-17 (GB0) 0
      z18-6 (TB1) - z18-16 (GB1) 1
      z18-5 (TB2) - z18-15 (GB2) 2
      z18-4 (TB3) - z18-14 (GB3) 3
      z18-3 (TB4) - z18-13 (GB4) 4
      z18-2 (TB5) - z18-12 (GB5) 5

      Standard Resistance

      Thermistor Temperature Switch Condition Standard Resistance
      0°C (32°F) Ignition switch off 27.3 to 28.4 kΩ
      25°C (77°F) Ignition switch off 9.9 to 10.1 kΩ
      40°C (104°F) Ignition switch off 5.72 to 5.90 kΩ
      TEXT IN ILLUSTRATION

      *1 Rear view of wire harness connector
      (to Battery Smart Unit)
    6. Measure the resistance according to the value(s) in the table below.
      Fig 3: Measuring Resistance Of Battery Smart Unit
      GTY305883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Standard Resistance
      z18-7 (TB0) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-6 (TB1) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-5 (TB2) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-4 (TB3) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-3 (TB4) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-2 (TB5) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-17 (GB0) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-16 (GB1) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-15 (GB2) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-14 (GB3) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-13 (GB4) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      z18-12 (GB5) - z21-1(IGCT) Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Rear view of wire harness connector
      (to Battery Smart Unit)

    NG → See step   9 

    OK: Go to next step 

  4. CHECK BATTERY SMART UNIT 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Disconnect the cable from the negative (-) battery terminal.
    2. 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 repair information because this may cause a malfunction.

    3. Remove the battery cover. Refer to REMOVAL .
    4. Remove the battery smart unit. Refer to REMOVAL .
      NOTE:

      Do not disconnect the battery smart unit connector.

    5. Connect the cable to the negative (-) battery terminal.
    6. Turn the ignition switch to ON.
    7. Measure the voltage according to the value(s) in the table below.
      Fig 4: Checking Battery Smart Unit
      GTY294813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      z18-10 (VIB) - z18-20 (GIB) Ignition switch ON 4.6 to 5.4 V
      TEXT IN ILLUSTRATION

      *1 Component with harness connected
      (Battery Smart Unit)
      NOTE:

      If the ignition switch is turned ON with the service plug grip removed, DTC P0A0D-350 for the interlock switch system will be stored. If this DTC is output, clear the DTC using the Techstream. Refer to DTC CHECK / CLEAR .

    NG → See step   13 

    OK: Go to next step 

  5. CHECK HYBRID VEHICLE RELAY ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Disconnect the cable from the negative (-) battery terminal.
    2. Check that the service plug grip is not installed.
      NOTE:

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

    3. Remove the battery cover. Refer to REMOVAL .
    4. Disconnect the z19 battery current sensor connector from the hybrid vehicle relay assembly.
      Fig 5: Identifying Z19 Battery Current Sensor Connector
      GTY305759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the cable to the negative (-) battery terminal.
    6. Turn the ignition switch to ON.
    7. Measure the voltage according to the value(s) in the table below.
      Fig 6: Checking Hybrid Vehicle Relay Assembly
      GTY300142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      z19-1 (VIB) - z19-2 (GIB) Ignition switch ON 4.6 to 5.4 V
      TEXT IN ILLUSTRATION

      *1 Front view of wire harness connector
      (to Hybrid Vehicle Relay Assembly)
      NOTE:

      Turning the ignition switch ON with the hybrid vehicle relay assembly (battery current sensor) connector disconnected causes DTC P0AC2-123 to be set. Use the Techstream to clear the DTCs. Refer to DTC CHECK / CLEAR .

    NG → See step   8 

    OK → See step   14 

  6. CHECK BATTERY COOLING BLOWER ASSEMBLY (NO. 0) See step   2 

    B → See step   15 

    A: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (BATTERY SMART UNIT - BATTERY COOLING BLOWER ASSEMBLY [NO. 0]) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Disconnect the cable from the negative (-) battery terminal.
    2. Check that the service plug grip is not installed.
      NOTE:

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

    3. Remove the battery cover. Refer to REMOVAL .
    4. Disconnect the z21 connector of the battery smart unit.
    5. Disconnect the O45 connector from the battery cooling blower (No. 0).
      Fig 7: Identifying Battery Cooling Blower Assembly & O45 Connector
      GTY301987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Measure the resistance according to the value(s) in the table below.
      Fig 8: Checking Harness And Connector (Battery Smart Unit - Battery Cooling Blower Assembly)
      GTY295840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      O45-2 (VM0) - z21-8 (VM0) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      O45-2 (VM0) or z21-8 (VM0) - O45-1 (IG0) Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Rear view of wire harness connector
      (to Battery Smart Unit)
      *2 Front view of wire harness connector
      (to Battery Cooling Blower Assembly [No. 0])

    NG → See step   10 

    OK → See step   13 

  8. CHECK HARNESS AND CONNECTOR (NO. 2 BATTERY PACK WIRE) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Disconnect the cable from the negative (-) battery terminal.
    2. 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 repair information because this may cause a malfunction.

    3. Remove the battery cover. Refer to REMOVAL .
    4. Disconnect the z18 connector from the battery smart unit.
    5. Disconnect the z19 battery current sensor connector from the hybrid vehicle relay assembly.
      Fig 9: Identifying Z19 Battery Current Sensor Connector
      GTY305759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Measure the resistance according to the value(s) in the table below.
      Fig 10: Checking Harness And Connector (No. 2 Battery Pack Wire)
      GTY302848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      z18-9 (IB) - z19-3 (IB) Ignition switch off Below 1 Ω
      z18-20 (GIB) - z19-2 (GIB) Ignition switch off Below 1 Ω
      z18-10 (VIB) - z19-1 (VIB) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      z18-9 (IB) or z19-3 (IB) - Body ground Ignition switch off 10 kΩ or higher
      z18-20 (GIB) or z19-2 (GIB) - Body ground Ignition switch off 10 kΩ or higher
      z18-10 (VIB) or z19-1 (VIB) - Body ground Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Rear view of wire harness connector
      (to Battery Smart Unit)
      *2 Front view of wire harness connector
      (to Hybrid Vehicle Relay Assembly)

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR (NO. 2 BATTERY PACK WIRE) 

    OK → See step   13 

  9. CHECK HARNESS AND CONNECTOR (NO. 2 BATTERY PACK WIRE) See step   4 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR (NO. 2 BATTERY PACK WIRE) 

    OK → See step   12 

  10. CHECK HARNESS AND CONNECTOR (NO. 2 BATTERY PACK WIRE) See step   6 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR (NO. 2 BATTERY PACK WIRE) 

    OK → REPAIR OR REPLACE HARNESS OR CONNECTOR 

  11. GO TO DTC P0AFC-123. Refer to  DTC P0AFC-123: Hybrid Battery Pack Sensor Module  
  12. REPLACE HV BATTERY ASSEMBLY. Refer to  REMOVAL 
  13. REPLACE BATTERY SMART UNIT. Refer to  REMOVAL 
  14. REPLACE HYBRID VEHICLE RELAY ASSEMBLY. Refer to  REMOVAL 
  15. REPLACE BATTERY COOLING BLOWER ASSEMBLY (NO. 0). Refer to  REMOVAL 
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