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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 P0A99-123: Hybrid Battery Pack Cooling Fan 2 Control Circuit Low >> Procedure

DTC P0A99-123: Hybrid Battery Pack Cooling Fan 2 Control Circuit Low: 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   20 

    A: Go to next step 

  2. CHECK DTC OUTPUT 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Read output DTCs. Refer to DTC CHECK / CLEAR .
      RESULT

      Result Proceed to
      P0A99-123 is output A
      P0A84-123, P0A99-123, and P0AD2-123 are output B

    B → See step   9 

    A: Go to next step 

  3. CHECK BATTERY COOLING BLOWER ASSEMBLY (NO. 1) See step   2 

    B → See step   19 

    A: Go to next step 

  4. CHECK HARNESS AND CONNECTOR (BATT FAN RELAY - BATTERY COOLING BLOWER ASSEMBLY [NO. 1]) 
    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 O46 connector from the battery cooling blower assembly (No. 1).
      Fig 1: Identifying Battery Cooling Blower Assembly (No. 1) & Connector
      GTY298492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the BATT FAN relay.
      Fig 2: Identifying Fuse (BATT FAN)
      GTY254294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room No. 3 Relay Block
      *2 BATT FAN Relay
    6. Measure the resistance according to the value(s) in the table below.
      Fig 3: Measuring Resistance Of BATT FAN Relay
      GTY301809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      BATT FAN relay terminal 5 - O46-1 (IG1) Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Engine Room No. 3 Relay Block
      *2 Front view of wire harness connector
      (to Battery Cooling Blower Assembly [No. 1])
      *3 BATT FAN Relay Holder
      NOTE:

      When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (BATTERY SMART UNIT - BATTERY COOLING BLOWER ASSEMBLY [NO. 1]) 
    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 O46 connector from the battery cooling blower assembly (No. 1).
      Fig 4: Identifying Battery Cooling Blower Assembly (No. 1) & Connector
      GTY298492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the z21 connector from the battery smart unit.
    6. Measure the resistance according to the value(s) in the table below.
      Fig 5: Checking Harness And Connector (Battery Smart Unit - Battery Cooling Blower Assembly [No. 1])
      GTY295841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      z21-7 (VM1) - O46-2 (VM1) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      z21-7 (VM1) or O46-2 (VM1) - 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 Battery Cooling Blower Assembly [No. 1])

    NG → See step   25 

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (BATTERY COOLING BLOWER ASSEMBLY [NO. 1] - BODY GROUND) 
    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 O46 connector from the battery cooling blower assembly (No. 1).
      Fig 6: Identifying Battery Cooling Blower Assembly (No. 1) & Connector
      GTY298492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the resistance according to the value(s) in the table below.
      Fig 7: Checking Harness And Connector (Battery Cooling Blower Assembly [No. 1] - Body Ground)
      GTY297717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      O46-4 (GND1) - Body Ground Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Front view of wire harness connector
      (to Battery Cooling Blower Assembly [No. 1])

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY COOLING BLOWER ASSEMBLY [NO. 1]) 
    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 O46 connector from the battery cooling blower assembly (No. 1).
      Fig 8: Identifying Battery Cooling Blower Assembly (No. 1) & Connector
      GTY298492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the A65 connector from the hybrid vehicle control ECU. Refer to REMOVAL .
    6. Measure the resistance according to the value(s) in the table below.
      Fig 9: Checking Harness And Connector (Hybrid Vehicle Control ECU - Battery Cooling Blower Assembly [No. 1])
      GTY296253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      O46-3 (SI1) - A65-28 (SI1) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      O46-3 (SI1) or A65-28 (SI1) - Body Ground Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
      *2 Front view of wire harness connector
      (to Battery Cooling Blower Assembly [No. 1])

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  8. CHECK HYBRID VEHICLE CONTROL ECU 
    1. Using an oscilloscope, measure the waveform according to the condition in the table below.
      Fig 10: Checking Hybrid Vehicle Control ECU With Waveform Reference
      GTY303186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Content
      Terminal A65-28 (SI1) - D72-6 (E1)
      Equipment Setting 1 V/DIV, 50 μs/DIV
      Condition Ignition switch ON or ON (READY)

      OK

      The waveform in the illustration can be measured.

      HINT: 

      • A and B in the DUTY waveform shown in the illustration vary depending on the cooling fan mode.
      • Duty command value is influenced by variance in fan motors and the change of power supply voltage.
      • Measure when the vehicle comes to a stop and an idling stop.
      TEXT IN ILLUSTRATION

      *1 Component with harness connected
      (Hybrid Vehicle Control ECU)

    NG → See step   21 

    OK → See step   22 

  9. INSPECT FUSE (BATT FAN) See step   9 

    NG → See step   16 

    OK: Go to next step 

  10. INSPECT RELAY (BATT FAN) See step   10 

    NG → REPLACE RELAY (BATT FAN) 

    OK: Go to next step 

  11. CHECK HARNESS AND CONNECTOR (BATT FAN RELAY - BATT FAN FUSE) See step   11 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  12. CHECK HARNESS AND CONNECTOR (BATT FAN RELAY - BATTERY COOLING BLOWER ASSEMBLY [NO. 1]) 
    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 BATT FAN relay.
      Fig 11: Identifying Fuse (BATT FAN)
      GTY254294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Room No. 3 Relay Block
      *2 BATT FAN Relay
    4. Remove the battery cover. Refer to REMOVAL .
    5. Disconnect the O46 connector from the battery cooling blower assembly (No. 1).
      Fig 12: Identifying Battery Cooling Blower Assembly (No. 1) & Connector
      GTY298492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Measure the resistance according to the value(s) in the table below.
      Fig 13: Checking Harness And Connector (BATT FAN Relay - Battery Cooling Blower Assembly [No. 1])
      GTY301775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      BATT FAN relay terminal 5 - O46-1 (IG1) Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Engine Room No. 3 Relay Block
      *2 Front view of wire harness connector
      (to Battery Cooling Blower Assembly [No. 1])
      *3 BATT FAN Relay Holder
      NOTE:

      When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  13. CHECK HARNESS AND CONNECTOR (BATT FAN RELAY - HYBRID VEHICLE CONTROL ECU) See step   13 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  14. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BODY GROUND) See step   14 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  15. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BODY GROUND) See step   15 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   21 

  16. CHECK HARNESS AND CONNECTOR (BATT FAN RELAY - BODY GROUND) See step   16 

    NG → See step   24 

    OK: Go to next step 

  17. CHECK HARNESS AND CONNECTOR (BATTERY COOLING BLOWER ASSEMBLY [NO. 1] - BODY GROUND) 
    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 each of the 3 battery cooling blower assembly connectors.
      Fig 14: Identifying Battery Cooling Blower Assembly (No. 1) & Connector
      GTY298492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the resistance according to the value(s) in the table below.
      Fig 15: Checking Harness And Connector (Battery Cooling Blower Assembly [No. 1] - Body Ground)
      GTY297714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      O46-1 (IG1) - Body Ground Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Front view of wire harness connector
      (to Battery Cooling Blower Assembly [No. 1])

    NG → See step   24 

    OK: Go to next step 

  18. CHECK BATTERY COOLING BLOWER ASSEMBLY See step   18 

    NG → See step   23 

    OK → REPLACE FUSE (BATT FAN) 

  19. REPLACE BATTERY COOLING BLOWER ASSEMBLY (NO. 1). Refer to  REMOVAL 
  20. GO TO DTC P0AFC-123. Refer to  DTC P0AFC-123: Hybrid Battery Pack Sensor Module  
  21. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
  22. REPLACE BATTERY SMART UNIT. Refer to  REMOVAL 
  23. REPLACE BATTERY COOLING BLOWER ASSEMBLY (MALFUNCTIONING BATTERY COOLING BLOWER ASSEMBLY) 
    1. Replace the battery cooling blower assembly (malfunctioning battery cooling blower assembly). Refer to REMOVAL .

    NEXT → REPLACE FUSE (BATT FAN) 

  24. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT → REPLACE FUSE (BATT FAN) 

  25. 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 Oz3 connector from the No. 2 battery pack wire.
      Fig 16: Identifying OZ3 Connector And No. 2 Battery Pack Wire
      GTY294919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the z21 connector from the battery smart unit.
    6. Measure the resistance according to the value(s) in the table below.
      Fig 17: Checking Harness And Connector (No. 2 Battery Pack Wire)
      GTY296028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      z21-7 (VM1) - Oz3-11 (VM1) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      z21-7 (VM1) or Oz3-11 (VM1) - 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 No. 2 Battery Pack Wire Connector)

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

    OK → REPAIR OR REPLACE HARNESS OR CONNECTOR 

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