DTC P2511-149: EV ECU Power Relay Sense Circuit Intermittent [09/2013 - ]: Procedure

1. Confirm whether the auxiliary battery terminals have been disconnected recently.

   Result

   Result	Proceed to
   Terminals have been disconnected.	A
   Terminals have not been disconnected.	B

B → See step   5 

A: Go to next step 

1. Turn the power switch on (READY) from off.
2. Confirm that the master warning light illuminates.

   Result

   Result	Proceed to
   Master warning light illuminates.	A
   Master warning light does not illuminate.	B

   HINT: 

   DTC P2511-149 may be stored after disconnecting and reconnecting the auxiliary battery terminals. If this happens, the DTC will not be output if the power switch is turned off and then on (READY) again. In this case, clear DTCs to complete the inspection.

3. Turn the power switch off.

B → END 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / EV / Trouble Codes.
4. Read and record the DTCs and freeze frame data.
5. Clear the DTCs and freeze frame data.
6. Turn the power switch off.

NEXT: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / EV / Trouble Codes.
4. Check if DTCs are output.

   Result

   Result	Proceed to
   DTC P2511-149 is output again.	A
   DTCs other than P2511-149 are also output.	B

5. Turn the power switch off.

B → See step   10 

A: Go to next step 

1. Check the connection of the auxiliary battery terminal.

   OK

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

NG → CONNECT SECURELY 

OK: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

1. Remove the IGCT 3 relay from the No. 1 motor compartment room relay block and junction block assembly.
2. Disconnect connectors A56 and A57 from the power management control ECU.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	No. 1 Motor Compartment Room Relay Block and Junction Block Assembly	*2	IGCT 3 Relay
   *a	Rear view of wire harness connector (to Power Management Control ECU)	-	-

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

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A57-5 (+B1) - 3 (IGCT 3 relay)	Power switch off	Below 1 Ω
   A56-2 (+B2) - 3 (IGCT 3 relay)	Power switch off	Below 1 Ω

4. Install the IGCT 3 relay.
5. Connect the power management control ECU connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check for intermittent problems. Refer to CHECK FOR INTERMITTENT PROBLEMS [09/2013 - ] .
   1. Check the connection and terminal contact pressure of the connectors and wire harnesses between the power management control ECU and the No. 1 motor compartment room junction block assembly.
   2. When the power switch is on (READY), jiggle the connectors and wire harnesses between the power management control ECU and the No. 1 motor compartment room relay block and junction block assembly.

      Result

      Result	Proceed to
      Problem symptom does not recur.	A
      Problem symptom recurs.	B

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A → See step   9