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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control System - Diagnostic Codes - (Hybrid) (4 Of 8) >> Hybrid Control System >> DTC P0AA1-231: Hybrid Battery Positive Contactor Circuit Stuck Closed [10/2015 - ] >> Procedure

DTC P0AA1-231: Hybrid Battery Positive Contactor Circuit Stuck Closed [10/2015 - ]: Procedure

  1. CHECK DTC OUTPUT (HYBRID CONTROL) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check for DTCs.

      Result

      Result Proceed to
      P0AA1-231 only is output, or DTCs except the ones in the table below are also output. A
      Any of the following DTCs including pending DTCs are also output. B
      DTC No. Relevant Diagnosis
      P06B0-163 Sensor Power Supply "A" Circuit / Open
      P06D6-511 Sensor Reference Voltage "F" Circuit / Open
      P06E6-164 Sensor Power Supply "C" Circuit / Open
      P0A1A-151, 658, 791 Generator Control Module
      P0A1B-786, 794 Drive Motor "A" Control Module
      P0A1D-148 Hybrid Powertrain Control Module
      P0A3F-243 Drive Motor "A" Position Sensor Circuit
      P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A41-245 Drive Motor "A" Position Sensor Circuit Range / Performance
      P0A4B-253 Generator Position Sensor Circuit
      P0A4C-513 Generator Position Sensor Circuit Range / Performance
      P0A4D-255 Generator Position Sensor Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P0CA3-442 DC/DC Converter Step Up Voltage Performance
      P0D2E-586 Drive Motor "A" Inverter Voltage Sensor Circuit Range / Performance
      P0D2F-266 Drive Motor "A" Inverter Voltage Sensor Circuit Low
      P0D30-267 Drive Motor "A" Inverter Voltage Sensor Circuit High
      P1C2A-155 Generator A/D Converter Circuit
      P1C73-512 Sensor Standard Voltage "F" Circuit / Open
      P1CA6-156 Generator Control Module Malfunction
      P1CA7-193 Drive Motor Control Module Malfunction
      P1CAC-200 Generator Position Sensor Angle Malfunction
      P1CAD-168 Drive Motor "A" Position Sensor Angle Malfunction
      P1CAF-792 Generator Position Sensor REF Signal Cycle Malfunction
      P1CB0-795 Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
      P1CB2-793 Generator Position Sensor REF Signal Stop Malfunction
      P1CB3-796 Drive Motor "A" Position Sensor REF Signal Stop Malfunction
      P2511-149 HV CPU Power Relay Sense Circuit Intermittent No Continuity
      P3004-132 High Voltage Power Resource
      P3133-659 Communication Error from Generator to Drive Motor "A"
      P3134-661 Communication Error from Drive Motor "A" to Generator
      P324E-788 MG-ECU Power Relay Intermittent Circuit
      U0110 (all INF codes)*1 Lost Communication with Drive Motor Control Module "A"

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • P0AA1-231 may be stored due to a malfunction which causes the DTCs in the preceding table to be stored. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a reproduction test to check that no DTCs are output.
    5. Turn the power switch off.

    Result: 

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) 

    (Refer to DIAGNOSTIC TROUBLE CODE CHART [10/2015 - ] )

    Result: 

    A 

    See step  2

  2. CHECK FREEZE FRAME DATA (HYBRID CONTROL) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Read the freeze frame data of DTC P0AA1-231.

      Result

      Result Proceed to
      "VL-Voltage before Boosting" is 55 V or more. A
      "VL-Voltage before Boosting" is less than 55 V. B

      HINT: 

      If VH-Voltage after Boosting is output even when an off command is being sent to the system main relay (positive side), P0AA1-231 is output. If the difference between the "VL-Voltage before Boosting" and the "VH-Voltage after Boosting" is large, it is determined that there is an inverter (VH sensor) malfunction.

    5. Turn the power switch off.

    Result: 

    B 

    REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

    Result: 

    A 

    See step  3

  3. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR) 

    Refer to PROCEDURE - Step 3

    Result: 

    OK 

    See step  5

    Result: 

    NG 

    See step  4

  4. CONNECT SECURELY 

    NEXT 

    See step  5

  5. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 FLOOR WIRE CONNECTOR) 
    1. Check the connector connections and contact pressure of the relevant terminals for the DK2 No. 2 floor wire connector.

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [10/2014 - ]

      OK

      The connectors are connected securely and there are no contact pressure problems.

    Result: 

    OK 

    See step  7

    Result: 

    NG 

    See step  6

  6. CONNECT SECURELY 

    NEXT 

    See step  7

  7. CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless otherwise instructed because this may cause a malfunction.

    2. Remove the No. 4 hybrid battery shield panel.

      Refer to PROCEDURE - Step 8

    3. Check the connector connections and contact pressure of the relevant terminals for the hybrid battery junction block assembly connector.
      GTY361148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [10/2014 - ]

      OK

      The connectors are connected securely and there are no contact pressure problems.

    4. Install the No. 4 hybrid battery shield panel.

    Result: 

    OK 

    See step  9

    Result: 

    NG 

    See step  8

  8. CONNECT SECURELY 

    NEXT 

    See step  9

  9. CHECK GROUND WIRE CONNECTION CONDITION (SMR ACTIVATION LOW-VOLTAGE CIRCUIT) 
    1. Check the installation condition of the ground wire K1.

      OK

      The ground wire K1 is securely installed.

    Result: 

    OK 

    See step  11

    Result: 

    NG 

    See step  10

  10. CONNECT SECURELY 

    NEXT 

    See step  11

  11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless otherwise instructed because this may cause a malfunction.

    2. Remove the No. 4 hybrid battery shield panel.

      Refer to PROCEDURE - Step 8

    3. Disconnect the K23 hybrid battery junction block assembly connector.
    4. Disconnect the D135 hybrid vehicle control ECU assembly connector.
    5. Measure the resistance according to the value(s) in the table below.
      GTY601499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU Assembly)
      *b Rear view of wire harness connector
      (to Hybrid Battery Junction Block Assembly)

      Standard Resistance (Check for Open)

      Tester Connection Condition Specified Condition
      D135-4 (SMRB) - K23-1 (SMRB) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Condition Specified Condition
      D135-4 (SMRB) and K23-1 (SMRB) - Body ground and other terminals Power switch off 10 kΩ or higher
    6. Reconnect the D135 hybrid vehicle control ECU assembly connector.
    7. Reconnect the K23 hybrid battery junction block assembly connector.
    8. Install the No. 4 hybrid battery shield panel.

    Result: 

    OK 

    See step  13

    Result: 

    NG 

    See step  12

  12. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT 

    See step  13

  13. CHECK HARNESS AND CONNECTOR (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless otherwise instructed because this may cause a malfunction.

    2. Remove the No. 4 hybrid battery shield panel.

      Refer to PROCEDURE - Step 8

    3. Disconnect the K23 hybrid battery junction block assembly connector.
    4. Measure the resistance according to the value(s) in the table below.
      GTY601624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rear view of wire harness connector
      (to Hybrid Battery Junction Block Assembly)

      Standard Resistance

      Tester Connection Condition Specified Condition
      K23-2 (GND) - Body ground Power switch off Below 1 Ω
    5. Reconnect the K23 hybrid battery junction block assembly connector.
    6. Install the No. 4 hybrid battery shield panel.

    Result: 

    OK 

    See step  15

    Result: 

    NG 

    See step  14

  14. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT 

    See step  15

  15. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless otherwise instructed because this may cause a malfunction.

    2. Remove the No. 4 hybrid battery shield panel.

      Refer to PROCEDURE - Step 8

    3. Disconnect the K23 hybrid battery junction block assembly connector.
    4. Measure the resistance according to the value(s) in the table below.
      GTY587582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Hybrid Battery Junction Block Assembly)

      Standard Resistance

      Tester Connection Condition Specified Condition
      K23-1 (SMRB) - K23-2 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 Ω
    5. Install the hybrid battery junction block assembly.

    Result: 

    NG 

    See step  17

    Result: 

    OK 

    See step  16

  16. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB) 
    WARNING:

    Be sure to wear insulated gloves.

    HINT: 

    • If a system main relay is stuck closed, inspect the hybrid battery junction block assembly without removing it from the vehicle, in order to keep the relay closed.
    • If the result of reading the freeze frame data is A, the hybrid battery junction block assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.
    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless otherwise instructed because this may cause a malfunction.

    2. Remove the No. 1 hybrid battery shield sub-assembly (Refer to PROCEDURE - Step 10 ).
    3. Measure the resistance according to the value(s) in the table below.
      GTY596570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      b2-1 (CBI) - A-1 (+) Power switch off 10 kΩ or higher
    4. Install the No. 1 hybrid battery shield sub-assembly.

    Result: 

    NG 

    See step  17

    Result: 

    OK 

    See step  17

  17. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 

    NEXT 

    See step  18

  18. CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY (CHECK FOR NORMAL OPERATION) 
    1. Install the service plug grip.
    2. Connect the Techstream to the DLC3.
    3. Turn the power switch on (IG).
    4. Clear the DTCs.

      Refer to DTC CHECK / CLEAR [10/2015 - ]

    5. Turn the power switch off and wait for 30 seconds or more.
    6. Turn the power switch on (READY).
    7. Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource VB, VL-Voltage before Boosting.
    8. According to the display on the Techstream, read the Data List and monitor the values of "Power Resource VB" and "VL-Voltage before Boosting" for 3 minutes.

      Result

      Result Proceed to
      Difference between "Power Resource VB" and "VL-Voltage before Boosting" is always less than 100 V. A
      Difference between "Power Resource VB" and "VL-Voltage before Boosting" is 100 V or more. B
    9. Turn the power switch off.

    Result: 

    A 

    END 

    Result: 

    B 

    REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY AND HV BATTERY JUNCTION BLOCK ASSEMBLY 

    HYBRID VEHICLE CONTROL ECU ASSEMBLY: Refer to COMPONENTS [10/2015 - ]

    HV BATTERY JUNCTION BLOCK ASSEMBLY: Refer to COMPONENTS [10/2014 - ]

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