DTC P0AE2-773: Hybrid Battery Precharge Contactor Circuit Stuck Closed [10/2015 - ]: Procedure

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
   P0AE2-773 only is output, or DTCs except the ones in the table below are also output.	A
   Any of the following 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 Low
   P0A4B-253	Generator Position Sensor Circuit
   P0A4C-513	Generator Position Sensor Circuit Range/Performance
   P0A4D-255	Generator Position Sensor Circuit Low
   P0AA4-232	Hybrid Battery Negative Contactor Circuit Stuck Closed
   P0AE0-228	Hybrid Battery Negative Contactor Control Circuit High
   P0AE7-224	Hybrid Battery Precharge 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 Range / Performance
   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	ECM/PCM Power Relay Sense Circuit Intermittent
   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.
   • P0AE2-773 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

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 P0AE2-773.

   Result

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

5. Turn the power switch off.

Result: 

B 

REPLACE INVERTER WITH CONVERTER ASSEMBLY 

(Refer to COMPONENTS [10/2014 - ] )

Result: 

A 

See step  3

Refer to PROCEDURE - Step 1

Result: 

OK 

See step  5

Result: 

NG 

See step  4

NEXT 

See step  5

See step  5

Result: 

OK 

See step  7

Result: 

NG 

See step  6

NEXT 

See step  7

See step  7

Result: 

OK 

See step  9

Result: 

NG 

See step  8

NEXT 

See step  9

See step  9

Result: 

OK 

See step  11

Result: 

NG 

See step  10

NEXT 

See step  11

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.

   Courtesy 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
   D135-3 (SMRP) - K23-4 (SMRP)	Power switch off	Below 1 Ω

   Standard Resistance (Check for Short)

   Tester Connection	Condition	Specified Condition
   D135-3 (SMRP) and K23-4 (SMRP) - 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

NEXT 

See step  13

See step  13

Result: 

OK 

See step  15

Result: 

NG 

See step  14

NEXT 

See step  15

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Component without harness connected (Hybrid Battery Junction Block Assembly)

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   K23-4 (SMRP) - K23-2 (GND)	-40 to 80°C (-40 to 176°F)	112 to 274 Ω

5. Install the hybrid battery junction block assembly.

Result: 

NG 

See step  17

Result: 

OK 

See step  16

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   b3-1 (CEI) - i1-1 (-)	Power switch off	10 kΩ or higher

   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.
4. Install the No. 1 hybrid battery shield sub-assembly.

Result: 

NG 

See step  17

Result: 

OK 

See step  17

(Refer to COMPONENTS [10/2014 - ] )

NEXT 

See step  18

See step  18

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 - ]