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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) (6 Of 8) >> Hybrid Control System >> DTC P0AE7-224: Hybrid Battery Precharge Contactor Control Circuit High [10/2014 - 10/2015] >> Procedure

DTC P0AE7-224: Hybrid Battery Precharge Contactor Control Circuit High [10/2014 - 10/2015]: Procedure

  1. READ VALUE USING TECHSTREAM (SMRP STATUS) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Hybrid Control / Data List / SMRP Status.
    4. Read the Data List.

      OK

      Tester Display Condition Specified Condition
      SMRP Status Power switch on (IG) OFF
    5. Turn the power switch off.

    Result: 

    NG 

    See step  4

    Result: 

    OK 

    See step  2

  2. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR) 

    Refer to PROCEDURE - Step 3

    Result: 

    NG 

    CONNECT SECURELY 

    Result: 

    OK 

    See step  3

  3. CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR) 

    See step  3

    Result: 

    OK 

    CHECK FOR INTERMITTENT PROBLEMS 

    (Refer to CHECK FOR INTERMITTENT PROBLEMS [10/2014 - ] )

    Result: 

    NG 

    CONNECT SECURELY 

  4. CHECK HARNESS AND CONNECTOR (SMRP VOLTAGE) 
    1. Turn the power switch on (IG).
    2. Measure the voltage according to the value(s) in the table below.
      GTY595682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component with harness connected
      (Power Management Control ECU)

      Standard Voltage

      Tester Connection Condition Specified Condition
      D104-3 (SMRP) - Body ground Power switch on (IG) Below 1 V
    3. Turn the power switch off.

    Result: 

    NG 

    See step  6

    Result: 

    OK 

    See step  5

  5. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR) 

    Refer to PROCEDURE - Step 3

    Result: 

    OK 

    REPLACE POWER MANAGEMENT CONTROL ECU 

    (Refer to COMPONENTS [10/2014 - 10/2015] )

    Result: 

    NG 

    CONNECT SECURELY 

  6. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - BODY GROUND) 
    1. Disconnect the D104 power management control ECU connector.
    2. Measure the resistance according to the value(s) in the table below.
      GTY608599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rear view of wire harness connector
      (to Power Management Control ECU)

      Standard Resistance

      Tester Connection Condition Specified Condition
      D104-3 (SMRP) - Body ground Power switch off 112 to 274 Ω
    3. Reconnect the D104 power management control ECU connector.

    Result: 

    NG 

    See step  8

    Result: 

    OK 

    See step  7

  7. CHECK HARNESS AND CONNECTOR (SHORT TO POWER SUPPLY WIRES) 
    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 PM IGCT fuse from the No. 2 engine room relay block.
      GTY595564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Engine Room Relay Block
      *2 PM IGCT Fuse
    3. Remove the AM2 fuse from the engine room relay block and junction block assembly.
      GTY563267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Engine Room Relay Block and Junction Block Assembly
      *2 AM2 Fuse
    4. Remove the ECU-IG2 NO. 1 fuse from the instrument panel junction block assembly.
    5. Remove the No. 4 hybrid battery shield panel (Refer to PROCEDURE - Step 8 ).
    6. Disconnect the K23 hybrid battery junction block assembly connector.
      GTY542449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the A53, A54, D104 and D105 power management control ECU connectors.
    8. Measure the resistance according to the value(s) in the table below.
      GTY601737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rear view of wire harness connector
      (to Power Management Control ECU)

      Standard Resistance

      Tester Connection Condition Specified Condition
      D104-3 (SMRP) - A53-2 (+B2) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - A54-5 (+B1) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - D104-1 (AM22) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - D105-7 (AM21) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - A54-6 (MREL) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - A54-1 (IG2) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - D105-1 (ACCD) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - D105-2 (IG1D) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - A54-2 (IG2D) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - D104-14 (SPDI) Power switch off 10 kΩ or higher
      D104-3 (SMRP) - A53-16 (GI) Power switch off 10 kΩ or higher
    9. Reconnect the A53, A54, D104 and D105 power management control ECU connectors.
    10. Reconnect the K23 hybrid battery junction block assembly connector.
    11. Install the No. 4 hybrid battery shield panel.
    12. Install the PM IGCT fuse, AM2 fuse and ECU-IG2 NO. 1 fuse.

    Result: 

    OK 

    REPLACE POWER MANAGEMENT CONTROL ECU 

    (Refer to COMPONENTS [10/2014 - 10/2015] )

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  8. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - 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 D104 power management control ECU connector.
    5. Measure the resistance according to the value(s) in the table below.
      GTY550886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rear view of wire harness connector
      (to Power Management Control ECU)
      GTY544673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *b Rear view of wire harness connector
      (to Hybrid Battery Junction Block Assembly)

      Standard Resistance (Check for Open)

      Tester Connection Condition Specified Condition
      D104-3 (SMRP) - K23-4 (SMRP) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Condition Specified Condition
      D104-3 (SMRP) and K23-4 (SMRP) - Body ground and other terminals Power switch off 10 kΩ or higher
    6. Reconnect the D104 power management control ECU connector.
    7. Reconnect the K23 hybrid battery junction block assembly connector.
    8. Install the No. 4 hybrid battery shield panel.

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  9

  9. 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.
      GTY557071Courtesy 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: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  10

  10. INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRP) 
    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 hybrid battery junction block assembly (Refer to COMPONENTS [10/2014 - ] ).
    3. Measure the resistance according to the value(s) in the table below.
      GTY598783Courtesy 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
    4. Install the hybrid battery junction block assembly.

    Result: 

    OK 

    CHECK FOR INTERMITTENT PROBLEMS 

    (Refer to CHECK FOR INTERMITTENT PROBLEMS [10/2014 - ] )

    Result: 

    NG 

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY 

    (Refer to COMPONENTS [10/2014 - ] )

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