DTC P0AA1-231: Hybrid Battery Positive Contactor Circuit Stuck Closed [11/2016 - ]: 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.

   Powertrain > Hybrid Control > Trouble Codes 

   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

   Relevant DTC
   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
   P0A1C-709, 710, 797	Drive Motor "B" 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
   P0A45-669	Drive Motor "B" Position Sensor Circuit
   P0A46-671	Drive Motor "B" Position Sensor Circuit Range/Performance
   P0A47-670	Drive Motor "B" 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
   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
   P1CA8-708	Drive Motor "B" Control Module Malfunction
   P1CAC-200	Generator Position Sensor Angle Malfunction
   P1CAD-168	Drive Motor "A" Position Sensor Angle Malfunction
   P1CAE-715	Drive Motor "B" Position Sensor Angle Malfunction
   P1CAF-792	Generator Position Sensor REF Signal Cycle Malfunction
   P1CB0-795	Drive Motor "A" Position Sensor REF Signal Cycle Malfunction
   P1CB1-798	Drive Motor "B" 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
   P1CB4-799	Drive Motor "B" Position Sensor REF Signal Stop Malfunction
   P2511-149	HV CPU Power Relay Sense Circuit Intermittent No Continuity
   P3004-132	High Voltage Power Resource
   P310A-711	Communication Error from MGR to MG2
   P310B-662	Communication Error from Motor to RMG
   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:  2

B 

GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2016 - 10/2017]  Refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2017 - ] 

Result:  1

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 P0AA1-231.

   HINT: 

   In the freeze frame data, read the item "VL-Voltage before Boosting".

   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:  2

B 

REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS [11/2016 - ] 

Result:  3

A 

See step  3

See step  1

Result

Result:  1

OK 

See step  5

Result:  2

NG 

See step  4

Result

Result:  1

NEXT 

See step  5

1. Check the connector connection condition and contact pressure of the relevant terminals of the FM1 No. 2 floor wire connector.

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [02/2014 - ]

   OK

   The connector is connected securely and there are no contact pressure problems.

   Result

   Proceed to
   OK
   NG

Result:  1

OK 

See step  7

Result:  2

NG 

See step  6

Result

Result:  1

NEXT 

See step  7

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 instructed by the repair information because this may cause a malfunction.

2. Check the connection condition of the Mx1 No. 2 HV battery pack wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [02/2014 - ]

   OK

   - The connector is connected securely.

   - The terminals are not deformed and are connected securely.

   - No water or foreign matter in the connector.

   Result

   Result	Proceed to
   OK	A
   NG (The connector is not connected securely.)	B
   NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.)	C

Result:  1

A 

See step  10

Result:  3

C 

See step  9

Result:  2

B 

See step  8

Result

Result:  1

NEXT 

See step  10

Result

Result:  1

NEXT 

See step  10

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 instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid vehicle battery cover sub-assembly.

   Refer to PROCEDURE - Step 36

3. Check the connector connection condition and contact pressure of the relevant terminals of the hybrid battery junction block assembly connector.

   Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE [02/2014 - ]

   OK

   The connector is connected securely and there are no contact pressure problems.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Install the upper hybrid vehicle battery cover sub-assembly.

   Result

   Proceed to
   OK
   NG

Result:  1

OK 

See step  12

Result:  2

NG 

See step  11

Result

Result:  1

NEXT 

See step  12

1. Check the installation condition of the ground wire MC.

   OK

   The ground wire MC is securely installed.

   Result

   Proceed to
   OK
   NG

Result:  1

OK 

See step  14

Result:  2

NG 

See step  13

Result

Result:  1

NEXT 

See step  14

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 instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid vehicle battery cover sub-assembly.

   Refer to PROCEDURE - Step 36

3. Disconnect the x3 hybrid battery junction block assembly connector.
4. Disconnect the F136 hybrid vehicle control ECU assembly connector.
5. Measure the resistance according to the value(s) in the table below.

   Standard Resistance (Check for Open)

   Tester Connection	Condition	Specified Condition
   F136-4 (SMRB) - x3-4 (SMRB)	Power switch off	Below 1 Ω

   Standard Resistance (Check for Short)

   Tester Connection	Condition	Specified Condition
   F136-4 (SMRB) and x3-4 (SMRB) - Body ground and other terminals	Power switch off	10 kΩ or higher

   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)

6. Reconnect the F136 hybrid vehicle control ECU assembly connector.
7. Reconnect the x3 hybrid battery junction block assembly connector.
8. Install the upper hybrid vehicle battery cover sub-assembly.

   Result

   Proceed to
   OK
   NG

Result:  1

OK 

See step  16

Result:  2

NG 

See step  15

Result

Result:  1

NEXT 

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 instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid vehicle battery cover sub-assembly.

   Refer to PROCEDURE - Step 36

3. Disconnect the x3 hybrid battery junction block assembly connector.
4. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   x3-2 (GND) - Body ground	Power switch off	Below 1 Ω

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Rear view of wire harness connector (to Hybrid Battery Junction Block Assembly)

5. Reconnect the x3 hybrid battery junction block assembly connector.
6. Install the upper hybrid vehicle battery cover sub-assembly.

   Result

   Proceed to
   OK
   NG

Result:  3

OK 

See step  18

Result:  2

NG 

See step  17

Result

Result:  1

NEXT 

See step  18

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 instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid vehicle battery cover sub-assembly.

   Refer to PROCEDURE - Step 36

3. Disconnect the x3 hybrid battery junction block assembly connector.
4. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   x3-4 (SMRB) - x3-2 (GND)	-40 to 80°C (-40 to 176°F)	18.4 to 36.3 Ω

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

5. Reconnect the x3 hybrid battery junction block assembly connector.
6. Install the upper hybrid vehicle battery cover sub-assembly.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

See step  21

Result:  1

OK 

See step  19

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 instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid vehicle battery cover sub-assembly.

   Refer to PROCEDURE - Step 36

3. Disconnect the 2 high voltage cable connectors of the HV battery from the hybrid battery junction block assembly.
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
   R6-1 (CBI) - t1-1 (+)	Power switch off	10 kΩ or higher

5. Reconnect the 2 high voltage cable connectors of the HV battery.
6. Install the upper hybrid vehicle battery cover sub-assembly.

   Result

   Proceed to
   OK
   NG

Result:  2

NG 

See step  22

Result:  1

OK 

See step  20

Refer to COMPONENTS [02/2014 - ]

Result

Result:  1

NEXT 

See step  23

Refer to COMPONENTS [02/2014 - ]

Result

Result:  1

NEXT 

See step  23

Refer to COMPONENTS [02/2014 - ]

Result

Result:  1

NEXT 

See step  23

1. Install the service plug grip.
2. Turn the power switch on (IG).
3. Clear the DTCs.

   Refer to DTC CHECK / CLEAR [11/2016 - ]

4. Turn the power switch off and wait for 30 seconds or more.
5. Turn the power switch on (READY).
6. Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource VB, VL-Voltage before Boosting.
7. 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.

   Powertrain > Hybrid Control > Data List 

   Tester Display
   Power Resource VB
   VL-Voltage before Boosting

   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

8. Turn the power switch off.

Result:  1

A 

END 

Result:  3

B 

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

HYBRID VEHICLE CONTROL ECU ASSEMBLY: Refer to COMPONENTS [11/2016 - ]

HYBRID BATTERY JUNCTION BLOCK ASSEMBLY: Refer to COMPONENTS [02/2014 - ]