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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 80 (Hybrid Control System (2GR-FXS) - Diagnostic Codes (4 Of 6)) >> Hybrid Control System >> DTC P0AE2-773: Hybrid Battery Precharge Contactor Circuit Stuck Closed [11/2016 - ] >> Procedure

DTC P0AE2-773: Hybrid Battery Precharge Contactor Circuit Stuck Closed [11/2016 - ]: Procedure

WARNING: This page is about a different car, the 2019 Toyota Highlander, 2018 Toyota Highlander, and 2017 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  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.

      Powertrain > Hybrid Control > Trouble Codes 

      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 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
      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 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.
      • 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:  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

  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 P0AE2-773.

      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:  1

    A 

    See step  3

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

    Refer to PROCEDURE - Step 1

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    See step  5

    Result:  2

    NG 

    See step  4

  4. CONNECT SECURELY 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  5

  5. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 FLOOR WIRE CONNECTOR) 

    Refer to PROCEDURE - Step 5

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    See step  7

    Result:  2

    NG 

    See step  6

  6. CONNECT SECURELY 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  7

  7. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV BATTERY PACK WIRE CONNECTOR) 

    Refer to PROCEDURE - Step 7

    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

  8. CONNECT SECURELY 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  10

  9. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  10

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

    Refer to PROCEDURE - Step 10

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    See step  12

    Result:  2

    NG 

    See step  11

  11. CONNECT SECURELY 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  12

  12. CHECK GROUND WIRE CONNECTION CONDITION (SMR ACTIVATION LOW-VOLTAGE CIRCUIT) 

    Refer to PROCEDURE - Step 12

    Result

    Proceed to
    OK
    NG

    Result:  1

    OK 

    See step  14

    Result:  2

    NG 

    See step  13

  13. CONNECT SECURELY 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  14

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

    Be sure to wear insulated gloves and protective goggles.

    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.
      GTY695216Courtesy 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
      F136-3 (SMRP) - x3-3 (SMRP) Power switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Condition Specified Condition
      F136-3 (SMRP) and x3-3 (SMRP) - Body ground and other terminals Power switch off 10 kΩ or higher
    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

  15. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  16

  16. CHECK HARNESS AND CONNECTOR (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND) 

    Refer to PROCEDURE - Step 16

    Result

    Proceed to
    OK
    NG

    Result:  3

    OK 

    See step  18

    Result:  2

    NG 

    See step  17

  17. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  18

  18. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP) 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    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
      x3-3 (SMRP) - x3-2 (GND) -40 to 80°C (-40 to 176°F) 112 to 274 Ω
      GTY559571Courtesy 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

  19. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    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.
      GTY441890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Hybrid Battery Junction Block Assembly)

      Standard Resistance

      Tester Connection Condition Specified Condition
      R7-1 (CEI) - u1-1 (-) 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

  20. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 

    Refer to COMPONENTS [02/2014 - ]

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  23

  21. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 

    Refer to COMPONENTS [02/2014 - ]

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  23

  22. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 

    Refer to COMPONENTS [02/2014 - ]

    Result

    Proceed to
    NEXT

    Result:  1

    NEXT 

    See step  23

  23. CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY (CHECK FOR NORMAL OPERATION) 

    Refer to PROCEDURE - Step 23

    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

    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 - ]

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