DTC P0A81-96: Hybrid/EV Battery Cooling Fan 1 Component Internal Failure [11/2015 - 12/2018]: Procedure

CHECK DTC OUTPUT (HYBRID CONTROL)

Connect the Techstream to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
Powertrain > Hybrid Control > Trouble Codes

Check for DTCs.

Result

Result	Proceed to
P0AFC-00 or P0AFC-96 is output	A
Other than above	B

Turn the power switch off.

Result:

GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to DIAGNOSTIC TROUBLE CODE CHART [11/2015 - 11/2017] , or refer to DIAGNOSTIC TROUBLE CODE CHART [11/2017 - 12/2018]

Result:

See step 2

CHECK DUCT AND BLOWER

WARNING:

Be sure to wear insulated gloves.

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.
Remove the rear seat cushion assembly.
HINT:

Refer to PROCEDURE - Step 7

Check that the No. 1 HV battery intake filter, battery cooling blower assembly and No. 1 hybrid battery intake duct are not disconnected, damaged, or clogged with foreign matter.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 HV Battery Intake Filter	*2	Battery Cooling Blower Assembly
*3	No. 1 Hybrid Battery Intake duct	-	-

Install the rear seat cushion assembly.

Result

Proceed to
OK
NG

Result:

CORRECT THE PROBLEM

Result:

See step 3

CHECK HARNESS AND CONNECTOR (BATTERY VOLTAGE SENSOR - BATTERY COOLING BLOWER ASSEMBLY)

WARNING:

Be sure to wear insulated gloves and protective goggles.

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.
Remove the No. 1 HV battery shield panel.
HINT:

Refer to PROCEDURE - Step 35
Disconnect the M35 battery voltage sensor connector.
HINT:

Refer to PROCEDURE - Step 36

NOTE:
Before disconnecting the connector, check that it is not loose or disconnected.

Disconnect the M38 battery cooling blower assembly connector.

NOTE:

Before disconnecting the connector, check that it is not loose or disconnected.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 Battery Voltage Sensor)
*b	Front view of wire harness connector (to Battery Cooling Blower Assembly)

Standard Resistance

(M35, M38)

(M35)

(M38)

Tester Connection	Condition	Specified Condition
M35-8 (FP0) - M38-1 (FP0)	Power switch off	Below 1 Ω
M35-8 (FP0) - Body ground and other terminals	Power switch off	10 kΩ or higher

Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard Voltage

(M35)

Tester Connection	Condition	Specified Condition
M35-8 (FP0) - Body ground	Power switch on (IG)	Below 1 V

NOTE:

Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.
If the power switch is turned on (IG) with the connectors disconnected, other DTCs will be stored. Be sure to clear the DTCs after the inspection.

HINT:

As there might be an intermittent malfunction, inspect the following items even if the measured voltage is as specified.

Check that each connector between the battery voltage sensor and battery cooling blower assembly is not loose or disconnected.

Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Reconnect the M38 battery cooling blower assembly connector.
Reconnect the M35 battery voltage sensor connector.

Install the No. 1 HV battery shield panel.

Result

Proceed to
OK
NG

Result:

REPAIR OR REPLACE HARNESS OR CONNECTOR

Result:

See step 4

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY COOLING BLOWER ASSEMBLY)

WARNING:

Be sure to wear insulated gloves.

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.
Disconnect the F2 hybrid vehicle control ECU connector.
NOTE:
- Before disconnecting the connector, check that it is not loose or disconnected.
- Check that each connector between the hybrid vehicle control ECU and battery cooling blower assembly is not loose or disconnected.
Remove the rear seat cushion assembly.
HINT:

Refer to PROCEDURE - Step 7

Disconnect the M38 battery cooling blower assembly connector.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Before disconnecting the connector, check that it is not loose or disconnected.
Check the terminals of the connector for deformation and corrosion.

Measure the resistance according to the value(s) in the table below.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front view of wire harness connector (to Hybrid Vehicle Control ECU)
*b	Front view of wire harness connector (to Battery Cooling Blower Assembly)

Standard Resistance

(F2, M38)

(F2)

(M38)

Tester Connection	Condition	Specified Condition
F2-38 (SI0) - M38-4 (SI0)	Power switch off	Below 1 Ω
M38-4 (SI0) - Body ground and other terminals	Power switch off	10 kΩ or higher

NOTE:

Make sure that each connector between the hybrid vehicle control ECU and battery cooling blower assembly is not loose or disconnected and its terminals are not deformed or corroded.

Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard Voltage

(M38)

Tester Connection	Condition	Specified Condition
M38-4 (SI0) - Body ground	Power switch on (IG)	Below 1 V

NOTE:

Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.
If the power switch is turned on (IG) with the connectors disconnected, other DTCs will be stored. Be sure to clear the DTCs after the inspection.

HINT:

As there might be an intermittent malfunction, inspect the following items even if the measured voltage is as specified.

Check the condition of each wire harness and each connector between the hybrid vehicle control ECU connector and battery cooling blower assembly.

Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Reconnect the M38 battery cooling blower assembly connector.
Install the rear seat cushion assembly.

Reconnect the F2 hybrid vehicle control ECU connector.

Result

Proceed to
OK
NG

Result:

REPAIR OR REPLACE HARNESS OR CONNECTOR

Result:

See step 5

CHECK HYBRID VEHICLE CONTROL ECU (GROUND SHORT CHECK)

Remove the hybrid vehicle control ECU.
HINT:

Refer to REMOVAL [11/2015 - 12/2018]

Measure the resistance according to the value(s) in the table below.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Component without harness connected
(Hybrid Vehicle Control ECU)

Standard Resistance

(F2)

Tester Connection	Condition	Specified Condition
F2-38(SI0) - F2-12(E01)	Power switch off	10 kΩ or higher
F2-38(SI0) - F2-11(E02)	Power switch off	10 kΩ or higher

Install the hybrid vehicle control ECU.

Result

Proceed to
OK
NG

Result:

REPLACE HYBRID VEHICLE CONTROL ECU. Refer to REMOVAL [11/2015 - 12/2018]

Result:

See step 6

READ VALUE USING TECHSTREAM (COOLING FAN FREQUENCY)

WARNING:

Be sure to wear insulated gloves.

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.
Remove the No. 1 HV battery shield panel.
HINT:

Refer to PROCEDURE - Step 35
Connect the cable to the negative (-) auxiliary battery terminal.
Connect the Techstream to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
Clear the DTCs and freeze frame data.
Powertrain > Hybrid Control > Clear DTCs

Enter the following menus: Powertrain / Hybrid Control / Active Test / Control the Hybrid Battery Cooling Fan.

Powertrain > Hybrid Control > Active Test

Tester Display	Measurement Item	Control Range	Restrict Condition
Control the Hybrid Battery Cooling Fan	Battery cooling blower assembly operation and blower volume can be checked.	OFF, 1, 2, 3, 4, 5, 6	Intake air temperature -10°C (14°F) or higher

Powertrain > Hybrid Control > Active Test

Tester Display
Control the Hybrid Battery Cooling Fan

Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Cooling Fan 1 Frequency.

Powertrain > Hybrid Control > Data List

Tester Display
Hybrid Battery Cooling Fan 1 Frequency

Select each air volume mode 1 to 6 in the "Control the Hybrid Battery Cooling Fan" Active Test to operate the battery cooling blower assembly.
NOTE:
If the Active Test cannot turn off the battery cooling blower assembly, skip it and proceed to the next step to check the frequency value. In accordance with fail-safe system operation, the hybrid vehicle control ECU sends a command to operate the battery cooling fan assembly.

While the cooling fan is operating, compare the value in the Data List (Hybrid Battery Cooling Fan 1 Frequency) with the frequency value that was actually measured at the battery voltage sensor connector.

Specified Condition

(M35)

Tester Connection	Condition
M35-8 (FP0) - M35-5 (GND)	Battery cooling blower assembly is operating.

NOTE:

Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Component with harness connected (Battery Voltage Sensor)

HINT:

Compare the values in each air volume mode 1 to 6. If the Active Test cannot be performed, compare the values only in the current air volume mode.

Result

Result	Proceed to
Both of the value in the Data List (Hybrid Battery Cooling Fan 1 Frequency) and the actual measured value at the battery voltage sensor connector are 0 Hz	A
Other than above	B

Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Install the No. 1 HV battery shield panel.

Result:

See step 8

Result:

See step 7

CHECK BATTERY VOLTAGE SENSOR

WARNING:

Be sure to wear insulated gloves.

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.
Remove the rear seat cushion assembly.
HINT:

Refer to PROCEDURE - Step 7

Disconnect the M38 battery cooling bower assembly connector.

NOTE:

Before disconnecting the connector, check that it is not loose or disconnected.

Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).

Measure the voltage according to the value(s) in the table below.

Standard Voltage

(M38)

Tester Connection	Condition	Specified Condition
M38-1 (FP0) - M38-3 (GND0)	Power switch on (IG)	4.5 to 5.5 V

*a	Front view of wire harness connector (to Battery Cooling Blower Assembly)

NOTE:

Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.
If the power switch is turned on (IG) with the connectors disconnected, other DTCs will be stored. Be sure to clear the DTCs after the inspection.

Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Reconnect the M38 battery cooling blower assembly connector.

Install the rear seat cushion assembly.

Result

Proceed to
OK
NG

Result:

REPLACE BATTERY COOLING BLOWER ASSEMBLY. Refer to REMOVAL [11/2015 -]

Result:

REPLACE BATTERY VOLTAGE SENSOR. Refer to REMOVAL [11/2015 - 12/2018]

CHECK BATTERY VOLTAGE SENSOR (FREQUENCY)

WARNING:

Be sure to wear insulated gloves and protective goggles.

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.
Remove the No. 1 HV battery shield panel.
HINT:

Refer to PROCEDURE - Step 35
Connect the cable to the negative (-) auxiliary battery terminal.
Connect the Techstream to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
Clear the DTCs.
Powertrain > Hybrid Control > Clear DTCs

Enter the following menus: Powertrain / Hybrid Control / Active Test / Control the Hybrid Battery Cooling Fan.

Powertrain > Hybrid Control > Active Test

Active Test Display
Control the Hybrid Battery Cooling Fan

Data List Display
Hybrid Battery Cooling Fan
Hybrid Battery Cooling Fan 1 Frequency

Powertrain > Hybrid Control > Active Test

Tester Display	Measurement Item	Control Range	Restrict Condition
Control the Hybrid Battery Cooling Fan	Battery cooling blower assembly operation and blower volume can be checked.	OFF, 1, 2, 3, 4, 5, 6	Intake air temperature -10°C (14°F) or higher

Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Cooling Fan 1 Frequency.
Select each air volume mode 1 to 6 in the "Control the Hybrid Battery Cooling Fan" Active Test to operate the battery cooling blower assembly.
NOTE:
If the Active Test cannot turn off the battery cooling blower assembly, skip it and proceed to the next step to check the frequency value. In accordance with fail-safe system operation, the hybrid vehicle control ECU sends a command to operate the battery cooling blower assembly.

Specified Condition

(M35)

Tester Connection	Condition	Specified Condition
M35-8 (FP0) - M35-5 (GND)	Battery cooling blower assembly is operating.	Difference between the value in the Data List (Hybrid Battery Cooling Fan 1 Frequency) and the actual measured value at the battery voltage sensor connector is 10% or less.

NOTE:

Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

*a	Component with harness connected (Battery Voltage Sensor)

HINT:

Compare the values in each air volume mode 1 to 6. If the Active Test cannot be performed, compare the values only in the current air volume mode.

Result

Result	Proceed to
Difference between the value in the Data List (Hybrid Battery Cooling Fan 1 Frequency) and the actual measured value at the battery voltage sensor connector is 10% or less	A
Other than above	B

Turn the power switch off.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Install the No. 1 HV battery shield panel.

Result:

REPLACE BATTERY COOLING BLOWER ASSEMBLY. Refer to REMOVAL [11/2015 -]

Result:

REPLACE BATTERY VOLTAGE SENSOR. Refer to REMOVAL [11/2015 - 12/2018]