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Home >> Toyota >> 2020 >> Highlander L, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 32 (Hybrid Control System - Diagnostic Codes (2 Of 5)) >> Hybrid Control System >> DTC P0A81-96: Hybrid/EV Battery Cooling Fan 1 Component Internal Failure; DTC P0A81-98: Hybrid/EV Battery Cooling Fan 1 Component or System Over Temperature; DTC P0A96-96: Hybrid/EV Battery Cooling Fan 2 Component Internal Failure; DTC P0A96-98: Hybrid/EV Battery Cooling Fan 2 Component or System Over Temperature [11/2023 - ] >> Procedure

DTC P0A81-96: Hybrid/EV Battery Cooling Fan 1 Component Internal Failure; DTC P0A81-98: Hybrid/EV Battery Cooling Fan 1 Component or System Over Temperature; DTC P0A96-96: Hybrid/EV Battery Cooling Fan 2 Component Internal Failure; DTC P0A96-98: Hybrid/EV Battery Cooling Fan 2 Component or System Over Temperature [11/2023 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota Highlander and 2024 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. CHECK DTC OUTPUT (HYBRID CONTROL) 
    1. Check for DTCs.

      Powertrain > Hybrid Control > Trouble Codes 

      Result

      Result Proceed to
      P0AFC-00, P0AFC-96 or P308A-12 is not output. A
      P0AFC-00, P0AFC-96 or P308A-12 is output. B
    2. Turn the ignition switch off.

    Result: 

    B 

    GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [11/2023 - ] 

    Result: 

    A 

    See step  2

  2. CHECK DTC 
    1. Check the DTCs that were output when the vehicle was brought to the workshop.

      Result

      Result Proceed to
      P0A81-96 or P0A81-98 is also output. A
      P0A96-96 or P0A96-98 is also output. B

    Result: 

    B 

    See step  10

    Result: 

    A 

    See step  3

  3. CHECK DUCT AND BLOWER 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the rear floor silencer.

      Refer to REMOVAL [12/2019 - ]

    3. Check that the No. 2 HV battery intake filter, battery cooling blower assembly (No. 0) and No. 1 hybrid battery intake duct are not disconnected, damaged, or clogged with foreign matter.
      GTY868218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 HV Battery Intake Filter *2 Battery Cooling Blower Assembly (No. 0)
      *3 No. 1 Hybrid Battery Intake Duct - -

      OK

      The No. 2 HV battery intake filter, No. 1 hybrid battery intake duct and battery cooling blower assembly (No. 0) are not disconnected, damaged, or clogged with foreign matter.

    4. Install the rear floor silencer.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    CORRECT THE PROBLEM 

    Result: 

    OK 

    See step  4

  4. CHECK HARNESS AND CONNECTOR (BATTERY VOLTAGE SENSOR - BATTERY COOLING BLOWER ASSEMBLY (NO. 0)) 

    Refer to PROCEDURE - Step 4

    Result

    Proceed to
    OK
    NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  5

  5. CHECK HARNESS AND CONNECTOR (BATTERY VOLTAGE SENSOR - BATTERY COOLING BLOWER ASSEMBLY (NO. 0)) 

    Refer to PROCEDURE - Step 13

    Result

    Proceed to
    OK
    NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  6

  6. CHECK BATTERY VOLTAGE SENSOR (GROUND SHORT CHECK) 
    1. Remove the battery voltage sensor.

      Refer to REMOVAL [11/2023 - ]

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      y1-5 (SI0) - y1-7 (GND) Ignition switch off 10 kΩ or higher
      GTY887129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Battery Voltage Sensor)
    3. Install the battery voltage sensor.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [11/2023 - ] 

    Result: 

    OK 

    See step  7

  7. READ VALUE USING GTS (HYBRID BATTERY COOLING FAN 1 FREQUENCY) 

    Refer to PROCEDURE - Step 5

    Result

    Result Proceed to
    Both of the values 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

    Result: 

    B 

    See step  9

    Result: 

    A 

    See step  8

  8. CHECK BATTERY VOLTAGE SENSOR 

    Refer to PROCEDURE - Step 6

    Result

    Proceed to
    OK
    NG

    Result: 

    OK 

    REPLACE BATTERY COOLING BLOWER ASSEMBLY (NO. 0). Refer to  REMOVAL [12/2019 - ] 

    Result: 

    NG 

    REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [11/2023 - ] 

  9. CHECK BATTERY VOLTAGE SENSOR (FREQUENCY) 

    Refer to PROCEDURE - Step 7

    Result

    Proceed to
    OK
    NG

    Result: 

    OK 

    REPLACE BATTERY COOLING BLOWER ASSEMBLY (NO. 0). Refer to  REMOVAL [12/2019 - ] 

    Result: 

    NG 

    REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [11/2023 - ] 

  10. CHECK DUCT AND BLOWER 
    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 ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the rear floor silencer.

      Refer to REMOVAL [12/2019 - ]

    3. Check that the No. 2 HV battery intake filter, battery cooling blower assembly (No. 1) and No. 1 hybrid battery intake duct are not disconnected, damaged, or clogged with foreign matter.
      GTY934171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 HV Battery Intake Filter *2 Battery Cooling Blower Assembly (No. 1)
      *3 No. 1 Hybrid Battery Intake Duct - -

      OK

      The No. 2 HV battery intake filter, No. 1 hybrid battery intake duct and battery cooling blower assembly (No. 1) are not disconnected, damaged, or clogged with foreign matter.

    4. Install the rear floor silencer.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    CORRECT THE PROBLEM 

    Result: 

    OK 

    See step  11

  11. CHECK HARNESS AND CONNECTOR (BATTERY VOLTAGE SENSOR - BATTERY COOLING BLOWER ASSEMBLY (NO. 1)) 

    Refer to PROCEDURE - Step 30

    Result

    Proceed to
    OK
    NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  12

  12. CHECK HARNESS AND CONNECTOR (BATTERY VOLTAGE SENSOR - BATTERY COOLING BLOWER ASSEMBLY (NO. 1)) 

    Refer to PROCEDURE - Step 39

    Result

    Proceed to
    OK
    NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  13

  13. CHECK BATTERY VOLTAGE SENSOR (GROUND SHORT CHECK) 
    1. Remove the battery voltage sensor.

      Refer to REMOVAL [11/2023 - ]

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      y1-6 (SI1) - y1-7 (GND) Ignition switch off 10 kΩ or higher
      GTY936950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Battery Voltage Sensor)
    3. Install the battery voltage sensor.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [11/2023 - ] 

    Result: 

    OK 

    See step  14

  14. READ VALUE USING GTS (HYBRID/EV BATTERY COOLING FAN 2 FREQUENCY) 

    Refer to PROCEDURE - Step 31

    Result

    Result Proceed to
    Both of the values in the Data List (Hybrid/EV Battery Cooling Fan 2 Frequency) and the actual measured value at the battery voltage sensor connector are 0 Hz. A
    Other than above B

    Result: 

    B 

    See step  16

    Result: 

    A 

    See step  15

  15. CHECK BATTERY VOLTAGE SENSOR 

    Refer to PROCEDURE - Step 32

    Result

    Proceed to
    OK
    NG

    Result: 

    OK 

    REPLACE BATTERY COOLING BLOWER ASSEMBLY (NO. 1). Refer to  REMOVAL [12/2019 - ] 

    Result: 

    NG 

    REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [11/2023 - ] 

  16. CHECK BATTERY VOLTAGE SENSOR (FREQUENCY) 

    Refer to PROCEDURE - Step 33

    Result

    Proceed to
    OK
    NG

    Result: 

    OK 

    REPLACE BATTERY COOLING BLOWER ASSEMBLY (NO. 1). Refer to  REMOVAL [12/2019 - ] 

    Result: 

    NG 

    REPLACE BATTERY VOLTAGE SENSOR. Refer to  REMOVAL [11/2023 - ] 

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