Up to 08/2009

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0AE2-773: Hybrid Battery Precharge Contactor Circuit Stuck Closed
P0AE2-773 - Hybrid Battery Precharge Contactor Circuit Stuck Closed

DESCRIPTION

The SMRs (System Main Relays) are the relays that connect or disconnect the high voltage power system in accordance with commands from the power management control ECU.

There are 3 SMRs and 1 precharge resistor. SMRB, SMRP, SMRG, and the precharge resistor are located in the HV battery junction block assembly in the HV battery pack.

To connect to the high voltage power system, the vehicle will first turn on SMRP and SMRB to charge the vehicle through the system main resistor. Then, SMRP will be turned off after SMRG is turned on. To shut off the high voltage power system, SMRB and SMRG are turned off.





WIRING DIAGRAM





INSPECTION PROCEDURE

CAUTION:
- Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
- After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.
HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CHECK DTC OUTPUT (HV)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check if DTCs are output.

Result:









HINT
- *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
- P0AE2-773 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.
(e) Turn the power switch off.

B -- GO TO DTC CHART Hybrid Control System
A -- Continue to next step.

2. CHECK FREEZE FRAME DATA

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Read the freeze frame data of DTC P0AE2-773.

Result:





(e) Turn the power switch off.

A -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components
B -- Continue to next step.

3. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Remove the battery cover sub-assembly Components.

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





Standard resistance:





Text in Illustration





HINT
- If a system main relay is stuck closed, inspect the HV relay assembly without removing it from the vehicle, in order to keep the relay closed.
- If the result of reading the freeze frame data is B, the HV battery junction block must be replaced. Measuring resistance can determine that this is either a present or past malfunction.
(d) Install the battery cover sub-assembly Components.

NG -- REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Components

OK -- REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Components