P0AE6

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0AE6-225: Hybrid Battery Precharge Contactor Control Circuit Low
P0AE6-225 - Hybrid Battery Precharge Contactor Control Circuit Low

DESCRIPTION

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

The SMR system is composed of three SMRs and one system main resistor. SMRB and SMRG are located on the hybrid battery junction block assembly in the battery carrier under the HV battery. SMRP and the system main resistor are located in the hybrid vehicle converter (DC/DC converter) assembly in the battery carrier.

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 the SMRG is turned on. To shut off the high voltage power system, SMRB and SMRG are turned off.

When there is an open in the AMD line or IGCT line, the following DTCs are output:

P0AE6-225 is output first because the time required for diagnosis is the shortest.

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.

(e) Refer to "Proceed to" in the table below to perform each inspection.

Result:

HINT
- o : DTCs that are output
- - : DTCs that are not output
(f) Turn the power switch off.

C -- CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

B -- CHECK FUSE (IGCT NO. 2)

A -- CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)
D -- Continue to next step.

2. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

(a) Check that the bolt for the frame wire terminals are tightened to the specified torque, the frame wire terminals are connected securely, and there are no contact problems.

Torque:

8.4 N*m {85 kgf*cm, 74 in.*lbf}

(b) Check for arc marks at the bolt for the frame wire.

Result:

C -- CONNECT SECURELY

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
A -- Continue to next step.

3. CHECK CONNECTOR CONNECTION CONDITION (FRAME WIRE CONNECTOR)

(a) Check the connection of the frame wire 1E connector.

OK:

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

NG -- CONNECT SECURELY
OK -- Continue to next step.

4. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

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

Standard Voltage:

NG -- CHECK FUSIBLE LINK BLOCK ASSEMBLY (MAIN)
OK -- Continue to next step.

5. CHECK FUSE (IGCT NO. 2)

(a) Disconnect the negative battery terminal.

(b) Remove the IGCT No. 2 fuse from the engine room junction block assembly.

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

Standard Resistance:

Text in Illustration

(d) Install the IGCT No. 2 fuse.

NG -- REPLACE FUSE (IGCT NO. 2)
OK -- Continue to next step.

6. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) P0343

NG -- CONNECT SECURELY
OK -- Continue to next step.

7. CHECK INVERTER TERMINAL (AMD TERMINAL CONNECTION CONDITION)

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) Check that the nuts for the AMD terminals are tightened to the specified torque, the AMD terminals are connected securely, and there are no contact problems.

Torque:

Nut A
9.0 N*m {92 kgf*cm, 80 in.*lbf}

Nut B
7.5 N*m {76 kgf*cm, 66 in.*lbf}

(c) Check for arc marks at the nuts for the inverter terminal.

Result:

C -- CONNECT SECURELY

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
A -- Continue to next step.

8. CHECK TERMINAL VOLTAGE (AMD TERMINAL VOLTAGE)

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

Standard Voltage:

NG -- CHECK FUSIBLE LINK (DC/DC)
OK -- Continue to next step.

9. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR) P0A09

NG -- CONNECT SECURELY
OK -- Continue to next step.

10. CHECK HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER)

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) Disconnect connector z17 from the hybrid vehicle converter.

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

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

Standard Voltage:

Text in Illustration

NOTICE:
Turning the power switch on (IG) with the hybrid vehicle converter connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

(e) Connect the hybrid vehicle converter connector.

(f) Turn the power switch off.

NG -- REPAIR OR REPLACE HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER)
OK -- Continue to next step.

11. CHECK HYBRID VEHICLE CONTROL ECU (FRAME WIRE CONNECTOR)

(a) Disconnect connector z17 from the hybrid vehicle converter.

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

Standard Resistance:

Text in Illustration

(c) Connect the hybrid vehicle converter connector.

NG -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID VEHICLE CONVERTER)

OK -- REPLACE HYBRID VEHICLE CONVERTER Components

12. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID VEHICLE CONVERTER)

(a) Disconnect connector A58 from the hybrid vehicle control ECU.

(b) Disconnect connector z17 from the hybrid vehicle converter.

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

Standard Resistance:

Text in Illustration

(d) Connect the hybrid vehicle converter connector.

(e) Connect the hybrid vehicle control ECU connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID VEHICLE CONVERTER)

OK -- REPLACE HYBRID VEHICLE CONTROL ECU Components

13. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

(a) Check that the bolt for the frame wire terminals are tightened to the specified torque, the frame wire terminals are connected securely, and there are no contact problems.

Torque:

8.4 N*m {85 kgf*cm, 74 in.*lbf}

(b) Check for arc marks at the bolt for the frame wire.

Result:

C -- CONNECT SECURELY

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
A -- Continue to next step.

14. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR)

(a) Check the connection of the frame wire 1E connector.

OK:

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

NG -- CONNECT SECURELY
OK -- Continue to next step.

15. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

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

Standard Voltage:

NG -- CHECK FUSIBLE LINK BLOCK ASSEMBLY (MAIN)
OK -- Continue to next step.

16. CHECK INVERTER TERMINAL (AMD TERMINAL CONNECTION CONDITION)

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) Check that the nuts for the AMD terminals are tightened to the specified torque, the AMD terminals are connected securely, and there are no contact problems.

Torque:

Nut A
9.0 N*m {92 kgf*cm, 80 in.*lbf}

Nut B
7.5 N*m {76 kgf*cm, 66 in.*lbf}

(c) Check for arc marks at the nuts for the inverter terminal.

Result:

C -- CONNECT SECURELY

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
A -- Continue to next step.

17. CHECK TERMINAL VOLTAGE (AMD TERMINAL VOLTAGE)

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

Standard Voltage:

NG -- CHECK FUSIBLE LINK (DC/DC)

OK -- REPLACE HYBRID VEHICLE CONVERTER Components

18. CHECK FUSE (IGCT NO. 2)

(a) Disconnect the negative battery terminal.

(b) Remove the IGCT No. 2 fuse from the engine room junction block assembly.

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

Standard Resistance:

Text in Illustration

(d) Install the IGCT No. 2 fuse.

NG -- REPLACE FUSE (IGCT NO. 2)
OK -- Continue to next step.

19. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR) P0A09

NG -- CONNECT SECURELY
OK -- Continue to next step.

20. CHECK HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER)

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) Disconnect connector z17 from the hybrid vehicle converter.

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

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

Standard Voltage:

Text in Illustration

NOTICE:
Turning the power switch on (IG) with the hybrid vehicle converter connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

(e) Connect the hybrid vehicle converter connector.

(f) Turn the power switch off.

NG -- REPAIR OR REPLACE HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER)

OK -- REPLACE HYBRID VEHICLE CONVERTER Components

21. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

(a) Check that the bolt for the frame wire terminals are tightened to the specified torque, the frame wire terminals are connected securely, and there are no contact problems.

Torque:

8.4 N*m {85 kgf*cm, 74 in.*lbf}

(b) Check for arc marks at the bolt for the frame wire.

Result:

C -- CONNECT SECURELY

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
A -- Continue to next step.

22. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR)

(a) Check the connection of the frame wire 1E connector.

OK:

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

NG -- CONNECT SECURELY
OK -- Continue to next step.

23. CHECK FRAME WIRE (ENGINE ROOM JUNCTION BLOCK ASSEMBLY SIDE)

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

Standard Voltage:

NG -- CHECK FUSIBLE LINK BLOCK ASSEMBLY (MAIN)
OK -- Continue to next step.

24. CHECK FUSE (IGCT NO. 2)

(a) Disconnect the negative battery terminal.

(b) Remove the IGCT No. 2 fuse from the engine room junction block assembly.

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

Standard Resistance:

Text in Illustration

(d) Install the IGCT No. 2 fuse.

NG -- REPLACE FUSE (IGCT NO. 2)
OK -- Continue to next step.

25. CHECK INVERTER TERMINAL (AMD TERMINAL CONNECTION CONDITION)

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) Check that the nuts for the AMD terminals are tightened to the specified torque, the AMD terminals are connected securely, and there are no contact problems.

Torque:

Nut A
9.0 N*m {92 kgf*cm, 80 in.*lbf}

Nut B
7.5 N*m {76 kgf*cm, 66 in.*lbf}

(c) Check for arc marks at the nuts for the inverter terminal.

Result:

C -- CONNECT SECURELY

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
A -- Continue to next step.

26. CHECK TERMINAL VOLTAGE (AMD TERMINAL VOLTAGE)

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

Standard Voltage:

NG -- CHECK FUSIBLE LINK (DC/DC)
OK -- Continue to next step.

27. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR) P0A09

NG -- CONNECT SECURELY
OK -- Continue to next step.

28. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID VEHICLE CONVERTER)

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) Disconnect connector z17 from the hybrid vehicle converter.

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

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

Standard Voltage:

Text in Illustration

NOTICE:
Turning the power switch on (IG) with the hybrid vehicle converter connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

(e) Connect the hybrid vehicle converter connector.

(f) Turn the power switch off.

NG -- REPAIR OR REPLACE HARNESS AND CONNECTOR (IGCT RELAY - HYBRID VEHICLE CONVERTER)

OK -- REPLACE HYBRID VEHICLE CONVERTER Components

29. CHECK FUSIBLE LINK BLOCK ASSEMBLY (MAIN)

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

Standard Resistance:

NG -- REPLACE FUSIBLE LINK BLOCK ASSEMBLY (MAIN)
OK -- Continue to next step.

30. CHECK AUXILIARY BATTERY (NEGATIVE TERMINAL)

(a) Turn the power switch off.

(b) Check the connection of the auxiliary battery negative terminal cable.

OK:

The cable is connected securely and there are no contact problems.

(c) Check for arc marks on the auxiliary battery negative terminal cable.

Result:

C -- CONNECT SECURELY

B -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
A -- Continue to next step.

31. CHECK HARNESS AND CONNECTOR (AUXILIARY NEGATIVE BATTERY TERMINAL - BODY GROUND)

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

Standard Resistance:

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY NEGATIVE BATTERY TERMINAL - BODY GROUND)

OK -- REPAIR OR REPLACE FRAME WIRE

32. CHECK FUSIBLE LINK (DC/DC)

(a) Disconnect connector 1E from the engine room junction block assembly.

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

Standard Resistance:

(c) Connect the engine room junction block assembly connector.

NG -- REPLACE FUSIBLE LINK (DC/DC)

OK -- REPAIR OR REPLACE FRAME WIRE