RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604232 HYBRID CONTROL SYSTEM C

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  P0AA000  Hybrid/EV Battery Positive Contactor Circuit Stuck Closed  


DTC SUMMARY

MALFUNCTION DESCRIPTION


The hybrid vehicle control ECU detects a stuck closed malfunction of a system main relay on the HV battery positive (+) terminal side.

The cause of this malfunction may be one of the following:

Inverter voltage sensor (VH) internal circuit malfunction
·

Voltage sensor (VH) malfunction

·

Motor generator control ECU (MG ECU) malfunction

·

Communication (wire harness) malfunction


High voltage system malfunction
·

HV battery junction block assembly malfunction


Low-voltage circuit (12 V) malfunction
·

Hybrid vehicle control ECU malfunction

·

HV battery junction block assembly malfunction

·

Low voltage wire harness malfunction

·

Low voltage connector malfunction



DESCRIPTION

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

There are 2 SMRs. SMRB and SMRG are located in the HV battery junction block assembly.

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

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate Note
P0AA000 Hybrid/EV Battery Positive Contactor Circuit Stuck Closed Even the system main relay of HV battery positive (+) terminal side is turned off, the inverter voltage (VH) does not drop.
(1 trip detection logic)
·

HV battery junction block assembly

·

Inverter with converter assembly

·

Hybrid vehicle control ECU

·

Wire harness or connector


Does not come on Master Warning:
Comes on
SAE Code:
P0AA1

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>UTILITY


1.

Connect the GTS to the DLC3.

2.

Turn the ignition switch to ON and turn the GTS on.

3.

Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

4.

Turn the ignition switch off and wait for 30 seconds or more.

5.

Turn the ignition switch to ON (READY).

6.

Turn the ignition switch off and wait for 30 seconds or more.

7.

Turn the ignition switch to ON (READY).

HINT:

According to the display on the GTS, read the Data List and monitor the values of "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" for 3 minutes. If the difference between "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" is always less than 100 V, the vehicle has returned to normal.


8.

Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

9.

Check the DTC judgment result.

HINT:
·

If the judgment result shows NORMAL, the system is normal.

·

If the judgment result shows ABNORMAL, the system has a malfunction.

·

If the judgment result shows INCOMPLETE, perform driving pattern again.




CAUTION / NOTICE / HINT

CAUTION:

Refer to the precautions before inspecting high voltage circuit.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PRECAUTION


NOTICE:
·

If the DTCs are cleared or the cable is disconnected and reconnected to the negative (-) auxiliary battery terminal before performing repairs, turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the ignition switch to ON (READY).

·

After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY

·

When disconnecting and reconnecting the auxiliary battery

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART




HINT:
·

If DTC P0AA000 is output, the ignition switch cannot be turned to ON (READY).

·

P0AA000 may be output as a result of the malfunction indicated by the DTCs in table below.

(a)

The chart above is listed in inspection order of priority.

(b)

Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)



Malfunction Content System Relevant DTC
Microcomputer malfunction Hybrid Control System P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
P060687 Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message
P060A47 Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure
P060A87 Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message
P0A1B49 Drive Motor "A" Control Module Internal Electronic Failure
P1C9E9F Hybrid/EV System Reset Stuck Off
Motor Generator Control System P0A1B1F Generator Control Module Circuit Intermittent
P0A1A47 Generator Control Module Watchdog / Safety MC Failure
P0A1A49 Generator Control Module Internal Electronic Failure
P1C2A1C Generator A/D Converter Circuit Circuit Voltage Out of Range
P1C2A49 Generator A/D Converter Circuit Internal Electronic Failure
P1C2B1C Drive Motor "A" Control Module A/D Converter Circuit Voltage Out of Range
P1C2B49 Drive Motor "A" Control Module A/D Converter Circuit Internal Electronic Failure
P1CAC49 Generator Position Sensor Internal Electronic Failure
P1CAD49 Drive Motor "A" Position Sensor Internal Electronic Failure
P1CAF38 Generator Position Sensor REF Signal Cycle Malfunction Signal Frequency Incorrect
P1CB038 Drive Motor "A" Position Sensor REF Signal Frequency Incorrect
P313383 Communication Error from Generator to Drive Motor "A" Value of Signal Protection Calculation Incorrect
P313386 Communication Error from Generator to Drive Motor "A" Signal Invalid
Power source circuit malfunction Motor Generator Control System P06D61C Generator Control Module Offset Power Circuit Voltage Out of Range
P06B01C Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range
Communication system malfunction Motor Generator Control System P313387 Communication Error from Generator to Drive Motor "A" Missing Message
Sensor and actuator circuit malfunction Hybrid Control System P0AD911 Hybrid/EV Battery Positive Contactor Circuit Short to Ground
P0AD915 Hybrid/EV Battery Positive Contactor Circuit Short to Auxiliary Battery or Open
P0ADD11 Hybrid/EV Battery Negative Contactor Circuit Short to Ground
P0ADD15 Hybrid/EV Battery Negative Contactor Circuit Short to Auxiliary Battery or Open
Motor Generator Control System P0A3F16 Drive Motor "A" Position Sensor Circuit Voltage Below Threshold
P0A4B16 Generator Position Sensor Circuit Voltage Below Threshold
P0A4B21 Generator Position Sensor Signal Amplitude < Minimum
P0A4B22 Generator Position Sensor Signal Amplitude > Maximum
P0C5013 Drive Motor "A" Position Sensor Circuit "A" Circuit Open
P0C5016 Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Below Threshold
P0C5017 Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Above Threshold
P0C5A13 Drive Motor "A" Position Sensor Circuit "B" Circuit Open
P0C5A16 Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Below Threshold
P0C5A17 Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Above Threshold
P0C6413 Generator Position Sensor Circuit "A" Circuit Open
P0C6416 Generator Position Sensor Circuit "A" Circuit Voltage Below Threshold
P0C6417 Generator Position Sensor Circuit "A" Circuit Voltage Above Threshold
P0C6913 Generator Position Sensor Circuit "B" Circuit Open
P0C6916 Generator Position Sensor Circuit "B" Circuit Voltage Below Threshold
P0C6917 Generator Position Sensor Circuit "B" Circuit Voltage Above Threshold
System malfunction Hybrid Control System P0D2D1C Drive Motor "A" Inverter Voltage Sensor Voltage Out of Range
P1C8349 High Voltage Power Resource Circuit Voltage Sensor after Boosting Malfunction
P0C7600 Hybrid/EV Battery System Discharge Time Too Long
Motor Generator Control System P0D2D16 Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Below Threshold
P0D2D17 Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold
P1CB69E Drive Motor "A" Inverter Voltage Sensor (VH) Stuck On


PROCEDURE

1.CHECK FREEZE FRAME DATA (HYBRID CONTROL)
a.

Read the Freeze Frame Data of DTC P0AA000.

Powertrain > Hybrid Control > Trouble Codes
50001 397
NOTICE:

As freeze frame data is stored immediately before and after a DTC is stored, make sure to only read the values for the moment the DTC was stored ("0(s)").


Result:
Result Proceed to
Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is less than 76 V. A
Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting" is 76 V or more. B


HINT:

If VH-Voltage after Boosting is output even when an off command is being sent to the system main relay (positive side), P0AA000 is output. If the difference between the "VL-Voltage before Boosting" and the "VH-Voltage after Boosting" is large, it is determined that there is an inverter (VH sensor) malfunction.



b.

Turn the ignition switch off.



A

2.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

B

2.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

OK

4.CHECK CONNECTOR CONNECTION CONDITION (FLOOR WIRE CONNECTOR)

NG

3.CONNECT SECURELY
3.CONNECT SECURELY
Result:
Proceed to
NEXT



NEXT

4.CHECK CONNECTOR CONNECTION CONDITION (FLOOR WIRE CONNECTOR)
4.CHECK CONNECTOR CONNECTION CONDITION (FLOOR WIRE CONNECTOR)
a.

Check the connection condition of the floor wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>ELECTRONIC CIRCUIT INSPECTION PROCEDURE

OK:

- The connector is connected securely.

- The terminals are not deformed and are connected securely.

- No water or foreign matter in the connector.



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



A

7.CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

B

5.CONNECT SECURELY

C

6.REPAIR OR REPLACE HARNESS OR CONNECTOR
5.CONNECT SECURELY
Result:
Proceed to
NEXT



NEXT

7.CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)
6.REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
Proceed to
NEXT



NEXT

7.CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)
7.CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517683N03
1.146,0.583 1.646,0.833 0.5,0.25 1.219,0.604 1.604,0.813 0.385,0.208 10 true O219

Check the connector connections and contact pressure of the relevant terminals of the HV battery junction block assembly connector.

Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>ELECTRONIC CIRCUIT INSPECTION PROCEDURE

OK:

The connectors are connected securely and there are no contact pressure problems.



Result:
Proceed to
OK
NG



OK

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

NG

8.CONNECT SECURELY
8.CONNECT SECURELY
Result:
Proceed to
NEXT



NEXT

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

Check the installation condition of the ground wire OF.

OK:

The ground wire OF is securely installed.



Result:
Proceed to
OK
NG



OK

11.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HV BATTERY JUNCTION BLOCK ASSEMBLY)

NG

10.CONNECT SECURELY
10.CONNECT SECURELY
Result:
Proceed to
NEXT



NEXT

11.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HV BATTERY JUNCTION BLOCK ASSEMBLY)
11.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HV 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the HV battery junction block assembly connector.


c.

Disconnect the hybrid vehicle control ECU connector.


d.

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

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
I278-3 (SMRB) - O219-4 (SMRB) Ignition switch off Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
I278-3 (SMRB) or O219-4 (SMRB) - Body ground and other terminals Ignition switch off 10 kΩ or higher



e.

Reconnect the hybrid vehicle control ECU connector.


f.

Reconnect the HV battery junction block assembly connector.


Result:
Proceed to
OK
NG



OK

13.CHECK HARNESS AND CONNECTOR (HV BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)

NG

12.REPAIR OR REPLACE HARNESS OR CONNECTOR
12.REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
Proceed to
NEXT



NEXT

13.CHECK HARNESS AND CONNECTOR (HV BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)
13.CHECK HARNESS AND CONNECTOR (HV BATTERY JUNCTION BLOCK ASSEMBLY - BODY GROUND)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the HV battery junction block assembly connector.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O219-2 (GND) - Body ground Ignition switch off Below 1 Ω



d.

Reconnect the HV battery junction block assembly connector.


Result:
Proceed to
OK
NG



OK

15.INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

NG

14.REPAIR OR REPLACE HARNESS OR CONNECTOR
14.REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
Proceed to
NEXT



NEXT

15.INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)
15.INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the HV battery junction block assembly connector.


c.

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

A515114C70
3.958,0.083 4.458,0.333 0.5,0.25 4.51,1.083 4.333,0.823 true 3.979,1.052 4.167,0.698 true 0.573,0.146 0.885,0.302 0.313,0.156 10 false *a 4.042,0.115 4.5,0.313 0.458,0.198 10 false O219 3.802,1.083 4.135,1.292 0.333,0.208 10 true GND 4.354,1.104 4.781,1.271 0.427,0.167 10 true SMRB
*a Component without harness connected
(HV Battery Junction Block Assembly)
- -


Standard Resistance:
Tester Connection Condition Specified Condition
O219-4 (SMRB) - O219-2 (GND) -40 to 80°C (-40 to 176°F) 20.6 to 40.8 Ω



d.

Reconnect the HV battery junction block assembly connector.


Result:
Proceed to
OK
NG



OK

16.CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

NG

18.REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY
16.CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517684N02
0.875,0.521 1.292,0.771 0.417,0.25 1.323,0.74 1.74,0.99 0.417,0.25 1.771,0.948 2.188,1.198 0.417,0.25 2.219,1.083 2.635,1.333 0.417,0.25 1.365,0.76 1.719,0.969 0.354,0.208 10 true W7 0.969,0.542 1.26,0.75 0.292,0.208 10 true z26 1.875,0.958 2.167,1.167 0.292,0.208 10 true W6 2.281,1.094 2.604,1.313 0.323,0.219 10 true z23

Disconnect the HV battery high voltage connectors from the HV battery junction block assembly.

NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.



c.
A517687C03
0.583,0.583 1.083,0.833 0.5,0.25 1.25,0.792 1.75,1.042 0.5,0.25 0.531,1.531 0.906,1.063 true 1.5,1.823 1.344,1.208 true 0.083,0.083 0.25,0.25 0.167,0.167 10 true *a 0.75,0.604 1.031,0.813 0.281,0.208 10 true z26 0.448,1.552 0.604,1.75 0.156,0.198 10 true + 1.333,0.813 1.688,1.021 0.354,0.208 10 true W7 1.406,1.854 1.688,2.052 0.281,0.198 10 true CBI
*a Component without harness connected
(HV Battery Junction Block Assembly)


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

Standard Resistance:
Tester Connection Condition Specified Condition
W7-1 (CBI) - z26-1 (+) Ignition switch off 10 kΩ or higher


HINT:
·

If a system main relay is stuck closed, inspect the HV 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 HV battery junction block assembly must be replaced. Measuring resistance can determine that this is either a present or past malfunction.




d.

Reconnect the HV battery high voltage connectors.


Result:
Result Judgment Proceed to
OK Past malfunction A
NG Present malfunction B



A

17.REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

B

19.REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY
17.REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

NEXT

20.CHECK DTC OUTPUT (HYBRID CONTROL, MOTOR GENERATOR, HV BATTERY)
18.REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

NEXT

20.CHECK DTC OUTPUT (HYBRID CONTROL, MOTOR GENERATOR, HV BATTERY)
19.REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

NEXT

20.CHECK DTC OUTPUT (HYBRID CONTROL, MOTOR GENERATOR, HV BATTERY)
20.CHECK DTC OUTPUT (HYBRID CONTROL, MOTOR GENERATOR, HV BATTERY)
CAUTION:

Be sure to wear insulated gloves.


a.

Install the service plug grip.


b.

Clear the DTCs.

Powertrain > Hybrid Control > Clear DTCs
50002 397

c.

Turn the ignition switch off and wait for 30 seconds or more.


d.

Turn the ignition switch to ON (READY).


e.

Turn the ignition switch off and wait for 30 seconds or more.


f.

Turn the ignition switch to ON (READY).


g.

Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes
50001 397
Powertrain > Motor Generator > Trouble Codes
50001 395
Powertrain > HV Battery > Trouble Codes
50001 398

Result:
Result Proceed to
DTCs are not output A
DTCs of Hybrid Control System are output. B
DTCs of Motor Generator Control System are output. C
DTCs of Hybrid Battery System are output. D


h.

Turn the ignition switch off.



A

21.CHECK HYBRID VEHICLE CONTROL ECU (CHECK FOR NORMAL OPERATION)

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

C

D

21.CHECK HYBRID VEHICLE CONTROL ECU (CHECK FOR NORMAL OPERATION)
a.

According to the display on the GTS, read the Data List and monitor the values of "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" for 3 minutes.

Powertrain > Hybrid Control > Data List
Tester Display
VL-Voltage before Boosting
Hybrid/EV Battery Voltage
50003 397 150,227

Result:
Result Proceed to
Difference between "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" is always less than 100 V. A
Difference between "Hybrid/EV Battery Voltage" and "VL-Voltage before Boosting" is 100 V or more. B


b.

Turn the ignition switch off.



A

END

B