RM36D0EC _51 Engine / Hybrid System _083048 HYBRID / BATTERY CONTROL _0709511 HYBRID CONTROL SYSTEM C

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  P1C8149  High Voltage Power Resource Circuit Consumption Circuit Short  P1C8249  High Voltage Power Resource Circuit Over Loading  


DTC SUMMARY

MALFUNCTION DESCRIPTION


The hybrid vehicle control ECU assembly monitors the high-voltage wiring between the HV battery and inverter with converter assembly and detects a short circuit malfunction or high-voltage system operation malfunction.

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

Battery current sensor (IB) circuit malfunction
·

Battery current sensor (IB) malfunction

·

Motor generator control ECU (MG ECU) malfunction

·

Communication (wire harness) malfunction


High voltage system malfunction
·

HV battery malfunction

·

HV battery junction block assembly malfunction

·

Inverter with converter assembly malfunction

·

Air conditioner system malfunction

·

High-voltage wire harness malfunction

·

High-voltage connector or connection malfunction


Low-voltage circuit (12 V) malfunction
·

Hybrid vehicle control ECU assembly malfunction

·

Low voltage wire harness malfunction

·

Low voltage connector malfunction



INSPECTION DESCRIPTION


A407908E10
1.813,3.729 2.656,4.313 0.844,0.583 10 false System Main Resistor 3.271,2.313 4.24,3.021 0.969,0.708 10 false Battery Current Sensor 0.573,1.573 1.688,1.979 1.115,0.406 10 false Service Plug Grip 0.771,3.281 2.302,3.479 1.531,0.198 10 false HV Battery 2.76,2.313 3.375,2.51 0.615,0.198 10 false SMRB 2.76,3.177 3.375,3.375 0.615,0.198 10 false SMRG 2.76,3.74 3.375,3.938 0.615,0.198 10 false SMRP 5.563,1 7.021,1.677 1.458,0.677 10 false Compressor with Motor Assembly 5.25,3.167 6.281,3.531 1.031,0.365 10 false Boost Converter 6.469,3.167 6.969,3.531 0.5,0.365 10 false Inverter 5.01,3.75 7.021,4.271 2.01,0.521 10 false Inverter with Converter Assembly 1.833,4.417 7.031,4.615 5.198,0.198 10 false HV Battery Junction Block Assembly 1.188,4.74 4.094,4.938 2.906,0.198 10 false : High Voltage Line 1.167,5.052 3.917,5.25 2.75,0.198 10 false : Inspection Areas 4.917,0.344 5.229,0.542 0.313,0.198 10 false *a 4.521,1.979 4.833,2.177 0.313,0.198 10 false *b

System Diagram Location Inspection Content Reason Inspection Step
*a Check high-voltage wiring connection condition of the air conditioner compressor with motor assembly Check for short circuit 2, 4
*b Check the high voltage cables between the HV battery junction block assembly and inverter with converter assembly. Check for short circuit 3, 5


DESCRIPTION

Refer to the description for DTC P0AE411.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>P0AE411

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate Note
P1C8149 High Voltage Power Resource Circuit Consumption Circuit Short High-voltage circuit malfunctions between the HV battery and inverter with converter assembly.
Excessive overcurrent equal to a short occurs during precharge (time from when SMRP turns on until SMRG turns on).
(1 trip detection logic)
·

Air conditioning wire

·

Compressor with motor assembly

·

Inverter with converter assembly

·

HV battery junction block assembly

·

HV floor under wire


Does not come on Master Warning:
Comes on 		SAE Code:
P3004
P1C8249 High Voltage Power Resource Circuit Over Loading High-voltage circuit malfunctions between the HV battery and inverter with converter assembly.
Small battery overcurrent occurs during precharge (time from when SMRP turns on until SMRG turns on) and current continues to flow after precharge.
(1 trip detection logic)
·

Air conditioning wire

·

Compressor with motor assembly

·

Inverter with converter assembly

·

HV battery junction block assembly

·

HV floor under wire


Does not come on Master Warning:
Comes on 		SAE Code:
P3004

Related Data List
DTC No. Data List
P1C8149
·

Hybrid/EV Battery Voltage

·

Hybrid/EV Battery Current

·

VL-Voltage before Boosting

·

VH-Voltage after Boosting


P1C8249

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 power switch on (IG) and turn the GTS on.

3.

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

4.

Turn the power switch off and wait for 2 minutes or more.

5.

Turn the power switch on (IG) and turn the GTS on.

6.

Turn the power switch on (READY).

7.

While driving the vehicle at a speed of 20 km/h (12 mph) or more in EV mode, depress the accelerator pedal to start the engine, and drive the vehicle for 3 seconds or more.*1

*1: When the HV system is normal, the engine starts when the accelerator pedal is depressed halfway or more. If the HV system is malfunctioning, the engine may not start. Even in this case, drive the vehicle at a speed of 20 km/h (12 mph) or more in EV mode for 3 seconds or more.

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


PROCEDURE

1.CHECK DTC OUTPUT (HYBRID CONTROL, MOTOR GENERATOR, HV BATTERY)
a.

Connect the GTS to the DLC3.


b.

Turn the power switch on (IG).


c.

Enter the following menus: Powertrain / Hybrid Control, Motor Generator, HV Battery / Trouble Codes.


d.

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
P1C8149 or P1C8249 only is output, or DTCs except the ones in the tables below are also output. A
DTCs of hybrid control system in the tables below are output. B
DTCs of motor generator control system in the tables below are output. C
DTCs of hybrid battery system in the tables below are output. D


Malfunction Content System Relevant DTC
Microcomputer malfunction Hybrid control system P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
P060B49 Hybrid/EV Powertrain Control Module A/D Processing Internal Electronic 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
Hybrid battery system P060B49 Hybrid/EV Battery Energy Control Module A/D Processing Internal Electronic Failure
P060687 Hybrid/EV Battery Energy Control Module Processor to Monitoring Processor Missing Message
P060A47 Hybrid/EV Battery Energy Control Module Monitoring Processor Watchdog / Safety MCU Failure
P060A87 Hybrid/EV Battery Energy Control Module Processor from Monitoring Processor Missing Message
P060B16 Hybrid/EV Battery Energy Control Module A/D Processing Circuit Voltage Below Threshold
P0E2D00 Hybrid/EV Battery Energy Control Module Hybrid/EV Battery Monitor Performance
Communication system malfunction Hybrid control system U011187 Lost Communication with Hybrid/EV Battery Energy Control Module "A" Missing Message
Sensor and actuator circuit malfunction Hybrid control system P0B231C Hybrid/EV Battery "A" Voltage Sensor Voltage Out of Range
P0ABF00 Hybrid/EV Battery Current Sensor "A" Circuit Range/Performance
Motor generator control system P0A1114 DC/DC Converter Enable Circuit Short to Ground or Open
P0A1112 DC/DC Converter Enable Circuit Short to Battery
P1CCC96 DC/DC Converter Enable Component Internal Failure
Hybrid battery system P0ABF11 Hybrid/EV Battery Current Sensor "A" Circuit Short to Ground
P0B0E11 Hybrid/EV Battery Current Sensor "B" Circuit Short to Ground
P0B0E15 Hybrid/EV Battery Current Sensor "B" Circuit Short to Auxiliary Battery or Open
P0ABF15 Hybrid/EV Battery Current Sensor "A" Circuit Short to Auxiliary Battery or Open
P301A1C Hybrid Battery Stack 1 Cell Voltage Detection Voltage Out of Range
P1A001C Hybrid Battery Stack 2 Cell Voltage Detection Voltage Out of Range
P1AFD1C Flying Capacitor/Internal Control Module Hybrid/EV Battery Monitor Voltage Out of Range
P0ABF28 Hybrid/EV Battery Current Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure
P0ABF2A Hybrid/EV Battery Current Sensor "A" Signal Stuck In Range
P1CBB12 Hybrid/EV Battery Current Sensor Power Supply Circuit Short to Auxiliary Battery
P1CBB14 Hybrid/EV Battery Current Sensor Power Supply Circuit Short to Ground or Open
P0B1362 Hybrid/EV Battery Current Sensor "A"/"B" Signal Compare Failure
System malfunction Hybrid control system P0A1F94 Hybrid/EV Battery Energy Control Module Unexpected Operation
Motor generator control system P0D3319 DC/DC Converter Circuit Current Above Threshold

HINT:

P1C8149 or P1C8249 may be output as a result of the malfunction indicated by the DTCs above.

(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.)





e.

Turn the power switch off.



A

2.CHECK COMPRESSOR WITH MOTOR ASSEMBLY

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>DIAGNOSTIC TROUBLE CODE CHART


C

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)

for 2WD:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>MOTOR GENERATOR CONTROL SYSTEM (for 2WD with LITHIUM-ION BATTERY [Production date from 2021/08])>DIAGNOSTIC TROUBLE CODE CHART

for AWD:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>MOTOR GENERATOR CONTROL SYSTEM (for AWD with LITHIUM-ION BATTERY)>DIAGNOSTIC TROUBLE CODE CHART


D

GO TO DTC CHART (HYBRID BATTERY SYSTEM)

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID BATTERY SYSTEM (for LITHIUM-ION BATTERY [Production date from 2021/08])>DIAGNOSTIC TROUBLE CODE CHART


2.CHECK COMPRESSOR WITH MOTOR 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.
C412477

Disconnect the HV air conditioning wire connector from the inverter with converter assembly.


c.
A380308C39
0.5,0.583 0.813,0.781 0.313,0.198 1.427,0.688 0.667,1.24 false 1.677,0.688 2.406,1.323 false 2.729,0.563 2.49,0.906 2.49,0.906 3.01,0.656 true 0.063,0.063 0.375,0.219 0.313,0.156 10 false *a 2.354,0.906 2.667,1.063 0.313,0.156 10 true *b 0.594,0.604 0.906,0.76 0.313,0.156 10 false Z2 0.51,1.281 0.927,1.469 0.417,0.188 10 false ACPE 2.292,1.354 2.708,1.542 0.417,0.188 10 false ACPB
*a HV Air Conditioning Wire
(Inverter with Converter Assembly Side)
*b Tip of Terminal


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

Standard Resistance:
Tester Connection
(Tester Probe Polarity) 		Condition Specified Condition
Z2-2 (ACPE) (Negative (-) probe) - Z2-1 (ACPB) (Positive (+) probe) Power switch off 100 kΩ or higher


NOTICE:
·

Do not use a megohmmeter.

·

Read the resistance after the value has stabilized.

·

Be sure to inspect with connecting the tester probes to the tips of the terminal.




d.

Reconnect the HV air conditioning wire connector.


Result:
Proceed to
OK
NG



OK

3.CHECK FLOOR UNDER WIRE

NG

4.CHECK HV AIR CONDITIONING WIRE
3.CHECK FLOOR UNDER WIRE
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.
C412478

Disconnect the floor under wire connector from the inverter with converter assembly.


c.
A556784C02
0.323,0.969 0.781,1.229 0.458,0.26 0.833,1.646 1.646,1.156 false 2.75,1.583 1.958,1.125 false 0.083,0.042 0.396,0.198 0.313,0.156 10 false *a 0.5,1.667 0.813,1.823 0.313,0.156 10 false CBI 2.896,1.698 3.208,1.854 0.313,0.156 10 false CEI 0.448,1.031 0.76,1.188 0.313,0.156 10 false Y2
*a Floor under wire
(Inverter with Converter Assembly Side)


for 2WD:

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

Standard Resistance:
Tester Connection Condition Specified Condition
Y2-1 (CBI) - Y2-2 (CEI) Power switch off 10 kΩ or higher


NOTICE:

Be sure not to damage or deform the terminal being inspected.



d.
A556785C05
0.521,0.813 0.979,1.073 0.458,0.26 0.917,1.604 1.677,0.938 false 2.625,1.385 1.938,0.969 false 0.083,0.042 0.396,0.198 0.313,0.156 10 false *a 0.646,1.542 0.958,1.698 0.313,0.156 10 false CBI 2.677,1.333 2.99,1.49 0.313,0.156 10 false CEI 0.667,0.865 0.979,1.021 0.313,0.156 10 false Y1
*a Floor under wire
(Inverter with Converter Assembly Side)


for AWD:

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

Standard Resistance:
Tester Connection Condition Specified Condition
Y1-1 (CBI) - Y1-2 (CEI) Power switch off 10 kΩ or higher


NOTICE:

Be sure not to damage or deform the terminal being inspected.



e.

Reconnect the floor under wire connector.


Result:
Proceed to
OK
NG



OK

REPLACE INVERTER WITH CONVERTER ASSEMBLY

for 2WD:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER (for 2WD)>REMOVAL

for AWD:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER (for AWD)>REMOVAL


NG

5.CHECK FLOOR UNDER WIRE
4.CHECK HV AIR CONDITIONING WIRE
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.
C412477

Disconnect the HV air conditioning wire connector from the inverter with converter assembly.


c.
C412482

Disconnect the HV air conditioning wire from the compressor with motor assembly.

for A25B-FXS: Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for A25B-FXS)>REMOVAL

for A25D-FXS: Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for A25D-FXS)>REMOVAL

for A25F-FXS: Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for A25F-FXS [Production date from 2021/08])>REMOVAL


d.
A380308C40
0.5,0.583 0.813,0.781 0.313,0.198 1.427,0.688 0.667,1.24 false 1.677,0.688 2.406,1.323 false 2.729,0.563 2.49,0.906 2.49,0.906 3.01,0.656 true 0.063,0.063 0.375,0.219 0.313,0.156 10 false *a 2.354,0.906 2.667,1.063 0.313,0.156 10 true *b 0.594,0.604 0.906,0.76 0.313,0.156 10 false Z2 0.51,1.281 0.927,1.469 0.417,0.188 10 false ACPE 2.292,1.354 2.708,1.542 0.417,0.188 10 false ACPB
*a HV Air Conditioning Wire
(Inverter with Converter Assembly Side)
*b Tip of Terminal


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

Standard Resistance:
Tester Connection Condition Specified Condition
Z2-2 (ACPE) - Z2-1 (ACPB) Power switch off 10 kΩ or higher


NOTICE:

Be sure to inspect with connecting the tester probes to the tips of the terminal.



e.

Reconnect the HV air conditioning wire connector to the inverter with converter assembly.


f.

Reconnect the HV air conditioning wire to the compressor with motor assembly.


Result:
Proceed to
OK
NG



OK

REPLACE COMPRESSOR WITH MOTOR ASSEMBLY

for A25B-FXS:

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for A25B-FXS)>REMOVAL

for A25D-FXS:

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for A25D-FXS)>REMOVAL

for A25F-FXS:

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for A25F-FXS [Production date from 2021/08])>REMOVAL


NG

REPLACE HV AIR CONDITIONING WIRE

5.CHECK FLOOR UNDER WIRE
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 No. 1 HV battery cover panel RH.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV BATTERY (for LITHIUM-ION BATTERY [Production date from 2021/08])>REMOVAL


c.
C529598

Disconnect the floor under wire connectors from the HV battery junction block assembly.


d.
C412478

Disconnect the floor under wire connector from the inverter with converter assembly.


e.
A556784C02
0.323,0.969 0.781,1.229 0.458,0.26 0.833,1.646 1.646,1.156 false 2.75,1.583 1.958,1.125 false 0.083,0.042 0.396,0.198 0.313,0.156 10 false *a 0.5,1.667 0.813,1.823 0.313,0.156 10 false CBI 2.896,1.698 3.208,1.854 0.313,0.156 10 false CEI 0.448,1.031 0.76,1.188 0.313,0.156 10 false Y2
*a Floor under wire
(Inverter with Converter Assembly Side)


for 2WD:

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

Standard Resistance:
Tester Connection Condition Specified Condition
Y2-1 (CBI) - Y2-2 (CEI) Power switch off 10 kΩ or higher


NOTICE:

Be sure not to damage or deform the terminal being inspected.



f.
A556785C06
0.521,0.813 0.979,1.073 0.458,0.26 0.917,1.604 1.677,0.938 false 2.625,1.385 1.938,0.969 false 0.083,0.042 0.396,0.198 0.313,0.156 10 false *a 0.646,1.542 0.958,1.698 0.313,0.156 10 false CBI 2.677,1.333 2.99,1.49 0.313,0.156 10 false CEI 0.667,0.865 0.979,1.021 0.313,0.156 10 false Y1
*a Floor under wire
(Inverter with Converter Assembly Side)


for AWD:

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

Standard Resistance:
Tester Connection Condition Specified Condition
Y1-1 (CBI) - Y1-2 (CEI) Power switch off 10 kΩ or higher


NOTICE:

Be sure not to damage or deform the terminal being inspected.



g.

Reconnect the floor under wire connector to the inverter with converter assembly.


h.

Reconnect the floor under wire connectors to the HV battery junction block assembly.


i.

Install the No. 1 HV battery cover panel RH.


Result:
Proceed to
OK
NG



OK

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY [Production date from 2021/08])>REMOVAL


NG

REPLACE FLOOR UNDER WIRE

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>FRAME WIRE>REMOVAL