Code No. C2016: Control relay stuck ON (Brake electric vacuum pump)



caution
  • If there is any problem in the CAN bus lines, an incorrect diagnosis code may be stored. Prior to this diagnosis, diagnose the CAN bus lines (Refer to GROUP 54C - CAN Bus Diagnostics Table ).
  • Whenever ECU is replaced, ensure that the CAN bus lines are normal.

TROUBLE JUDGEMENT


The PHEV-ECU stores diagnosis code No. C2016 when the brake electric vacuum pump control relay 1 or 2 is stuck on.

PROBABLE CAUSES



  • Malfunction of brake electric vacuum pump control relay 1 or 2
  • Malfunction of the brake electric vacuum pump relay box
  • Damaged harness or connector
  • Malfunction of PHEV-ECU

DIAGNOSIS PROCEDURE


STEP 1. M.U.T.-III CAN bus diagnostics


Use the M.U.T.-III to diagnose the CAN bus lines.

Q. Is the check result normal?

Go to Step 3.
Repair the CAN bus lines (Refer to GROUP 54C - Troubleshooting ). On completion, go to Step 2.

STEP 2. Check whether the diagnosis code is stored again.


Recheck if the diagnosis code is stored.
(1)Erase the diagnosis code.
(2)Turn on the power supply mode of the electric motor switch.
(3)Check if the diagnosis code is stored.

Q. Is the diagnosis code stored?

Go to Step 3.
The procedure is complete.

STEP 3. Brake electric vacuum pump main relay check


Refer to GROUP 35A - On vehicle Service - Relay Check .

Q. Is the check result normal?

Go to Step 4.
Replace the brake electric vacuum pump main relay.

STEP 4. Voltage measurement at PHEV-ECU connector (VPR1, VPR2 terminals).


(1)Disconnect the connector, and measure at the wiring harness side.
(2)Measure the voltage between the electric vacuum pump main relay connector terminal (VPM2 terminal) and body earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 10.
Go to Step 5.

STEP 5. Voltage measurement at brake electric vacuum pump main relay connector terminal No.5.


(1)Disconnect the connector, and measure at the wiring harness side.
(2)Measure the voltage between the brake electric vacuum pump main relay connector terminal No.5 and body earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 7.
Go to Step 6.

STEP 6. Check the power supply line for open and short circuit (fusible rink and electric vacuum pump main relay).



  • Fusible rink and brake electric vacuum pump main relay connector terminal No.5.

Q. Is the check result normal?

The trouble can be an intermittent malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction ).
Repair the connector or wiring harness.

STEP 7. Voltage measurement at brake electric vacuum pump control relay 1 and 2 connector terminal No.5.


(1)Disconnect the connector, and measure at the wiring harness side.
(2)Measure between the connectors below and body earth.

  • Measure the voltage between the brake electric vacuum pump control relay 1 connector terminal No.5 and body earth.
  • Measure the voltage between the brake electric vacuum pump control relay 2 connector terminal No.5 and body earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 9.
Go to Step 8.

STEP 8. Check the power supply line for open and short circuit (electric vacuum pump main relay and electric vacuum pump control relay 1 or 2).


Check the following wiring harness wires.

  • Between brake electric vacuum pump main relay 1 connector (terminal No.4) and brake electric vacuum control main relay 1 connector (terminal No.5) connector.
  • Between brake electric vacuum pump main relay 2 connector (terminal No.4) and brake electric vacuum control main relay 1 connector (terminal No.5) connector.

Q. Is the check result normal?

The trouble can be an intermittent malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction ).
Repair the connector or wiring harness.

STEP 9. Check the signal line for open and short circuit (Electric vacuum pump control relay 1 or 2 and PHEV-ECU).


Check the following wiring harness wires.

  • Between brake electric vacuum pump control relay 1 connector (terminal No.4) and PHEV-ECU (VPM2 terminal) connector.
  • Between brake electric vacuum pump control relay 2 connector (terminal No.4) and PHEV-ECU (VPM2 terminal) connector.

Q. Is the check result normal?

The trouble can be an intermittent malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction ).
Repair the connector or wiring harness.

STEP 10. Voltage measurement at PHEV-ECU (VPR1, VPR2) connector terminal.


(1)Measure the PHEV-ECU connector side by backprobing.
(2)Measure the voltage between the PHEV-ECU (VPR1, VPR2 terminals) connector and body earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 14.
Go to Step 11.

STEP 11. Voltage measurement at brake electric vacuum pump control relay 1 and 2 connector terminal No.3.


(1)Disconnect the connector, and measure at the wiring harness side.
(2)Measure between the connectors below and body earth.

  • Measure the voltage between the brake electric vacuum pump control relay 1 connector (terminal No.3) and body earth.
  • Measure the voltage between the brake electric vacuum pump control relay 2 connector (terminal No.3) and body earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 13.
Go to Step 12.

STEP 12. Check the power supply line for open and short circuit (IGCT control relay and electric vacuum pump control relay 1 or 2).


Check the following wiring harness wires.

  • Check the wiring harness between IGCT control relay and the electric vacuum pump control relay 1 (terminal No.3) connector.
  • Check the wiring harness between IGCT control relay and the electric vacuum pump control relay 2 (terminal No.3) connector.

Q. Is the diagnosis code stored?

The trouble can be an intermittent malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction ).
Repair the connector or wiring harness.

STEP 13. Check the power supply line for open and short circuit (Electric vacuum pump control relay 1 or 2 and PHEV-ECU).


Check the following wiring harness wires.

  • Between brake electric vacuum pump control relay 1 connector (terminal No.1) and PHEV-ECU (VPR1 terminal) connector.
  • Between brake electric vacuum pump control relay 2 connector (terminal No.1) and PHEV-ECU (VPR2 terminal) connector.

Q. Is the diagnosis code stored?

The trouble can be an intermittent malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction ).
Repair the connector or wiring harness.

STEP 14. Check whether the diagnosis code is stored again.


Recheck if the diagnosis code is stored.
(1)Erase the diagnosis code.
(2)Turn on the power supply mode of the electric motor switch.
(3)Check if the diagnosis code is stored.

Q. Is the diagnosis code stored?

Replace the PHEV-ECU (Refer to ).
The procedure is complete.