Code No. P0AE2: Charging contactor (weld)



danger
  • When servicing the high voltage system parts, always shut off the high voltage by removing the service plug (Refer to ).
  • When servicing the high voltage system parts, always wear the protective equipment or armour to measure the high voltage (Refer to ).
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. P0AE2 when the charging contactor fails.

PROBABLE CAUSES



  • Damaged harness or connector
  • Malfunction of charging contactor
  • Malfunction of main contactor (P)
  • Malfunction of electric heater <Vehicles with electric heater>
  • Malfunction of A/C control panel (A/C-ECU)
  • Malfunction of on board charger/DC-DC converter
  • Malfunction of front EMCU
  • Malfunction of rear EMCU
  • Malfunction of GCU
  • 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 2.
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. Check whether the diagnosis code is stored.


Check if the diagnosis code No. P0AE7 is stored to the PHEV-ECU.

Q. Is the diagnosis code stored?

Carry out troubleshooting for the diagnosis code P0AE7. (Refer to .)
Go to Step 4.

STEP 4. Check the signal line for short circuit (PHEV-ECU connector and drive battery connector).



  • Check the wiring harness between PHEV-ECU (CNTP terminal) connector and the drive battery connector.

Q. Is the check result normal?

Go to Step 5.
Repair the connector or wiring harness.

STEP 5. Voltage measurement at high-voltage, service plug connector


danger Carry out the check on the high-voltage circuit while reading carefully the precautions on handling a high-voltage vehicle.
danger Be sure to wear the specified protective equipment when removing the service plug.
Connect a high-voltage compatible multimeter between the drive battery high-voltage terminal and the drive battery service plug front terminal.
OK: 0 V

Q. Is the check result normal?

Go to Step 14.
Check the resistance at the coil of the drive battery charging contactor (Refer to ). Then go to Step 6.

STEP 6. M.U.T.-III other system diagnosis code


Use M.U.T.-III to check whether the PHEV-ECU-related diagnosis code is stored. (Refer to ).

Q. Is any diagnosis code stored?

Troubleshoot for the relevant diagnosis code.
Go to Step 7.

STEP 7. M.U.T.-III other system diagnosis code


Use M.U.T.-III to check whether the A/C control panel (A/C-ECU) related diagnosis code is stored. (Refer to GROUP 55 <PHEV> - Diagnosis Code Chart (A/C control panel (A/C-ECU)) .)

Q. Is any diagnosis code stored?

Troubleshoot for the relevant diagnosis code.
NO <Vehicles with electric heater> : Go to Step 8.
NO <Vehicles without electric heater> : Go to Step 12.

STEP 8. Resistance measurement of the electric heater connector.


danger Carry out the check on the high-voltage circuit while reading carefully the precautions on handling a high-voltage vehicle.
danger Wear the specified protection equipment during the check.
(1)Remove the service plug.
(2)Disconnect the electric heater connector (high voltage) and measure at the equipment side.
(3)Measure the resistance between electric heater connector (high voltage) terminal No. 1 and terminal No. 2.
OK: 1 MΩ or more

Q. Is the check result normal?

Go to Step 9.
Check the high-voltage fuse No.5 (Refer to ). Replace the electric heater (Refer to GROUP 55 - Heater ).

STEP 9. Resistance measurement at electric heater connector.


(1)Disconnect the electric heater connector and measure it on the resistance at the electric heater side.
(2)Measure the resistance between the electric heater connector (HTR1, HTR2, HTR3 terminals) and the body earth.
OK: No continuity

Q. Is the check result normal?

Go to Step 10.
Replace the electric heater (Refer to GROUP 55 - Heater ).

STEP 10. Resistance measurement at electric heater connector.


(1)Disconnect the electric heater connector and measure it on the resistance at the wiring harness side.
(2)Measure the resistance between the electric heater connector (HTR1, HTR2, HTR3 terminals) and the body earth.
OK: No continuity

Q. Is the check result normal?

Go to Step 11.
Repair the connector or wiring harness.

STEP 11. Check the power supply line for short circuit (electric heater connector and A/C control panel (A/C-ECU) connector).



  • Check the wiring harness between electric heater connector and the A/C control panel (A/C-ECU) connector (HTR1, HTR2, HTR3 terminals).

Q. Is the check result normal?

Replace the A/C control panel (A/C-ECU) (Refer to GROUP 55 - Heater Control Unit ). Then go to Step 12.
Repair the connector or wiring harness.

STEP 12. 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 13.
The trouble can be an intermittent malfunction (Refer to GROUP 00, How to Cope with Intermittent Malfunction ).

STEP 13. Contactor check


Disassemble the drive battery and check the contactor.

Q. Is the check result normal?

Go to Step 14.
Replace the contactor.

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.