Toyota Avalon (XX50): Hybrid/EV Battery Temperature Sensor "A" Voltage Out of Range (P0A9B1C,P0AC51C,P0ACA1C). Hybrid/EV Battery Temperature Sensor "A" Signal Stuck In Range (P0A9B2A,P0AC52A,P0ACA2A,P306562). Hybrid/EV Bat

Hybrid/EV Battery Temperature Sensor "A" Voltage Out of Range (P0A9B1C,P0AC51C,P0ACA1C)

DESCRIPTION

These DTCs will be stored if the difference between the maximum and minimum output of each battery temperature sensors exceeds a certain amount and if the output of one battery temperature sensor deviates from that of the other sensors.

HINT:

If the vehicle as is left as is for 24 hours, the value of "Hybrid Battery Temperature" will be almost the same as the ambient temperature.

The following items can be helpful when performing repairs:

• Vehicle Speed
• Ambient Temperature

MONITOR DESCRIPTION

The battery temperature sensors are provided at 3 locations on the bottom of the HV battery. The resistance of the thermistor, which is built into each battery temperature sensor, varies in accordance with changes in the HV battery temperature. The lower the battery temperature, the higher the thermistor resistance. Conversely, the higher the temperature, the lower the resistance. The battery voltage sensor uses the battery temperature sensor to detect the HV battery temperature, and sends the detected value to the hybrid vehicle control ECU. Based on the results of this detection, the hybrid vehicle control ECU controls the blower fan. (The blower fan starts when the HV battery temperature rises above a predetermined level.)

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

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 here

• When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

  Click here

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream 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 Techstream on.
6. With power switch on (IG) and wait for 10 seconds or more.[*1]

   HINT:

   [*1]: Normal judgment procedure.

   The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. 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 or N/A, perform the normal judgment procedure again.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A9B2A.

Click here

CAUTION / NOTICE / HINT

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
• After removing 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.

  Click here

  

  *a	Without waiting for 10 minutes

  HINT:

  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

PROCEDURE

(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 for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

Click here

B

REPLACE HYBRID BATTERY THERMISTOR

C

INSTALL PARTS CORRECTLY

A

Click here

OK

REPLACE BATTERY VOLTAGE SENSOR

NG

Click here

OK

REPLACE HYBRID BATTERY THERMISTOR

NG

REPAIR HARNESS OR CONNECTOR (BATTERY TEMPERATURE SENSOR)

Hybrid/EV Battery Temperature Sensor "A" Signal Stuck In Range (P0A9B2A,P0AC52A,P0ACA2A,P306562)

DESCRIPTION

Refer to the description for DTC P0A9B11.

Click here

HINT:

If the vehicle as is left as is for 24 hours, the value of "Hybrid Battery Temperature" will be almost the same as the ambient temperature.

The following items can be helpful when performing repairs:

• Vehicle Speed
• Ambient Temperature

MONITOR DESCRIPTION

The battery temperature sensors are provided at 3 locations on the bottom of the HV battery. The resistance of the thermistor, which is built into each battery temperature sensor, varies in accordance with changes in the HV battery temperature. The lower the battery temperature, the higher the thermistor resistance. Conversely, the higher the temperature, the lower the resistance. The battery voltage sensor uses the battery temperature sensor to detect the HV battery temperature, and sends the detected value to the hybrid vehicle control ECU. Based on the results of this detection, the hybrid vehicle control ECU controls the blower fan. (The blower fan starts when the HV battery temperature rises above a predetermined level.)

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

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 here

• When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

  Click here

P0A9C (INF P0A9B2A), P0AC6 (INF P0AC52A), P0ACB (INF P0ACA2A):

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream 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 Techstream on.
6. Drive the vehicle for approximately 10 minutes according to the freeze frame data items "Vehicle Speed", "Accelerator Position", "Hybrid Battery Temperature 1 to 3" and "Hybrid Battery Current" when ambient temperature is -10°C (14°F) or higher.[*1]

   HINT:

   • Check that the output of each battery temperature sensor varies.
   • Check that the difference in output between each battery temperature sensor is not excessively large.
   • [*1]: Normal judgment procedure.

     The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. 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 or N/A, perform the normal judgment procedure again.

P3065 (INF P306562):

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream 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 Techstream on.
6. With power switch on (IG) and wait for 10 seconds or more when the ambient temperature is -10°C (14°F) or higher.[*1]

   HINT:

   • Check that the difference in output between each battery temperature sensor is not excessively large.
   • [*1]: Normal judgment procedure.

     The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. 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 or N/A, perform the normal judgment procedure again.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
• After removing 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.

  Click here

  HINT:

  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  

  *a	Without waiting for 10 minutes

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

PROCEDURE

(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 for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(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 upper HV battery cover sub-assembly.

Click here

(c) Visually check the installation condition of the relevant battery temperature sensor.

Standard Condition:

Each battery temperature sensor is installed in the correct location with the correct orientation and its claws are engaged securely.

(d) Install the upper HV battery cover sub-assembly.

B

REPLACE HYBRID BATTERY THERMISTOR

C

INSTALL PARTS CORRECTLY

A

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 hybrid battery exhaust duct.

Click here

(c) Disconnect the y6 battery voltage sensor connector.

NOTICE:

Before disconnecting the connector, check that it is not loose or disconnected.

(d) Measure the resistance of the circuit for the malfunctioning sensor (battery temperature sensor 0 to 2). Tester Connection: Tester Connection Battery Temperature Sensor y6-4 (TB0) - y6-10 (GB0) 0 y6-3 (TB1) - y6-9 (GB1) 1 y6-2 (TB2) - y6-8 (GB2) 2 Standard Resistance: Thermistor Temperature Condition Specified Condition 0 to 10°C (32 to 50°F) Power switch off 17.7 to 27.8 kΩ 10 to 20°C (50 to 68°F) Power switch off 12.0 to 18.2 kΩ 20 to 30°C (68 to 86°F) Power switch off 8.22 to 12.2 kΩ 30 to 40°C (86 to 104°F) Power switch off 5.74 to 8.41 kΩ 40 to 50°C (104 to 122°F) Power switch off 4.09 to 5.91 kΩ NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder.

*a Rear view of wire harness connector (to Battery Voltage Sensor)

(e) Disconnect the K17 battery voltage sensor connector.

NOTICE:

Before disconnecting the connector, check that it is not loose or disconnected.

(f) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition y6-4 (TB0) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-4 (TB0) - K17-5 (GND) Power switch off 10 kΩ or higher y6-10 (GB0) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-10 (GB0) - K17-5 (GND) Power switch off 10 kΩ or higher y6-3 (TB1) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-3 (TB1) - K17-5 (GND) Power switch off 10 kΩ or higher y6-9 (GB1) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-9 (GB1) - K17-5 (GND) Power switch off 10 kΩ or higher y6-2 (TB2) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-2 (TB2) - K17-5 (GND) Power switch off 10 kΩ or higher y6-8 (GB2) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-8 (GB2) - K17-5 (GND) Power switch off 10 kΩ or higher y6-1 (TC0) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-1 (TC0) - K17-5 (GND) Power switch off 10 kΩ or higher y6-7 (GC0) - K17-1 (IGCT) Power switch off 10 kΩ or higher y6-7 (GC0) - K17-5 (GND) Power switch off 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder.

*a Rear view of wire harness connector (to Battery Voltage Sensor)

(g) Reconnect the K17 and y6 battery voltage sensor connectors.

(h) Install the No. 1 hybrid battery exhaust duct.

OK

REPLACE BATTERY VOLTAGE SENSOR

NG

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(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 upper HV battery cover sub-assembly.

Click here

(c) Check the wire harness and connectors of the battery temperature sensor for abnormalities by sight and touch.

Specified Condition:

There are no open or short circuits in the wire harness and connectors. There are no short circuits to other wire harnesses.

(d) Install the upper HV battery cover sub-assembly.

OK

REPLACE HYBRID BATTERY THERMISTOR

NG

REPAIR HARNESS OR CONNECTOR (BATTERY TEMPERATURE SENSOR)

Hybrid/EV Battery Temperature Sensor "A" Circuit Short to Ground (P0A9B11,P0A9B15,P0AC511,P0AC515,P0ACA11,P0ACA15)

DESCRIPTION

The battery temperature sensors are provided at 3 locations of the HV battery. The resistance of the thermistor, which is built into each battery temperature sensor, varies in accordance with changes in the HV battery temperature. The lower the battery temperature, the higher the thermistor resistance. Conversely, the higher the temperature, the lower the resistance. The battery voltage sensor uses the battery temperature sensors to detect the HV battery temperature, and sends the detected value to the hybrid vehicle control ECU. Based on the results of this detection, the hybrid vehicle control ECU controls the blower fan. (The blower fan starts when the HV battery temperature rises above a predetermined level.)

Temperature Sensor Identification Cross Reference Table:

HINT:

Use the reference table above to determine which battery temperature sensor each DTC corresponds to. For example, sensor A in the DTC title column is battery temperature sensor 0. This sensor is displayed as Hybrid Battery Temperature 1 in the Data List.

HINT:

• After checking for the above DTCs, check the hybrid system Data List item "Hybrid Battery Temperature" using the Techstream.

  Temperature Displayed	Malfunction
  Below -45°C (-49°F)	Open or +B short circuit
  95°C (203°F) or more	GND short circuit

• If the vehicle as is left as is for 24 hours, the value of "Hybrid Battery Temperature" will be almost the same as the ambient temperature.

MONITOR DESCRIPTION

If a malfunction in the HV battery temperature sensor was detected, the hybrid vehicle control ECU will illuminate the MIL and set a DTC.

MONITOR STRATEGY

TYPICAL ENABLING CONDITIONS

TYPICAL MALFUNCTION THRESHOLDS

COMPONENT OPERATING RANGE

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 here

• When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

  Click here

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG) and turn the Techstream 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 Techstream on.
6. With power switch on (IG) and wait for 5 seconds or more.[*1]

   HINT:

   [*1]: Normal judgment procedure.

   The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

7. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
8. 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 or N/A, perform the normal judgment procedure again.

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A9B2A.

Click here

CAUTION / NOTICE / HINT

CAUTION:

• Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
  • Inspecting the high-voltage system
  • Disconnecting the low voltage connector of the inverter with converter assembly
  • Disconnecting the low voltage connector of the HV battery
• To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
• After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
• After removing 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.

  Click here

  

  *a	Without waiting for 10 minutes

  HINT:

  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

PROCEDURE

(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 for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

(a) Connect the Techstream to the DLC3.

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

(c) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Temperature 1 to 3.

(d) Read the Data List.

HINT:

A malfunctioning sensor (battery temperature sensor 0, 1 or 2) can be determined by comparing the output temperature of the 3 battery temperature sensors.

(e) Turn the power switch off.

NEXT

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 hybrid battery exhaust duct.

Click here

(c) Check the connections of the y6 battery voltage sensor connector. Click here OK: The connector is connected securely and there are no contact problems.

(d) Install the No. 1 hybrid battery exhaust duct.

NG

CONNECT SECURELY

OK

Click here

OK

REPLACE BATTERY VOLTAGE SENSOR

NG

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(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 upper HV battery cover sub-assembly.

Click here

(c) Check the wire harness and connectors of the battery temperature sensors for abnormalities by sight and touch.

Specified Condition:

There are no open or short circuits in the wire harness and connectors. There are no short circuits to other wire harnesses.

(d) Install the upper HV battery cover sub-assembly.

OK

REPLACE HYBRID BATTERY THERMISTOR

NG

REPAIR HARNESS OR CONNECTOR (BATTERY TEMPERATURE SENSOR)