Toyota Avalon (XX50): Hybrid/EV Battery Sensor Module Internal Electronic Failure (P0AFC49). Hybrid/EV Battery Sensor Module Signal Compare Failure (P0AFC62,...,P308A13). Hybrid/EV Battery "A" Voltage Sensor Voltage Out of

Hybrid/EV Battery Sensor Module Internal Electronic Failure (P0AFC49)

DTC SUMMARY

MALFUNCTION DESCRIPTION

When the hybrid control system is activated, the hybrid vehicle control ECU checks the power supply voltage of the battery voltage sensor and detects malfunction.

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

• Battery voltage sensor malfunction

• Battery voltage sensor malfunction
• Low voltage wire harness malfunction

DESCRIPTION

When the hybrid control system is activated, the hybrid vehicle control ECU checks the power supply voltage of the battery voltage sensor.

MONITOR DESCRIPTION

When the hybrid vehicle control ECU detects a low power supply voltage for the battery voltage sensor while pre-charge is occurring, it determines that there is a malfunction in the battery voltage sensor circuit. If the hybrid vehicle control ECU detects a malfunction, it will illuminate the MIL and store 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. Turn the power switch on (READY) and wait for 15 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 P0AFC00.

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

  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

Click here

OK

REPLACE BATTERY VOLTAGE SENSOR

NG

Click here

OK

REPAIR OR REPLACE HARNESS OR CONNECTOR (IGCT NO. 2 FUSE - BATTERY VOLTAGE SENSOR)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY VOLTAGE SENSOR - BODY GROUND)

Hybrid/EV Battery Sensor Module Signal Compare Failure (P0AFC62,...,P308A13)

DESCRIPTION

Refer to the description for DTC P1AC000.

Click here

HINT:

Hybrid Battery Block 1 to 11 Voltage values smaller than 2.0 V may not be shown in the Data List because a fail-safe value is substituted.

HINT:

• *1: Under normal conditions, the values of Hybrid Battery Block 1, 2, 9, 10 and 11 Voltage will be approximately 16 V and Hybrid Battery Block 3, 4, 5, 6, 7 and 8 Voltage will be approximately 32 V.
• If there is a short or open in a battery block voltage detection line, the value of Hybrid Battery Block Voltage for the corresponding battery block will be lower than 8 V.

MONITOR DESCRIPTION

If the battery voltage sensor detects a voltage drop in a battery block, the hybrid vehicle control ECU will illuminate the MIL and store 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 20 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.

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

• Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

  If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

• When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

  *a	Dealer
  *b	Battery Collection Agent

  • Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.
• After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.

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 and record any HV system DTCs and freeze frame data.

(e) Read output DTCs.

(f) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

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) 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

NEXT

(a) Connect the Techstream to the DLC3.

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

(c) Enter the following menus: Powertrain / Hybrid Control / Clear DTCs.

(d) Clear the DTCs and freeze frame data.

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

(f) Turn the power switch on (IG) and wait for 20 seconds or more.

NEXT

(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) Read output DTCs.

(e) Turn the power switch off.

A

END

B

REPLACE HV BATTERY

Hybrid/EV Battery "A" Voltage Sensor Voltage Out of Range (P0B231C)

DTC SUMMARY

MALFUNCTION DESCRIPTION

The hybrid vehicle control ECU detects a VB sensor malfunction.

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

• Battery voltage sensor malfunction
• Communication (wire harness) malfunction

• HV battery malfunction

DESCRIPTION

The battery voltage sensor sends HV battery voltage information to the hybrid vehicle control ECU via serial communication.

MONITOR DESCRIPTION

The hybrid vehicle control ECU calculates the differences between the received HV battery voltage, boost converter voltage, and inverter voltage. If the differences exceed prescribed values, the hybrid vehicle control ECU determines that there is a malfunction in the battery voltage sensor circuit. If the hybrid vehicle control ECU detects this malfunction, it will illuminate the MIL and store 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. Turn the power switch on (READY). [*1]
7. With the shift lever in D, depress both the accelerator pedal and brake pedal at the same time to raise the "Hybrid Battery SOC" to a sufficient level. [*2]
8. Move the shift lever to P, check that the engine is stopped and move the shift lever to N. [*3]
9. Set the A/C for maximum cooling. [*4]
10. Leave the vehicle for a few minutes. [*5]

    HINT:

    • After the repair if "VL-Voltage before Boosting" and the "Hybrid Battery Voltage" are approximately the same when the power switch is turned on (READY) with shift lever in P and the accelerator pedal not depressed, the condition is judged as normal.
    • [*1] to [*5] : Normal judgment procedure.

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

11. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
12. 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.

CAUTION / NOTICE / HINT

NOTICE:

Performing the check procedures for a long time with shift lever in N may cause DTC P300000 to be set.

HINT:

• If the battery voltage sensor has been replaced, it is necessary to confirm the voltage of each battery block. With power switch on (READY), shift lever in P, the engine stopped and the HV battery voltage 224 V or more, check the value of Data List items "Hybrid Battery Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting". When the system is normal, the values of "Hybrid Battery Voltage", "VL-Voltage before Boosting", and "VH-Voltage after Boosting" should be almost equal. If the difference between each value is more than the voltages specified below, the system is malfunctioning.

  Inspection Voltage	Maximum Voltage Difference
  Difference between "Hybrid Battery Voltage" and "VL-Voltage before Boosting"	39 V
  Difference between "Hybrid Battery Voltage" and "VH-Voltage after Boosting"	60 V
  Difference between "VL-Voltage before Boosting" and "VH-Voltage after Boosting"	76 V

PROCEDURE

(a) Connect the Techstream to the DLC3.

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

(c) Enter the following menus: Powertrain / Hybrid Control and Motor Generator / Trouble Codes.

(d) Check for DTCs.

HINT:

• P0B231C may be output as a result of the malfunction indicated by the DTCs above.
  1. The chart above is listed in inspection order of priority.
  2. 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

REPLACE BATTERY VOLTAGE SENSOR

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

C

GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM)