Toyota Avalon (XX50): Motor/Generator Shutdown Signal Stuck Off (P321E9F). ECM/PCM Power Relay Sense Circuit Intermittent (P06881F). Hybrid/EV Battery Control System Over Temperature (P30004B)

Motor/Generator Shutdown Signal Stuck Off (P321E9F)

DTC SUMMARY

MALFUNCTION DESCRIPTION

The hybrid vehicle control ECU detects malfunctions which prevent the inverter with converter assembly emergency shutdown circuit (HSDN) from shutting down the hybrid control system. Detection is performed when the power switch is turned on (IG) and during the shutdown sequence when the power switch is turned off.

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

• Hybrid vehicle control ECU malfunction
• Connector or wire harness malfunction (between hybrid vehicle control ECU and inverter with converter assembly) malfunction
• Inverter with converter assembly malfunction

DESCRIPTION

The hybrid vehicle control ECU sends a block signal to the motor generator control ECU (MG ECU) to shutdown the power supply to the motor. When the system is not in the on (READY) state, it sends an HSDN (MG shutdown signal) signal from the hybrid vehicle control ECU to the motor generator control ECU (MG ECU) to check the function of the HV gate block. When a malfunction is detected in the HV gate block function, DTCs are stored.

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

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 (READY) and wait for 30 seconds or more.
6. Turn the power switch off and wait for 2 minutes or more.
7. Turn the power switch on (READY) and wait for 30 seconds or more.
8. Turn the power switch off and wait for 2 minutes or more.
9. Turn the power switch on (IG) and turn the Techstream on.
10. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
11. 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 driving pattern again.

WIRING DIAGRAM

Refer to the wiring diagram for the shut down signal circuit.

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

(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.

HINT:

• P321E9F 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.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

Click here

NG

CONNECT SECURELY

OK

Click here

B

CONNECT SECURELY

C

REPAIR OR REPLACE HARNESS OR CONNECTOR

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) Disconnect the A42 inverter with converter assembly connector.

(c) Disconnect the A24 hybrid vehicle control ECU connector.

(d) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition A42-22 (HSDN) - A24-12 (HSDN) Power switch off Below 1 Ω A42-22 (HSDN) or A24-12 (HSDN) - Body ground and other terminals Power switch off 10 kΩ or higher

*a Front view of wire harness connector (to Inverter with Converter Assembly) *b Rear view of wire harness connector (to Hybrid Vehicle Control ECU)

(e) Reconnect the A24 hybrid vehicle control ECU connector.

(f) Reconnect the A42 inverter with converter assembly connector.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

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) Disconnect the A42 inverter with converter assembly connector.

(c) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition A42-22 (HSDN) - A42-24 (GND1) Power switch off 2.65 to 3.55 kΩ NOTICE: Be sure not to damage or deform the terminal being inspected.

*a Component without harness connected (Inverter with Converter Assembly)

(d) Reconnect the A42 inverter with converter assembly connector.

OK

REPLACE HYBRID VEHICLE CONTROL ECU

NG

REPLACE INVERTER WITH CONVERTER ASSEMBLY

ECM/PCM Power Relay Sense Circuit Intermittent (P06881F)

DESCRIPTION

This DTC indicates that the hybrid vehicle control ECU detected an instantaneous interruption in +B power source voltage.

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

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 30 seconds or more.

   (If the DTC is not output, drive the vehicle on urban roads according to the freeze frame data item "Vehicle Speed" for approximately 5 minutes.)

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 driving pattern again.

WIRING DIAGRAM

PROCEDURE

(a) Confirm whether the auxiliary battery terminals have been disconnected recently.

B

GO TO STEP 5

A

(a) Turn the power switch on (READY) from off.

(b) Confirm that the master warning light illuminates.

NOTICE:

DTC P06881F may be stored after disconnecting and reconnecting the auxiliary battery terminals. If this happens, the DTC will not be output if the power switch is turned off and then on (READY) again. In this case, clear the DTCs to complete the inspection.

(c) Turn the power switch off.

B

END

A

(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 and record the DTCs and freeze frame data.

(e) Clear the DTCs and freeze frame data.

(f) Turn the power switch off and wait for 2 minutes 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) Check for DTCs.

(e) Turn the power switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

(a) Check the connection of the auxiliary battery terminal.

OK:

The terminal is connected securely and there is no contact problem.

NG

CONNECT SECURELY

OK

Click here

NG

CONNECT SECURELY

OK

(a) Remove the IGCT relay from the No. 3 relay block.

(b) Disconnect the A23 and A24 hybrid vehicle control ECU connectors.

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

Standard Resistance:

(d) Reconnect the A23 and A24 hybrid vehicle control ECU connectors.

(e) Reinstall the IGCT relay.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

(a) Check for intermittent problems.

Click here

(1) Check the connection and terminal contact pressure of the connectors and wire harnesses between the hybrid vehicle control ECU and the No. 3 relay block.

(2) When the power switch is on (READY), jiggle the connectors and wire harnesses between the hybrid vehicle control ECU and the No. 3 relay block.

A

REPLACE HYBRID VEHICLE CONTROL ECU

B

REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

Hybrid/EV Battery Control System Over Temperature (P30004B)

DESCRIPTION

The hybrid vehicle control ECU monitors its internal operation and detects the following malfunction.

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

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", "Hybrid Battery Temperature 1 to 3", "Hybrid Battery Cooling Fan Intake Air Temperature 1", "Ambient Temperature" and "Hybrid Battery Current".
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 driving pattern 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.

  *a	Without waiting for 10 minutes

  Click here

  HINT:

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

• 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

• Before returning the HV battery, make sure to perform a recovery inspection.
• Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HV battery.

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) Check the HV battery cooling system intake port for blockage. HINT: If anything is blocking the HV battery cooling system intake port, remove it.

*a Intake Port

(b) Clean the No. 1 HV battery intake filter.

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 / Trouble Codes.

(d) Read the freeze frame data of DTC P30004B.

NOTICE:

Although freeze frame data is recorded before and after a DTC is stored, for this step it is only necessary to read the freeze frame data recorded before "0s" (when the DTC was stored).

(e) Turn the power switch off.

B

GO TO STEP 7

A

(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 the freeze frame data of DTC P30004B.

NOTICE:

Although freeze frame data is recorded before and after a DTC is stored, for this step it is only necessary to read the freeze frame data recorded at "0s" (when the DTC was stored).

(e) Turn the power switch off.

B

GO TO STEP 8

A

(a) Apply the parking brake and secure the wheels using chocks.

(b) Connect the Techstream to the DLC3.

(c) Turn the power switch on (READY).

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

(e) According to the display on the Techstream, read the Data List and check that the value of each "Hybrid Battery Temperature 1 to 3" is 40°C (104°F) or less.

HINT:

If the value of any of "Hybrid Battery Temperature 1 to 3" is more than 40°C (104°F), turn the power switch off and wait until the values to decrease to 40°C (104°F) or less before continuing this procedure.

(f) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Block 1, 2, 9, 10, 11 Voltage.

(g) According to the display on the Techstream, read the Data List and check the value of each "Hybrid Battery Block 1, 2, 9, 10 and 11 Voltage" with the power switch on (IG).

(h) Turn the power switch off.

B

GO TO STEP 8

A

(a) Apply the parking brake and secure the wheels using chocks.

(b) Connect the Techstream to the DLC3.

(c) Turn the power switch on (READY).

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

(e) According to the display on the Techstream, read the Data List and check that the value of each "Hybrid Battery Temperature 1 to 3" is 40°C (104°F) or less.

HINT:

If the value of any of "Hybrid Battery Temperature 1 to 3" is more than 40°C (104°F), turn the power switch off and wait until the values to decrease to 40°C (104°F) or less before continuing this procedure.

(f) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Block 3 to 8 Voltage.

(g) According to the display on the Techstream, read the Data List and check the value of each "Hybrid Battery Block 3 to 8 Voltage" with the power switch on (IG).

(h) Turn the power switch off.

A

END

B

GO TO STEP 8

Click here

NEXT

REPLACE HV BATTERY

Click here

NEXT

REPLACE HV BATTERY