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DTC P0D52-406: On-Board Charger Output Current Sensor Circuit Range / Performance [08/2014 - ]: Procedure

  1. CHECK DTC OUTPUT (PLUG-IN CONTROL) 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Plug-in Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      Only P0D52-406 is output or P0D52-406 and DTCs other than the ones in the table below are also output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P060B-134, 135, 570 Internal Control Module A/D Processing Performance
      P0D52-407 On-Board Charger Output Current Sensor Circuit Range / Performance
      P0D53-408 On-Board Charger Output Current Sensor Circuit Low
      P0D54-409 On-Board Charger Output Current Sensor Circuit High

      HINT: 

      P0D52-406 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

    5. Turn the power switch off.

    B → See step   16 

    A: Go to next step 

  2. CHECK PLUGIN CHARGE CONTROL ECU ASSEMBLY (ICHG SENSOR VOLTAGE) 
    NOTE:

    If the power switch is turned on (IG) during plug-in charging, the power switch will be turned off automatically after several tens of seconds.

    1. Connect the Techstream to the DLC3.
    2. Start plug-in charging the vehicle.
    3. Turn the power switch on (IG).
    4. Enter the following menus: Powertrain / Plug-in Control / Data List.
    5. Select "On-Board Charger Current Sensor Voltage" in the Data List.
      Tester Display Measurement Item/Range
      On-Board Charger Current Sensor Voltage Output voltage of the ICHG sensor based on the amperage output from the electric vehicle charger assembly/
      Min.: 0.00 V, Max.: 79.99 V
    6. Measure the voltage according to the value(s) in the table below.
      GTY341213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition
      z12-24 (ICHG) - z12-21 (CGND) During plug-in charging
      TEXT IN ILLUSTRATION

      *a Component with harness connected
      (Plugin Charge Control ECU Assembly)
    7. While plug-in charging the vehicle, compare the Data List item "On-Board Charger Current Sensor Voltage" with actual measurement of ICHG terminal voltage.

      Result

      Result Proceed to
      Difference between "On-Board Charger Current Sensor Voltage" and actual measurement of ICHG terminal voltage is less than 1 V. A
      Difference between "On-Board Charger Current Sensor Voltage" and actual measurement of ICHG terminal voltage is 1 V or more. B
    8. Turn the power switch off.
    9. Stop plug-in charging the vehicle.

    B → See step   17 

    A: Go to next step 

  3. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY (CHECK FOR OPEN (CGND CIRCUIT)) See step   2 

    NG → See step   18 

    OK: Go to next step 

  4. CHECK PLUGIN CHARGE CONTROL ECU ASSEMBLY (CHECK WAVEFORM (CHPW)) See step   7 

    B → See step   17 

    A: Go to next step 

  5. CHECK PLUGIN CHARGE CONTROL ECU ASSEMBLY (CHECK WAVEFORM (ILMT)) See step   6 

    B → See step   17 

    A: Go to next step 

  6. CHECK ELECTRIC VEHICLE CHARGER CABLE (CHARGING INLET - ELECTRIC VEHICLE CHARGER WIRE CONNECTOR) See step   9 

    NG → See step   19 

    OK: Go to next step 

  7. CHECK ELECTRIC VEHICLE CHARGER WIRE (ELECTRIC VEHICLE CHARGER WIRE CONNECTOR - ELECTRIC VEHICLE CHARGER ASSEMBLY) See step   10 

    NG → See step   20 

    OK: Go to next step 

  8. CHECK ELECTRIC VEHICLE CHARGER WIRE (ELECTRIC VEHICLE CHARGER ASSEMBLY - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY) See step   11 

    NG → See step   20 

    OK: Go to next step 

  9. CHECK ELECTRIC VEHICLE FUSE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      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.

    2. Remove the No. 1 hybrid vehicle battery shield panel. Refer to REMOVAL [08/2014 - ] - Step 29 .
    3. Measure the resistance according to the value(s) in the table below.
      GTY441274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      Electric vehicle fuse Power switch off Below 1 Ω
    4. Install the No. 1 hybrid vehicle battery shield panel.

    NG → See step   21 

    OK: Go to next step 

  10. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (CHRB, CHRG) See step   8 

    NG → See step   15 

    OK: Go to next step 

  11. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB). Refer to  PROCEDURE - Step 18 

    NG → See step   22 

    OK: Go to next step 

  12. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG). Refer to  PROCEDURE - Step 19 

    NG → See step   22 

    OK: Go to next step 

  13. CHECK NO. 2 HYBRID VEHICLE BATTERY PACK CABLE See step   16 

    NG → See step   23 

    OK: Go to next step 

  14. CHECK NO. 1 HYBRID VEHICLE BATTERY PACK CABLE See step   17 

    NG → See step   24 

    OK → See step   18 

  15. CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY) See step   10 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   22 

  16. GO TO DTC CHART (PLUG-IN CHARGE CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2014 - ] 
  17. REPLACE PLUGIN CHARGE CONTROL ECU ASSEMBLY. Refer to  COMPONENTS [08/2014 - ] 
  18. REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY. Refer to  COMPONENTS [08/2014 - ] 
  19. REPLACE ELECTRIC VEHICLE CHARGER CABLE. Refer to  COMPONENTS [08/2014 - ] 
  20. REPLACE ELECTRIC VEHICLE CHARGER WIRE. Refer to  COMPONENTS [08/2014 - ] 
  21. REPLACE ELECTRIC VEHICLE FUSE. Refer to  COMPONENTS [08/2014 - ] 
  22. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  COMPONENTS [08/2014 - ] 
  23. REPLACE NO. 2 HYBRID VEHICLE BATTERY PACK CABLE. Refer to  COMPONENTS [08/2014 - ] 
  24. REPLACE NO. 1 HYBRID VEHICLE BATTERY PACK CABLE. Refer to  COMPONENTS [08/2014 - ] 
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