DTC P0D67-844: On-Board Charger Malfunction [08/2014 - ]: Procedure

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Check if DTCs are output.

   Result

   Result	Proceed to
   Only P0D67-844 is output or P0D67-844 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
   P0A1D-144, 148, 162, 721, 722, 723, 787, 818, 821, 823	Hybrid Powertrain Control Module
   P0ADC-226	Hybrid Battery Positive Contactor Control Circuit High
   P0AE0-228	Hybrid Battery Negative Contactor Control Circuit High
   P2511-149	HV CPU Power Relay Sense Circuit Intermittent No Continuity
   P3004-131, 803	Power Cable Malfunction
   U019B-440	Lost Communication with Battery Charger Control Module

   HINT: 

   P0D67-844 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   5 

A: Go to next step 

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 P0D67-844 is output or P0D67-844 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
   P0D20-422	Charger Relay Stuck Open
   P0D4D-404	On-Board Charger Output Voltage Sensor Circuit Range / Performance
   P2511-441	Reset Detected
   P321D-644	Charging System Voltage High
   U0293-439, 449	Lost Communication with Hybrid Powertrain Control Module

   HINT: 

   P0D67-844 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   6 

A: Go to next step 

HINT: 

• Check with the customer if the 120 V power used for plug-in charging was supplied by a power company.
• If the electric vehicle charger cable assembly that was used to plug-in charge the vehicle is available, perform a reproduction test using it and a known good 120 V outlet as follows. This allows the electric vehicle charger cable assembly to be determined as OK or NG when the vehicle is not malfunctioning.

1. Plug-in charge the vehicle using a known good 120 V outlet.
   1. Connect the Techstream to the DLC3.
   2. Turn the power switch on (IG).
   3. Clear DTC.
   4. Enter the following menus: Powertrain / Plug-in Control / Data List.
   5. Check that "State of Charge (All Bat)" shows 70% or less.
   6. Turn the power switch off.
   7. Connect the electric vehicle charger cable assembly and fully charge the vehicle. Check that plug-in charge control system DTCs are not output.

      Result

      Result	Proceed to
      DTCs are output or plug-in charge cannot be completed.	A
      DTCs are not output and plug-in charge has been completed.	B

      HINT: 

      • This DTC could be output due to rapid fluctuation of AC input voltage.
      • As the voltage fluctuates quickly, it is difficult to check the plug-in charge state by reading the freeze frame data or Data List item "On-Board Charger Input Voltage".

B → END (NO MALFUNCTION IN VEHICLE) 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Connect an oscilloscope between the plugin charge control ECU assembly terminals specified in the table below.
3. Turn the power switch on (IG).
4. Enter the following menus: Powertrain / Plug-in Control / Data List
5. Select "Charger State Pulse Duty Ratio" in the Data List.

   Tester Display	Measurement Item/Range
   Charger State Pulse Duty Ratio	Electric vehicle charger assembly charging status indicated by duty/ Min.: 0.0 %, Max.: 100.0%

6. Measure the waveform.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Item	Contents
   Tester Connection	z12-29 (CHST) - S31-14 (E1)
   Equipment Setting	5 V/DIV., 50 ms/DIV.
   Condition	Power switch on (IG)

   TEXT IN ILLUSTRATION
   
   

   *a	Component with harness connected (Plugin Charge Control ECU Assembly)

7. Calculate duty (%) based on the CHST waveform.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a	Reference diagram for duty calculation

   HINT: 

   Calculate duty (%) using the following formula: Duty (%) = T1 / T2 x 100 (%)

8. Compare the Data List item "Charger State Pulse Duty Ratio" with the duty (%) calculated based on CHST waveform.

   Result

   Result	Proceed to
   The difference between "Charger State Pulse Duty Ratio" and the duty (%) calculated based on CHST waveform is less than 20 %.	A
   The difference between "Charger State Pulse Duty Ratio" and the duty (%) calculated based on CHST waveform is 20 % or more.	B

9. Turn the power switch off.

B → See step   8 

A → See step   7