DTC Troubleshooting
DTC P0AE1 (62): Bypass Contactor MalfunctionCAUTION: Be careful not to touch high voltage cables and parts when you turn the battery module switch ON, or while the battery module switch is ON.
NOTE: Before you troubleshoot, record all freeze data, and review the general troubleshooting information.
1. Turn the ignition switch ON (II).
2. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0A78 (32) or P1570 (66) indicated?
YES - Do the troubleshooting for DTC P0A78 (32), or DTC P1570 (66).
NO - Go to step 3.
3. Clear the DTC with the HDS.
4. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0AE1 (62) indicated?
YES - Go to step 5.
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the junctions board, the DC-DC converter, the MCM, and the BCM module.
5. Turn the ignition switch OFF.
6. Turn the battery module switch OFF.
7. Remove the IPU lid.
8. Check the busbars (A) on the DC-DC converter, and the MCM for bending and for damaged insulation.
Are the busbars OK?
YES - Go to step 9.
NO - Replace the busbar, then go to step 29.
9. Clear the DTC with the HDS.
10. Turn the battery module switch ON
NOTE: Put on gloves to protect your hands from electrical shock.
11. Turn the ignition switch ON (II), and listen for a clicking sound from the relay inside the battery module.
Is there a clicking sound?
YES - Go to step 12.
NO - Go to step 19.
12. Clear the DTC with the HDS.
13. Turn the ignition switch OFF.
14. Turn the ignition switch ON (II), then measure voltage between the battery module terminals (A).
Is there momentary voltage when the ignition switch is turned on?
YES - Go to step 15.
NO - Replace the battery module, then go to step 30.
15. Turn the ignition switch OFF.
16. Remove the DC-DC converter.
17. Clear the DTC with the HDS.
18. Check for Temporary DTCs or DTCs with the HDS.
Is DTC POAE1 (62) indicated?
YES - Go to step 42.
NO - Replace the DC-DC converter, then go to step 30.
19. Disconnect BCM module connector A (40P).
20. Measure resistance between BCM module 40P connector terminals No. 13 and No. 28.
Is there 92.7 - 113.3 ohms?
YES - GO to step 26.
NO - Go to step 21.
21. Measure resistance between BCM module 40P connector terminals No. 13 and No. 28.
Is it lower (NO) or higher (YES) than a 92.7 - 113.3 ohms?
YES - Go to step 24.
NO - Go to step 22.
22. Disconnect the junction board 12P connector.
23. Check for continuity between BCM module connector terminals A13 and A28.
Is there continuity?
YES - Repair short in the wire between the junction board 12P connector and the BCM module (No. 13, No. 28), then go to step 30.
NO - Replace the battery module, then go to step 30.
24. Disconnect the junction board 12P connector.
25. Check for continuity between these terminals:
- BCM module connector terminal A13 and junction board 12P connector terminal No. 7.
- BCM module connector terminal A28 and junction board 12P connector terminal No. 2.
Is there continuity?
YES - Replace the battery module, then go to step 30.
NO - Repair open in the wire between the junction board 12P connector and the BCM module (A13, A28), then go to step 30.
26. Check for continuity between BCM module connector terminal A13 and body ground.
Is there continuity?
YES - Go to step 27.
NO - Check for poor connections or loose terminals at the junction board and the BCM module, then go to step 36.
27. Disconnect the junction board l2P-connector.
28. Check for continuity between BCM module connector terminal A13 and body ground.
Is there continuity?
YES - Repair short in the wire between the junction board 12P connector and the BCM module (A13), then go to step 30.
NO - Replace the battery module.
29. Turn the ignition switch OFF.
30. Reconnect all connectors.
31. Reinstall the IPU lid, then turn the battery module switch ON.
32. Turn the ignition switch ON (II).
33. Clear the DTC with the HDS.
34. Check for Temporary DTCs or DTCs with the HDS.
Is DTC POAE (62) indicated?
YES - Check for poor connections or loose terminals at the high voltage connector, the bypass contactor, the DC-DC converter, the MCM, and the BCM module, then go to step 1.
NO - Go to step 35.
35. Monitor the OBD STATUS for DTC P0AE1 (62) in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - Troubleshooting is completed. If any other Temporary DTCs or DTCs were indicated in step 34, go to the indicated DTC's troubleshooting.
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the high voltage connector, the bypass contactor, the DC-DC converter, the MCM, and the BCM module, then go to step 1. If the screen indicates NOT COMPLETED, keep the ignition switch ON (II) until a result comes on.
36. Reconnect all connectors.
37. Reinstall the IPU lid, then turn the battery module switch ON.
38. Update the BCM module if it does not have the latest software, or substitute a known-good BCM module.
39. Clear the DTC with the HDS.
40. Check for Temporary DTCs or DTCs with the HDS.
Is DTC POAE7 (62) indicated?
YES - Check for poor connections or loose terminals at the high voltage connector, the bypass contactor, the DC-DC converter, the MCM, and the BCM module. If the BCM module was updated, substitute a known-good BCM module, then recheck. If the BCM module was substituted, go to step 42.
NO - Go to step 41.
41. Monitor the OBD STATUS for DTC P0AE1 (62) in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - If the BCM module was updated, troubleshooting is complete. If the BCM module was substituted, replace the original BCM module. If any other Temporary DTCs or DTCs were indicated in step 40, go to the indicated DTC's troubleshooting.
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the high voltage connector, the bypass contactor, the DC-DC converter, the MCM, and the BCM module. If the BCM module was updated, substitute a known-good BCM module, then recheck. If the BCM module was substituted, go to step 42. If the screen indicates NOT COMPLETED, keep the ignition switch ON (II) until a result comes on.
42. Update the MCM if it does not have the latest software, or substitute a known-good MCM.
43. Clear the DTC with the HDS
44. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0AE1 (62) indicated?
YES - Check for poor connections or loose terminals at the high voltage connector, the bypass contactor, the DC-DC converter, the MCM, and the BCM module. If the MCM was updated, substitute a known-good MCM, then recheck. If the MCM was substituted, go to step 1.
NO - Go to step 45.
45. Monitor the OBD STATUS for DTC P0AE1 (62) in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - If the MCM was updated, troubleshooting is complete. If the MCM was substituted, replace the original MCM. If any other Temporary DTCs or DTCs were indicated in step 44, go to the indicated DTC's troubleshooting.
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the high voltage connector, the bypass contactor, the DC-DC converter, the MCM, and the BCM module. If the MCM was updated, substitute a known-good MCM, then recheck. If the MCM was substituted, go to step 1. If the screen indicates NOT COMPLETED, keep the ignition switch ON (II) until a result comes on.