Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001H3JW
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [02/2019 - 06/2020]
Title: HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE BATTERY): P1C8549; High Voltage Power Resource Internal Electronic Failure; 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]

DTC

P1C8549

High Voltage Power Resource Internal Electronic Failure

DESCRIPTION

The hybrid vehicle control ECU assembly monitors the system internal operation, and it will store a DTC and perform fail-safe control if it detects the following malfunction.

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P1C8549

High Voltage Power Resource Internal Electronic Failure

Battery overcurrent or overload current occurs due to a malfunction in the high-voltage circuit between the hybrid system, battery and inverter.

(1 trip detection logic)
  • Hybrid vehicle control ECU assembly
  • Battery voltage sensor
  • HV battery junction block assembly
  • Wire harness or connector

Does not come on

Master Warning:

Comes on

Related Data List

DTC No.

Data List

P1C8549
  • Hybrid Battery Current
  • Hybrid Battery Voltage
  • VL-Voltage before Boosting
  • VH-Voltage after Boosting

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 2019 - 2024 MY RAV4 HV [02/2019 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE BATTERY): UTILITY

  1. Connect the Techstream to the DLC3.
  2. Turn the ignition switch to ON and turn the Techstream on.
  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  4. Turn the ignition switch off and wait for 2 minutes or more.
  5. Turn the ignition switch to ON and turn the Techstream on.
  6. Drive the vehicle for approximately 10 minutes according to the freeze frame data items "Vehicle Speed", "Accelerator Position" 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, perform driving pattern again.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

CAUTION:

  • Before the following operations are conducted, take precautions to prevent electric shock by turning the ignition 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 2019 - 2024 MY RAV4 HV [02/2019 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE BATTERY): PRECAUTION

    *a

    Without waiting for 10 minutes

    HINT:

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

NOTICE:

  • After turning the ignition 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 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

  • If the DTCs are cleared or the cable is disconnected and reconnected to the negative (-) auxiliary battery terminal before performing repairs, turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the ignition switch to ON (READY).

PROCEDURE

1.

CHECK DTC OUTPUT (HYBRID CONTROL)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

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

(d) Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes

Result

Proceed to

P1C8549 only is output.

A

DTCs other than P1C8549 is also output.

B

(e) Turn the ignition switch off.

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

A

2.

READ VALUE USING TECHSTREAM (HYBRID BATTERY CURRENT)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid Battery Current.

Powertrain > Hybrid Control > Data List

Tester Display

Hybrid Battery Current

(d) Read the Data List.

Result

Proceed to

The value of Hybrid Battery Current is between -4 A and 4 A

A

Other than above

B

(e) Turn the ignition switch off.

A

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HYBRID VEHICLE CONTROL ECU: REMOVAL 2020 MY RAV4 HV [10/2019 - 08/2020]; HYBRID / BATTERY CONTROL: HYBRID VEHICLE CONTROL ECU: REMOVAL

B

3.

CHECK HARNESS AND CONNECTOR (BATTERY VOLTAGE SENSOR - HV BATTERY JUNCTION BLOCK ASSEMBLY)

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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Remove the No. 1 HV battery cover panel RH.

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+ 2020 MY RAV4 HV [10/2019 - 06/2020]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

(c) Disconnect the z20 battery current sensor connector.

NOTICE:

Before disconnecting the connector, check that it is not loose or disconnected.

(d) Remove the No. 1 hybrid battery exhaust duct.

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+ 2020 MY RAV4 HV [10/2019 - 06/2020]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

(e) Disconnect the z19 battery voltage sensor connector.

NOTICE:

Before disconnecting the connector, check that it is not loose or disconnected.

(f) Measure the resistance according to the value(s) in the tables below.

Standard Resistance (Check for Open):

Tester Connection

Condition

Specified Condition

z19-5 (IB0) - z20-4 (IB0)

Ignition switch off

Below 1 Ω

z19-12 (GIB) - z20-3 (GIB)

Ignition switch off

Below 1 Ω

z19-6 (VIB) - z20-1 (VIB)

Ignition switch off

Below 1 Ω

Standard Resistance (Check for Short):

Tester Connection

Condition

Specified Condition

z19-5 (IB0) or z20-4 (IB0) - Body ground and other terminals

Ignition switch off

10 kΩ or higher

z19-12 (GIB) or z20-3 (GIB) - Body ground and other terminals

Ignition switch off

10 kΩ or higher

z19-6 (VIB) or z20-1 (VIB) - Body ground and other terminals

Ignition switch off

10 kΩ or higher

HINT:

As the battery harness is not available as a supply part, if the harness cannot be repaired, replace the HV battery.

*a

Rear view of wire harness connector

(to Battery Voltage Sensor)

*b

Front view of wire harness connector

(to HV Battery Junction Block Assembly (Battery Current Sensor))

(g) Reconnect the z19 battery voltage sensor connector.

(h) Install the No. 1 hybrid battery exhaust duct.

(i) Reconnect the z20 battery current sensor connector.

(j) Install the No. 1 HV battery cover panel RH.

NG

REPLACE HYBRID BATTERY THERMISTOR 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HV BATTERY THERMISTOR: REMOVAL 2020 MY RAV4 HV [10/2019 - 08/2020]; HYBRID / BATTERY CONTROL: HV BATTERY THERMISTOR: REMOVAL

OK

4.

CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (BATTERY CURRENT SENSOR (IB))

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 ignition switch to 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 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+ 2020 MY RAV4 HV [10/2019 - 06/2020]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

(c) Connect the cable to the negative (-) auxiliary battery terminal.

(d) Turn the ignition switch to ON.

(e) Using a Toyota electrical tester set to 40 V, measure the VIB voltage according to the value(s) in the table below.

Tester Connection

Tester Connection

z19-6 (VIB) - z19-12 (GIB)

Ignition switch ON

NOTICE:

  • Turning the ignition switch to ON with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.
  • Be sure to set the Toyota electrical tester to 40 V when performing this test.

*a

Component with harness connected

(Battery Voltage Sensor)

(f) Using a Toyota electrical tester set to 4 V, measure the IB0 voltage according to the value(s) in the table below.

Tester Connection

Tester Connection

z19-5(IB0) - z19-12(GIB)

Ignition switch ON

NOTICE:

Be sure to set the Toyota electrical tester to 4 V when performing this test.

*a

Component with harness connected

(Battery Voltage Sensor)

(g) Compare the measured values of the IB0 terminal voltage and VIB terminal voltage using the following formula:

IB0 voltage - VIB Voltage / 2 = less than 0.081 V

IB0 voltage - VIB Voltage / 2 = -0.081 V or higher

Result

Proceed to

Within the specified range above

A

Other than above

B

(h) Turn the ignition switch off.

(i) Disconnect the cable from the negative (-) auxiliary battery terminal.

(j) Install the No. 1 hybrid battery exhaust duct.

HINT:

When the ignition switch is ON, the actual current will be approximately 0 A. The following graph shows the relation of the actual output voltage between the battery current sensor terminal IB0 and the actual current used for DTC judgment.

B

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL 2020 MY RAV4 HV [10/2019 - 06/2020]; HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL

A

5.

REPLACE BATTERY VOLTAGE SENSOR

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: BATTERY VOLTAGE SENSOR: REMOVAL 2020 MY RAV4 HV [10/2019 - 08/2020]; HYBRID / BATTERY CONTROL: BATTERY VOLTAGE SENSOR: REMOVAL

NEXT

6.

SIMULATION TEST

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

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

(d) Clear the DTCs and freeze frame data.

Powertrain > Hybrid Control > Clear DTCs

(e) Drive the vehicle on urban roads for approximately 10 minutes.

(f) Turn the ignition switch off and wait for 2 minutes or more.

(g) Turn the ignition switch to ON and wait for 30 seconds or more.

NEXT

7.

RECONFIRM DTC OUTPUT (HYBRID CONTROL)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

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

(d) Read output DTCs.

Powertrain > Hybrid Control > Trouble Codes

Result

Proceed to

DTCs are not output

A

P1C8549 is output

B

(e) Turn the ignition switch off.

A

END
B

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL 2020 MY RAV4 HV [10/2019 - 06/2020]; HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL