Reversed polarity...What a mess

[maciekmaciek19]

Hello.

Long story short. The top Battery pack got connected wrong and probably even shorted to ground in the process as burn marks visible on the metal Battery cage.

After P3004/131 high voltage power resource error I had the Inverter replaced and now getting these two instead.

P0A09 - DC/DC Converter Status Circuit Low Input

P0AE6 - Hybrid Battery Precharge Contactor Control Circuit Low

Also the hybrid battery fan comes on high speed the second I press the start button which I don't recall was the case back when the car was running OK.

I suppose it's probably good news as the Inveter swap seems to have made some difference but there is something else that needs doing.

All fuses are OK in all 5 fuse boxes

Battery in the boot fully charged

I suspect the HV Power Management ECU is fried but I am not sure which box that actually is.

Can anybody help me narrow it down?

[flash22]

I would agree with the power management ecu

give me a while and I will pull some diagrams

[maciekmaciek19]

That would be great mate. I've failed looking for a part number but already ordered the box that sits underneath the driver's seat. 

Not sure if that is the power management one but seems to be connected to a big terminal that seems to be carrying some serious voltage. 

[flash22]

Module under the driver's seat is the 100v inverter iirc

eg. https://www.ebay.co.uk/itm/254758131768

[flash22]

Doesn't look like there is a power manglement ecu, only conclusion i can come to is it part of the HV control ECU,  AHR20, 89981-28050

is it possible that it hasn't been plugged in to the DC-DC convertor ?

 

I'm hunting for wiring information but not having much luck

[maciekmaciek19]

The inverter converter unit under the hood is all connected up. 

I've got this on order now. Not sure this is relevant? 

https://www.ebay.co.uk/itm/403233132327?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=4oKqFtubSLG&sssrc=2349624&ssuid=&var=&widget_ver=artemis&media=COPY

 

I suppose there is a chance the inverter converter assembly i bought is also faulty... 

[flash22]

That is a HV convertor, not sure if it's the DC-DC convertor - it has power in from the pack and an output with a 6 pin control plug, a bit stuffed without diagrams tbh

[maciekmaciek19]

Yeah it's really hard to find good i for in this car. 

Will swap that convertor in a couple of days and see what happens. 

If no change I'll get another inverter converter assembly and swap that again. 

[flash22]

a bit more digging show 2 codes for P0A09

P0A09-265

P0A09-591

 

[maciekmaciek19]

Yes and it looks like the troubleshooting for one of them requires the HV Control ECU to be accessed.

I have not found that part on my Estima anywhere... Unless it is in fact the two multipin plug black box located just above the engine. It seems to control the immobiliser functions by the way as swapping that gave me a immo error codes. This is the one:

https://www.ebay.co.uk/itm/324831443601

The only two multi pin/multi plug boxes I have found are the ones with small fuse boxes integrated (under dash left and right side) An eBay search suggests this is a body control module:

https://www.ebay.co.uk/itm/403839436639?var=0&mkevt=1&mkcid=1&mkrid=710-53481-19255-0&campid=5338749392&toolid=20006&_trkparms=ispr%3D1&amdata=enc%3A1dPrzBRsxS3iVV5HhELd1ZA70&customid=GB_131090_403839436639.139652105680~1658855848070-g_Cj0KCQjwyt-ZBhCNARIsAKH1176YqoPLMytOnCV_RIjrPCQxuzpGFR5Bb-VF5hsUuCygGTH85wCLW6kaAtgNEALw_wcB

 

Also replacing the HV Convertor made no difference. 

https://www.ebay.co.uk/itm/403754983025?epid=4031006425&hash=item5e01ac1e71:g:wEQAAOSwsaliw1jD&amdata=enc%3AAQAHAAAA4LxL2qc8wWKk0jWlTwLlSNN4M9EMjIpvq5SWaZDqM4WQvCaXoISIfATRLWBsE%2B75e6sy58ha%2BKSqvjjtAEgkY7fqFXFviIZcuEwII3uGU8d81phW0KYMN%2BQJZUEymWP5lfVWCdiBLjmntv8Q2Uv9q9ZJYpe1WjTIbWWE6ULgwQUZGT%2FeiwdZxcgtimc8wYr33eSIbdMwIlzt%2F2H0w%2FhaMlrG8tKL5ryA8LtxKn9qrSDft3c61LMarYReishkZF2WOMaC5IlAtPL1Du%2BHp89bgjGItRuObfvmPlfyIn8DU4GX|tkp%3ABFBMtvnJ1fJg

Will order another Inverter Converter Assembly now I guess and start again but in retrospect I think the black ECU might be the culprit. Straight swap didnt help but that might be because the Immobiliser need to be reprogrammed somehow to allow for the start procedure to even begin? Not sure this is how it works but really running out of options now.

 

 

 

[maciekmaciek19]

UPDATE! 

I got the READY state back this morning. 

It turns out the only bit that got fried was the Battery inverter module. 

Last night I forgot to plug in one of the plugs. Correcting it this morning has brought the life back into the hv system.

Seems this is the only bit that took the hit. 

This one:

https://go.skimresources.com/?id=2061X562073&isjs=1&jv=15.3.0-stackpath&sref=https%3A%2F%2Fwww.toyotaownersclub.com%2Fforums%2Ftopic%2F209482-reversed-polaritywhat-a-mess%2F%23comment-1661992&url=https%3A%2F%2Fwww.ebay.co.uk%2Fitm%2F403754983025%3Fepid%3D4031006425%26hash%3Ditem5e01ac1e71%3Ag%3AwEQAAOSwsaliw1jD%26amdata%3Denc%3AAQAHAAAA4LxL2qc8wWKk0jWlTwLlSNN4M9EMjIpvq5SWaZDqM4WQvCaXoISIfATRLWBsE%2B75e6sy58ha%2BKSqvjjtAEgkY7fqFXFviIZcuEwII3uGU8d81phW0KYMN%2BQJZUEymWP5lfVWCdiBLjmntv8Q2Uv9q9ZJYpe1WjTIbWWE6ULgwQUZGT%2FeiwdZxcgtimc8wYr33eSIbdMwIlzt%2F2H0w%2FhaMlrG8tKL5ryA8LtxKn9qrSDft3c61LMarYReishkZF2WOMaC5IlAtPL1Du%2BHp89bgjGItRuObfvmPlfyIn8DU4GX%7Ctkp%3ABFBMtvnJ1fJg&xs=1&xtz=-60&xuuid=9c65a4ba227fa10c2481860f2f52e7ea&xguid=ee429a052f5d91220cf481ee802957f9&xjsf=other_click__contextmenu [-1]

Still got some codes to clear and the reassembly to do but all is looking well now. 

Flash22 thank you for taking the time. 

 

[flash22]

Glad you got there in the end, not having access to the documents make it very difficult to diag - clear the codes and take for a run and see if anything comes back

[maciekmaciek19]

Just been out in it. 

Seems fine. 

No issues form the HV system so far. 

What a load off my chest!

 

[maciekmaciek19]

Oh actually... There is one issue..

No aircon. No air blowing through the vents even with the fan on max.

Probably a fuse somewhere or some relay.

Will hopefully find something online without having to blanket test everything again.

[flash22]

The motor has its own power feed is either 30 or 50 amp, check the connector on the motor and "resistor" in the duct work just after the motor, with the fan on, give the motor a few love taps, pull the cabin filter too, make sure it's not blocked

No issue with body electrics, the HV system is highly complex tho

i will keep an eye out for AHR20 GSIC

[maciekmaciek19]

Sorted. I left the blower motor unplugged when digging up the car... All good now. 

Thanks for your help.

[flash22]

Sounds about right 😉, you only do it a few times before you learn

[Tee_J]

@maciekmaciek19

I am fully impressed with your perseverance and abilities to fight this through and resolve the issue!

If it had been me, not being mechanically nor electrically minded, I would have had to get a garage to look at it! Well done dude!!  

[maciekmaciek19]

Cheers bud. I would have given it to a specialist but there isn't one willing to take this kind of thing on. 

They all just want to replace the Battery packs using cheap Chinese cells. 

When it comes to more complex hybrid jobs it is mission impossible to find anybody. Even spent to a cooel of Toyota master technicians doing their own independent thing and they both refused the job. 

This is why I had to spend almost 5 months researching and working on the car using trial and error method as there is virtually no tech info on Estima available in English. 

Im glad it's over and I'm happy I am now a lot more competent. Have again fallen in love with this car despite the months of hating it...

[Derek.w]

Reverse polarity everybody afraid of what else may have blown that electronic parts assemblies not just fuses.

[Tee_J]

27 minutes ago, maciekmaciek19 said:

Im glad it's over and I'm happy I am now a lot more competent.

I would be also - if it were me!! 😁 Lol!

I wonder whether Toyota UK might re-consider bringing these vehicles into the UK as it would make things easier for the (no doubt) few 100's (if not 1000's) of current owners in the UK... One hopes...