Pinpoint Test AI: DTC P0AE1:00
High-Voltage Traction Battery
Pinpoint Test AI: DTC P0AE1:00
Refer to Wiring Diagram Set 12 (Fusion/Milan/MKZ, Fusion Hybrid, Milan Hybrid, MKZ Hybrid), Charging System for schematic and connector information. Diagrams By Number
Normal Operation
When the ignition is turned on, the Battery Energy Control Module (BECM) makes various vehicle checks. If these checks are normal, the BECM sends a signal to the contactor to close, which will supply high-voltage power to the vehicle. If a precharge contactor overcurrent condition is sensed by the BECM, the stop safely hazard (red triangle) warning indicator is illuminated and the vehicle will shut down and/or not start.
- DTC P0AE1:00 (High Voltage Battery Precharge Contactor Circuit: No Sub Type Information) - Fault sets when the precharge contactor attempts to close and current flow exceeds set values. This could indicate a short in the high-voltage system. Reports as a continuous memory (historical) DTC only.
This pinpoint test is intended to diagnose the following:
- High-voltage cables
- DC to DC Converter Control Module (DC/DC)
- BECM
- High Voltage Traction Battery (HVTB)
- Transmission Control Module (TCM)
PINPOINT TEST AI: DTC P0AE1:00
WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage hybrid system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.
WARNING: Always inspect gloves before each use to prevent high-voltage shock. High-voltage insulated safety gloves with a leather outer glove are required to service some components of this vehicle where specified in the service procedures. All high-voltage insulated safety gloves must meet or exceed ANSI/ASTM class 00. Refer to Rubber Insulating Gloves Testing Rubber Insulating Gloves Testing. Failure to follow these instructions may result in serious personal injury or death.
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when taking measurements. Failure to use the correct probe adapter(s) may damage the connector.
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AI1 RETRIEVE TCM DTCs
- Connect the scan tool.
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: Self Test - TCM.
- Are any TCM DTCs retrieved?
Yes
REFER to Computers and Control Systems Information and diagnose those DTCs first.
No
GO to AI2.
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AI2 CHECK CONTACTOR RESISTOR
WARNING: Never install the service disconnect plug with the high-voltage bussed electrical center (BEC) cover removed. Always install the cover prior to connecting the service disconnect plug. The high-voltage BEC cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.
- Ignition OFF.
- Depower the HVTB system. Refer to High-Voltage Traction Battery Systems Depowering High-Voltage Traction Battery Systems Depowering.
- Remove the high-voltage Bussed Electrical Center (BEC) cover. Refer to the exploded view in Battery Pack Sensor Module (BPSM) Service and Repair.
- With the service disconnect plug removed, measure the resistance of the precharge resistor in the high-voltage BEC.
- Is the resistance between 6 and 10 ohms?
Yes
GO to AI3.
No
INSTALL a new high-voltage BEC. REFER to High-Voltage Bussed Electrical Center Service and Repair. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
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AI3 MEASURE VOLTAGE AT BPSM CONNECTOR
WARNING: Always wear high-voltage insulated safety gloves with leather outer gloves and a face shield when servicing the battery pack sensor module (BPSM) and never remove the high-voltage BPSM connector unless directed by a service procedure. High voltage is present at the BPSM at all times, even with service disconnect plug removal. Depowering the system will not remove voltage from the BPSM connector with the orange harness. Follow all service instructions. Failure to follow these instructions may result in serious personal injury or death.
WARNING: Never install the service disconnect plug with the high-voltage bussed electrical center (BEC) cover removed. Always install the cover prior to connecting the service disconnect plug. The high-voltage BEC cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.
- Ignition ON.
- With the service disconnect plug removed, measure the voltage between BPSM C4238B-35, circuit J2-B35, harness side and ground by back-probing at C4238B-35.
- Is the voltage between 2.25 and 2.75 volts?
Yes
GO to AI6.
No
GO to AI4.
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AI4 CHECK CONTACTOR CIRCUIT FOR AN OPEN
- Ignition OFF.
- With the service disconnect plug removed, measure the resistance between high-voltage BEC C4236E-D, circuit J2-B35, harness side and BPSM C4238B-35, circuit J2-B35, harness side.
- Is the resistance less than 5 ohms?
Yes
GO to AI5.
No
INSTALL a new HVTB (includes HVTB system wire harness). REFER to High-Voltage Traction Battery High-Voltage Traction Battery. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
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AI5 CHECK FOR OPEN CONTACTOR
- With the service disconnect plug removed, measure the resistance between the 2 points of the high-voltage BEC as shown.
- Is the resistance greater than 10,000 ohms?
Yes
INSTALL a new BPSM. REFER to Battery Pack Sensor Module (BPSM) Service and Repair. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
No
INSTALL a new high-voltage BEC. REFER to High-Voltage Bussed Electrical Center Service and Repair. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
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AI6 CHECK FOR HIGH-VOLTAGE SHORT TO CHASSIS
- Ignition OFF.
- Disconnect: High-voltage BEC C4236A.
- With the service disconnect plug removed, measure the resistance between high-voltage BEC C4236A-1, circuit HYT04 (OG/BK), harness side and ground; and between high-voltage BEC C4236A-2, circuit HYT03 (OG/WH), harness side and ground.
- Are the resistances greater than 147,000 ohms?
Yes
GO to AI9.
No
GO to AI7.
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AI7 CHECK DC/DC FOR HIGH-VOLTAGE SHORT TO CHASSIS
- Disconnect: DC/DC C1457A.
- With the service disconnect plug removed, measure the resistance between DC/DC C1457A pin 1, component side and ground; and between DC/DC C1457A pin 2, component side and ground.
- Are the resistances greater than 147,000 ohms?
Yes
INSTALL a new DC/DC. REFER to High Voltage Converter/Inverter Service and Repair. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
No
GO to AI8.
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AI8 CHECK ACCM FOR HIGH-VOLTAGE SHORT TO CHASSIS
- Disconnect: Air Conditioning Compressor Module (ACCM) C1469B.
- With the service disconnect plug removed, measure the resistance between ACCM C1469B pin 1, component side and ground; and between ACCM C1469B pin 2, component side and ground.
- Are the resistances greater than 147,000 ohms?
Yes
INSTALL a new ACCM and A/C compressor assembly. REFER to Climate Control Service and Repair. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
No
INSTALL new high-voltage cables. REFER to High-Voltage Cables Service and Repair. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
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AI9 CHECK THE HIGH-VOLTAGE CABLES
- Install new high-voltage cables. Refer to High-Voltage Cables Service and Repair.
- Install the high-voltage BEC cover. Refer to the exploded view in Battery Pack Sensor Module (BPSM) Service and Repair.
- Connect: Service Disconnect Plug.
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: Clear DTCs - BECM.
- Enter the following diagnostic mode on the scan tool: Self Test - BECM.
- Is DTC P0AE1:00 retrieved?
Yes
GO to AI10.
No
Repair is complete. TEST the system for normal operation.
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AI10 CHECK THE DC/DC
WARNING: Never install the service disconnect plug with the high-voltage bussed electrical center (BEC) cover removed. Always install the cover prior to connecting the service disconnect plug. The high-voltage BEC cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.
- Ignition OFF.
- Depower the HVTB system. Refer to High-Voltage Traction Battery Systems Depowering High-Voltage Traction Battery Systems Depowering.
- Install a new DC/DC. Refer to High Voltage Converter/Inverter Service and Repair.
- Connect: Service Disconnect Plug.
- Ignition ON.
- Enter the following diagnostic mode on the scan tool: Clear DTCs - BECM.
- Enter the following diagnostic mode on the scan tool: Self Test - BECM.
- Is DTC P0AE1:00 retrieved?
Yes
INSTALL a new ACCM and A/C compressor assembly. REFER to Climate Control Service and Repair. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
No
Repair is complete. TEST the system for normal operation.
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