2nd Gen Main System Relay Open

did you slide the main orange battery switch all the way up after closing it?

 

Time to get Mini VCI so that you can retrieve the DTC. Maybe the traction battery ECU has a fault or there is a problem with the wiring to the system main relays, which results in the relays not closing when they should.

 

Battery computer connection to car? , double check those low voltage connections

 

The computer is what commands the SMR to close. The answer to why the SMR isn't closing (barring some dead simple explanation like you left the wires unattached) is ... whatever the computer is detecting so it decides not to close the SMR.

In other words ... read the codes.

-Chap

 

Up ???????????????

Inserting the orange safety disconnect takes three distinct movements.

1. Push the plug in.
2. Flip the lever up.
3. Push the level straight down.

Step three closes a 12 volt micro switch. This circuit lets your car know the plug is in place. The main relays will not close without this circuit being complete.

Brad

 

right, when i said up, i had my laptop upside down.

 

I agree that last step is likely your problem. I've experienced the same thing - although I thought I also triggered the red triangle as a result.

 

aha!

 

Hi all,
I know this is an old post. But I am having similar problems as OP. I just replaced my hybrid battery and after reinstalling the car does not start, only dashboard, warning signs, radio and lights turn on. Cannot put in drive or reverse. I realized I did not click down on the orange plug to lock in place, so I did that but it still won't start. I have tried disconnecting 12V Aux battery to clear codes but that didn't work either. Tried clearing codes using Blue Driver OBD2 and that didn't help, warning signs come back instantly.

I was able to gather some codes from the OBD2.
Hybrid Control Codes:
1) P0AE7: HV Precharge Contactor "A"
- looked online and some people have mentioned replacing the system main relay

Gateway code:
2) B1271: ECU combination stop
- looked online and some people have replaced ECU

Just wondering if any of you folks have experienced this same issue.

I will try checking the continuity of the relays and check if any contacts were damaged or corroded and let you guys know if failure still occurs.

 

Check you installed the safety interlock correctly, most importantly the third step to push the handle down till it clicks in.


If this is all ok, check you connected the thin wire to the connector below the interlock.

Let us know if this fixes it.

 

So damn HAPPY right now! I was so close to giving up, I even went to the dealership yesterday to get a quote for repairs. But finally, after 3 weeks of struggling i got the car to start! And im so pissed that it took me this long to figure it out. This whole time it was one of the green wires connected to the precharge relay. I checked every wired connection tonight and this one was loose and the pin was actually bent! And not directly connected even though it looked like it. As soon as I fixed the pin and plugged the wire in and cleared codes, the relay switched on and car started!

Attached is a picture of the green wire, not exactly sure what the wire is but my guess is that its a neutral wire because its green?

 

Having similar problem only getting 11.2 volts and to traction battery relays, 12 volt battery is up , need to check relay for this in front power box if that is where it is and I can find it!

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