P0A0D

L110F HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A0D-350,P0A0D-351: High Voltage System Inter-Lock Circuit High
P0A0D-351 - High Voltage System Inter-Lock Circuit High

DESCRIPTION

When the hybrid vehicle control ECU detects that a safety device is operated, it will prohibit hybrid system operation or shut off the system main relay. There are four safety devices in four different locations. The first safety device is located at the service plug grip. The second one is located at the connector cover of the inverter with converter assembly. The third one is located at the air conditioning harness assembly that is connected to the inverter with converter assembly. The fourth one is located at the inverter terminal cover where the motor and generator cables are connected to the inverter with converter assembly. If the service plug grip, inverter with converter assembly connector cover, inverter terminal cover, or air conditioning harness assembly is removed, the interlock signal line will be open. If the vehicle is being driven, this condition will be determined to be an open circuit and the system main relays will not be shut off. If the safety devices are reinstalled correctly, the system will return to normal when the power switch is turned on (IG).





WIRING DIAGRAM





INSPECTION PROCEDURE

CAUTION:
- Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
- After disconnecting 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.
HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CHECK DTC OUTPUT (HV)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

(d) Check if DTCs are output.

Result:





B -- GO TO DTC CHART Hybrid Control System
A -- Continue to next step.

2. CLEAR DTC (HV)

(a) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

(b) Read and record the DTCs and freeze frame data.

(c) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

(d) Clear DTCs and freeze frame data.

NEXT -- Continue to next step.

3. CHECK DTC OUTPUT (HV)

(a) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

(b) Check if DTCs are output.

Result:





B -- CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)
A -- Continue to next step.

4. CHECK SERVICE PLUG GRIP

CAUTION:
Be sure to wear insulated gloves.

(a) Check if the service plug grip is installed correctly.

HINT
- For the removal and installation procedures, Hybrid Control System.
- P0A0D-350 is also set if the power switch is turned on (IG) with the service plug grip removed. Confirm the conditions when the malfunction occurred.

NG -- CONNECT SECURELY
OK -- Continue to next step.

5. CHECK INVERTER TERMINAL COVER

CAUTION:
Be sure to wear insulated gloves.

(a) Turn the power switch off.

(b) Remove the service plug grip Hybrid Control System.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY) unless instructed by the repair manual because this may cause a malfunction.

(c) Check if the inverter terminal cover of the inverter with converter assembly is installed correctly.





OK:

The inverter terminal cover is installed correctly.

NG -- CONNECT SECURELY
OK -- Continue to next step.

6. CHECK INVERTER WITH CONVERTER ASSEMBLY

(a) Check if the connector cover of the inverter with converter assembly is installed correctly.





OK:

The connector cover is installed correctly.

NG -- CONNECT SECURELY
OK -- Continue to next step.

7. CHECK AIR CONDITIONING HARNESS ASSEMBLY

CAUTION:
Be sure to wear insulated gloves.

(a) Check if the air conditioning harness assembly connector is connected correctly.





OK:

The air conditioning harness assembly connector is connected correctly.

NG -- CONNECT SECURELY
OK -- Continue to next step.

8. CHECK HYBRID VEHICLE CONTROL ECU

CAUTION:
Be sure to wear insulated gloves.

(a) Disconnect the low voltage connector from the inverter with converter assembly.





(b) Turn the power switch on (IG).

(c) Measure the voltage according to the value(s) in the table below.

Standard voltage:





NG -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY)
OK -- Continue to next step.

9. CHECK INVERTER WITH CONVERTER ASSEMBLY

CAUTION:
Be sure to wear insulated gloves.

(a) Turn the power switch off.

(b) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY) unless instructed by the repair manual because this may cause a malfunction.

(c) Measure the resistance according to the value(s) in the table below.





Standard resistance:





NG -- CHECK INVERTER TERMINAL COVER
OK -- Continue to next step.

10. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - NO. 1 BATTERY PACK WIRE CONNECTOR)

(a) Connect the low voltage connector of the inverter with converter assembly.

(b) Disconnect the No. 1 battery pack wire connector.





HINT
For the removal and installation procedures related to the No. 1 battery pack wire connector, Components.

(c) Turn the power switch on (IG).

(d) Measure the voltage according to the value(s) in the table below.





Standard voltage:





NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

11. CHECK HARNESS AND CONNECTOR (NO. 1 BATTERY PACK WIRE CONNECTOR - BODY GROUND)

(a) Measure the resistance according to the value(s) in the table below.





Standard resistance:





NG -- CHECK SERVICE PLUG GRIP
OK -- Continue to next step.

12. CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)

(a) Check the connections of each connector.

OK:

Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

NG -- REPAIR OR REPLACE CONNECTOR

OK -- REPLACE HYBRID VEHICLE CONTROL ECU Components

13. CHECK SERVICE PLUG GRIP

(a) Check the condition of the service plug grip interlock.





OK:

Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

NG -- REPLACE SERVICE PLUG GRIP Removal
OK -- Continue to next step.

14. CHECK HARNESS AND CONNECTOR

(a) Check that the interlock connector at the service plug grip installation socket is connected correctly.





OK:

The connector is connected correctly.

NG -- CONNECT SECURELY
OK -- Continue to next step.

15. CHECK HARNESS AND CONNECTOR (NO. 1 BATTERY PACK WIRE CONNECTOR - SERVICE PLUG GRIP)

CAUTION:
Be sure to wear insulated gloves.

(a) Measure the resistance according to the value(s) in the table below.





Standard resistance:





NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPAIR OR REPLACE HARNESS OR CONNECTOR

16. CHECK INVERTER TERMINAL COVER

CAUTION:
Be sure to wear insulated gloves.

(a) Turn the power switch off.





(b) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY) unless instructed by the repair manual because this may cause a malfunction.

(c) Remove the inverter terminal cover from the inverter with converter assembly Removal.

NOTICE:
Lift the inverter terminal cover horizontally so that it does not tilt. Failure to do so may break the inverter cover guide pins.

(d) Check the condition of the inverter terminal cover interlock.

OK:

Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.





NG -- REPLACE INVERTER TERMINAL COVER
OK -- Continue to next step.

17. CHECK INVERTER WITH CONVERTER ASSEMBLY (CONNECTOR COVER ASSEMBLY OF INVERTER WITH CONVERTER ASSEMBLY)

CAUTION:
Be sure to wear insulated gloves.

(a) Turn the power switch off.

(b) Check that the service plug grip is not installed.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY) unless instructed by the repair manual because this may cause a malfunction.

(c) Remove the connector cover from the inverter with converter assembly.





(d) Check the condition of the connector cover interlock.





OK:

Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Installation
OK -- Continue to next step.

18. CHECK AIR CONDITIONING HARNESS ASSEMBLY (AIR CONDITIONING HARNESS ASSEMBLY CONNECTOR)

CAUTION:
Be sure to wear insulated gloves.

(a) Disconnect the air conditioning harness assembly from the inverter with converter assembly.





(b) Check the condition of the air conditioning harness assembly interlock.





OK:

Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.

NG -- REPLACE AIR CONDITIONING HARNESS ASSEMBLY

OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Installation

19. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY)

(a) Turn the power switch off.





(b) Disconnect connector A76 from the hybrid vehicle control ECU.

(c) Measure the resistance according to the value(s) in the table below.

Standard resistance:





NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE CONTROL ECU Components