P0A0D

HYBRID / BATTERY 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 (interlock) is operated, it will prohibit hybrid system operation or shut off the system main relay. There are four safety devices in three different locations. The first safety device is located at the service plug grip. The second one is located at the air conditioner fuse maintenance A/C fuse cover (connector cover assembly) of the inverter with converter assembly. The third one is located at the No. 2 engine wire (air conditioning harness) that is connected to the inverter with converter assembly. If the service plug grip, connector cover assembly, or No. 2 engine wire 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 re-installed 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) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check if DTCs are output.

Result:

(e) Turn the power switch off.

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

2. CLEAR DTC (HV)

(a) Connect the Techstream to the DLC3.

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

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

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

(e) Clear DTCs and freeze frame data.

(f) Turn the power switch off.

NEXT -- Continue to next step.

3. RECONFIRM DTC OUTPUT (HV)

(a) Connect the Techstream to the DLC3.

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

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

(d) Check if DTCs are output.

Result:

(e) Turn the power switch off.

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
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 -- INSTALL PARTS CORRECTLY
OK -- Continue to next step.

5. CHECK CONNECTOR COVER 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

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

OK:

The connector cover assembly is installed correctly.

NG -- INSTALL PARTS CORRECTLY
OK -- Continue to next step.

6. CHECK NO. 2 ENGINE WIRE

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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Check if the No. 2 engine wire (air conditioning harness) D2 is connected correctly.

OK:

The No. 2 engine wire is connected correctly.

NG -- INSTALL PARTS CORRECTLY
OK -- Continue to next step.

7. CHECK HYBRID VEHICLE CONTROL ECU

(a) Disconnect the low voltage connector A59 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:

Text in Illustration

(d) Turn the power switch off.

(e) Connect the inverter with converter assembly connector.

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

8. CHECK INVERTER WITH CONVERTER ASSEMBLY (INTERLOCK)

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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect the low voltage connector A59 from the inverter with converter assembly.

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

Standard Resistance:

Text in Illustration

NOTICE:
Do not remove the inverter terminal cover.

(d) Connect the inverter with converter assembly connector.

NG -- CHECK CONNECTOR COVER ASSEMBLY
OK -- Continue to next step.

9. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - BODY GROUND)

(a) Install the service plug grip Components.

(b) Disconnect the low voltage connector A59 from the inverter with converter assembly.

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

Standard Resistance:

Text in Illustration

(d) Connect the inverter with converter assembly connector.

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

10. 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

11. CHECK SERVICE PLUG GRIP

(a) Remove the service plug grip Components.

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

Text in Illustration

OK:

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

(c) Install the service plug grip Components.

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

12. CHECK HARNESS AND CONNECTOR

(a) 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.

(b) 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.

13. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - SERVICE PLUG GRIP)

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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect the low voltage connector A59 from the inverter with converter assembly.

(c) Disconnect the interlock connector.

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

Standard Resistance:

Text in Illustration

(e) Connect the service plug grip connector.

(f) Connect the inverter with converter assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPAIR OR REPLACE HARNESS OR CONNECTOR

14. CHECK CONNECTOR COVER 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

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

Text in Illustration

OK:

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

HINT
The connector cover assembly is not available separately. If it requires replacement, replace the inverter with converter assembly.

(d) Install the connector cover assembly to the inverter with converter assembly.

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

15. CHECK NO. 2 ENGINE WIRE (NO. 2 ENGINE WIRE CONNECTOR)

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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

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

(d) Check the No. 2 engine wire (air conditioning harness) interlock.

Text in Illustration

OK:

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

(e) Connect the No. 2 engine wire (air conditioning harness) to the inverter with converter assembly.

(f) Install the connector cover assembly to the inverter with converter assembly.

NG -- REPLACE NO. 2 ENGINE WIRE

OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

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

(a) Turn the power switch off.

(b) Disconnect the low voltage connector A59 from the inverter with converter assembly.

(c) Disconnect connector A58 from the hybrid vehicle control ECU.

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

Standard Resistance:

Text in Illustration

(e) Connect the hybrid vehicle control ECU connector.

(f) Connect the inverter with converter assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE CONTROL ECU Components