DTC    P0A0D-350    High Voltage System Inter-Lock Circuit High

DTC    P0A0D-351    High Voltage System Inter-Lock Circuit High

for Preparation Click here


DESCRIPTION

  1. When the power management control ECU detects that a safety device is operated, it will prohibit hybrid system operation or shut off the system main relay. There are three safety devices in three different locations. The first safety device is located at the service plug grip. The second one is located at the frame wire that is connected to the inverter with converter assembly. The third one is located at the inverter cover where the motor and generator cables and No. 2 engine wire (air conditioning harness) are connected to the inverter with converter assembly. If the service plug grip, inverter cover, or frame 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).

DTC No.
INF Code
DTC Detection Condition
Trouble Are
P0A0D
350
Operating any of the safety devices with the vehicle stopped (ILK signal is ON) and turning the power switch on (IG)
  1. Wire harness or connector
  2. Power management control ECU
  3. Service plug grip
  4. Inverter with converter assembly
  5. Frame wire
  6. Inverter cover
P0A0D
351
Interlock signal line opens (ILK signal is ON) while the vehicle is being driven

WIRING DIAGRAM


A217821E09


INSPECTION PROCEDURE

CAUTION:
  1. 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.
  2. After removing 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 (Click here).

    HINT:
    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work (Click here).

1.CHECK DTC OUTPUT (HYBRID CONTROL)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Enter the following menus: Powertrain / Hybrid Control / DTC.

  1. Check if DTCs are output.

    Result:
    Result
    		Proceed to
    P0A0D only is output.
    		A
    P0A1D is output.
    		B

  1. Turn the power switch off.



B
GO TO DTC CHART (P0A1D) (Click here)
A


2.CLEAR DTC

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Enter the following menus: Powertrain / Hybrid Control / DTC.

  1. Read and record the DTCs and freeze frame data.

  1. Clear DTCs and freeze frame data.

  1. Turn the power switch off.


NEXT


3.CHECK DTC OUTPUT (HYBRID CONTROL)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

  1. Enter the following menus: Powertrain / Hybrid Control / DTC.

  1. Check if DTCs are output.

    Result:
    Result
    		Proceed to
    P0A0D-350 or P0A0D-351 is output again.
    		A
    Neither P0A0D-350 or P0A0D-351 is output again.
    		B

  1. Turn the power switch off.



B
Go to step 10
A


4.CHECK SERVICE PLUG GRIP

CAUTION:
Be sure to wear insulated gloves.

  1. Check if the service plug grip is installed correctly.

    HINT:
    1. For the removal and installation procedures (Click here).
    2. 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


5.CHECK INVERTER COVER

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Check if the inverter cover of the inverter with converter assembly is installed correctly.

    OK:
    The inverter cover is installed correctly.



NG
INSTALL PARTS CORRECTLY
OK


6.CHECK FRAME WIRE

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A215642E06

  1. Check if the frame wire S1 is connected correctly.

    OK:
    The frame wire connector is connected correctly.

  1. Install the inverter cover from the inverter with converter assembly.



NG
INSTALL PARTS CORRECTLY
OK


7.CHECK POWER MANAGEMENT CONTROL ECU


    A214647

  1. Disconnect connector A62 from the inverter with converter assembly.

  1. Turn the power switch on (IG).



    A215725E43

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-35 (ILKI) - Body ground
    		Power switch on (IG)
    		10 to 14 V

    Text in Illustration 
    *a
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

  1. Turn the power switch off.

  1. Connect the inverter with converter assembly connector.



NG
Go to step 16
OK


8.CHECK INVERTER WITH CONVERTER ASSEMBLY (INTERLOCK)

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A214647

  1. Disconnect connector A62 from the inverter with converter assembly.



    A215652E27

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-35 (ILKI) - A62-36 (ILKO)
    		Power switch off
    		Less than 10 Ω

    Text in Illustration 
    *a
    		Component without harness connected
    (Inverter with Converter Assembly)

NOTICE:
Do not remove the inverter cover.

  1. Connect the inverter with converter assembly connector.



NG
Go to step 14
OK


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

  1. Install the service plug grip (Click here).



    A214647

  1. Disconnect connector A62 from the inverter with converter assembly.



    A215725E44

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-36 (ILKO) - Body ground
    		Power switch off
    		Less than 1 Ω

    Text in Illustration 
    *a
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

  1. Connect the inverter with converter assembly connector.



NG
Go to step 11
OK


10.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)

  1. 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 POWER MANAGEMENT CONTROL ECU (Click here)  

11.CHECK SERVICE PLUG GRIP

  1. Remove the service plug grip (Click here).



    A206690E02

  1. Check the condition of the service plug grip interlock.
    Text in Illustration 
    *1
    		Service Plug Grip

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

  1. Install the service plug grip (Click here).



NG
REPLACE SERVICE PLUG GRIP (Click here)
OK


12.CHECK HARNESS AND CONNECTOR

  1. 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.



    A245321E02

  1. Check that the interlock connector at the service plug grip installation socket is connected correctly.
    Text in Illustration 
    *1
    		Inter Lock Connector

    OK:
    The connector is connected correctly.



NG
INSTALL PARTS CORRECTLY
OK


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

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A214647

  1. Disconnect connector A62 from the inverter with converter assembly.

  1. Disconnect connector i2.



    A245322E02

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-36 (ILKO) - i2-1 (ILK)
    		Power switch off
    		Below 1 Ω

    Text in Illustration 
    *a
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)
    *b
    		Front view of wire harness connector
    (to Service Plug Grip)

  1. Connect the service plug grip connector.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - SERVICE PLUG GRIP)
OK

REPAIR OR REPLACE HARNESS OR CONNECTOR (SERVICE PLUG GRIP - BODY GROUND) 

14.CHECK INVERTER COVER

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A215623

  1. Check the condition of the inverter cover interlock.

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

  1. Install the inverter cover from the inverter with converter assembly.



NG
REPLACE INVERTER COVER (Click here)
OK


15.CHECK FRAME WIRE (FRAME WIRE CONNECTOR)

CAUTION:
Be sure to wear insulated gloves.

  1. 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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A215642E06

  1. Disconnect the frame wire S1 from the inverter with converter assembly.



    A215624

  1. Check the frame wire interlock.

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

  1. Connect the frame wire to the inverter with converter assembly.

  1. Install the inverter cover from the inverter with converter assembly.



NG
REPLACE FRAME WIRE (Click here)
OK

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)  

16.CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

  1. Turn the power switch off.



    A214647

  1. Disconnect connector A62 from the inverter with converter assembly.



    A217808E04

  1. Disconnect connector A19 from the power management control ECU.

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A19-32 (ILK) - A62-35 (ILKI)
    		Power switch off
    		Below 1 Ω

    Text in Illustration 
    *a
    		Rear view of wire harness connector
    (to Power Management Control ECU)
    *b
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

  1. Connect the power management control ECU connector.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

REPLACE POWER MANAGEMENT CONTROL ECU (Click here)