RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604232 HYBRID CONTROL SYSTEM C

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  P0A0A13  High Voltage System Interlock Circuit Open  P0A0A92  High Voltage System Interlock Performance or Incorrect Operation  


DTC SUMMARY

MALFUNCTION DESCRIPTION


The hybrid vehicle control ECU detects that a safety device (interlock) is operated or that there is an open circuit in the detection circuit. (Even if an open circuit occurs while the vehicle is stopped, the system determines that the safety device was operated.)

The cause of this malfunction may be one of the following:

Detection switch system malfunction
·

Service plug malfunction


Low-voltage system malfunction
·

Hybrid vehicle control ECU malfunction

·

Service plug malfunction

·

Wire harness malfunction

·

Connector malfunction



INSPECTION DESCRIPTION


A368832E16
1.208,3.333 1.823,3.531 0.615,0.198 10 false : *b 3.365,1.219 3.656,1.438 0.292,0.219 10 false *a 5,2.031 5.292,2.25 0.292,0.219 10 false *a 4.979,3.063 6.74,3.5 1.76,0.438 10 false Hybrid Vehicle Control ECU 2.104,2.125 4.406,2.344 2.302,0.219 10 false Service Plug Grip (Interlock Switch)

System Diagram Location Inspection Content Reason
*a
·

Check whether the safety device (interlock) is connected securely and installed properly (service plug grip, etc.).

·

Check the connection condition of the hybrid vehicle control ECU connector.


DTC output due to improper connection or forgetting to install parts.
*b Inspect the detection circuit. DTC output due to an open circuit or improper connection (dirt, foreign matter, etc.).


DESCRIPTION

When the hybrid vehicle control ECU detects that a safety device (interlock) is operated, such as when the service plug grip, or inverter cover is removed, it will prohibit hybrid system operation or shut off the system main relay. The 3 safety devices are located as follows; 1 in the service plug grip, 1 on the inverter cover for the terminals of the inverter with converter assembly motor cable and generator cable, that is connected to the inverter with converter assembly. If the service plug grip, inverter cover 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. When the safety devices are re-installed correctly, the system will return to normal when the ignition switch is turned to ON.

The system main relay will be turned off from the next trip after the open is detected until the condition returns to normal.

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate Note
P0A0A13 High Voltage System Interlock Circuit Open Interlock signal line opens while the vehicle is being driven (at 5 km/h (3 mph) or more)
(1 trip detection logic)
·

Wire harness or connector

·

Hybrid vehicle control ECU

·

Service plug grip


Does not come on Master Warning:
Comes on 		SAE Code:
P0A0D
P0A0A92 High Voltage System Interlock Performance or Incorrect Operation Either of the following conditions is met:
·

With the vehicle stopped, the service plug grip with a safety device was removed.

·

With the vehicle stopped, the interlock signal line became open.


(1 trip detection logic)
·

Wire harness or connector

·

Hybrid vehicle control ECU

·

Service plug grip


Does not come on Master Warning:
Comes on 		SAE Code:
P0A0D

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>UTILITY


1.

Connect the GTS to the DLC3.

2.

Turn the ignition switch to ON and turn the GTS on.

3.

Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

4.

Turn the ignition switch off and wait for 2 minutes or more.

5.

Turn the ignition switch to ON and turn the GTS on.

6.

With ignition switch ON and wait for 5 seconds or more.

7.

Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

8.

Check the DTC judgment result.

HINT:
·

If the judgment result shows NORMAL, the system is normal.

·

If the judgment result shows ABNORMAL, the system has a malfunction.

·

If the judgment result shows INCOMPLETE, perform driving pattern again.




WIRING DIAGRAM

A368831E78
4.781,3.063 6.719,3.448 1.938,0.385 10 false Hybrid Vehicle Control ECU 2.219,2.115 4.479,2.365 2.26,0.25 10 false Service Plug Grip (Interlock Switch) 5.229,1.573 5.688,1.771 0.458,0.198 10 false ILK 3.51,1.583 3.969,1.781 0.458,0.198 10 false ILK 2.833,1.583 3.292,1.781 0.458,0.198 10 false GND 2.656,1.573 2.906,1.792 0.25,0.219 10 false 2 3.813,1.573 4.063,1.792 0.25,0.219 10 false 1 2.229,1.958 2.667,2.177 0.438,0.219 10 false O220 4.792,2.875 5.156,3.104 0.365,0.229 10 false I278 4.958,1.573 5.208,1.792 0.25,0.219 10 false 32 5.76,0.854 6.052,1.073 0.292,0.219 10 false +B

CAUTION / NOTICE / HINT

CAUTION:

Refer to the precautions before inspecting high voltage circuit.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PRECAUTION


NOTICE:
·

After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY

·

When disconnecting and reconnecting the auxiliary battery

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART


·

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

·

As interlock circuit DTCs or other DTCs may be stored when the ignition switch is turned to ON in the following procedure, make sure to clear the DTCs after inspection.



HINT:
·

P0A0A13 or P0A0A92 may be output as a result of the malfunction indicated by the DTCs in table below.

(a)

The chart above is listed in inspection order of priority.

(b)

Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)



Malfunction Content Relevant DTC
Microcomputer malfunction P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
P060687 Hybrid/EV Powertrain Control Module Processor to Monitoring Processor Missing Message
P060A47 Hybrid/EV Powertrain Control Module Monitoring Processor Watchdog / Safety MCU Failure
P060A87 Hybrid/EV Powertrain Control Module Processor from Monitoring Processor Missing Message
P060B49 Hybrid/EV Powertrain Control Module A/D Processing Internal Electronic Failure
P060B71 Hybrid/EV Powertrain Control Module A/D Processing Actuator Stuck
P060B1C Hybrid/EV Powertrain Control Module A/D Processing Voltage Out of Range
P1CE349 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Internal Electronic Failure
P1CE371 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Actuator Stuck
P1CE31C Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Voltage Out of Range
P060A45 Hybrid/EV Powertrain Control Module Monitoring Processor Program Memory Failure
P060A44 Hybrid/EV Powertrain Control Module Monitoring Processor Data Memory Failure
P060A29 Hybrid/EV Powertrain Control Module Monitoring Processor Signal Invalid
P060A49 Hybrid/EV Powertrain Control Module Monitoring Processor Internal Electronic Failure
Power source circuit malfunction P06881F ECM/PCM Power Relay Sense Circuit Intermittent
System malfunction P1C9E9F Hybrid/EV System Reset Stuck Off


PROCEDURE

2.CHECK DTC OUTPUT (HYBRID CONTROL)
a.

Check if DTCs are output.

Powertrain > Hybrid Control > Trouble Codes
50001 397
Result:
Result Proceed to
P0A0A13 or P0A0A92 is output again. A
Neither P0A0A13 or P0A0A92 is output again. B



b.

Turn the ignition switch off.



A

3.CHECK SERVICE PLUG GRIP

B

9.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)
3.CHECK SERVICE PLUG GRIP
CAUTION:

Be sure to wear insulated gloves.


a.
A365595C01
0.104,0.094 0.417,0.25 0.313,0.156 10 false *1
*1 Service Plug Grip


Check if the service plug grip is installed correctly.

NOTICE:

Insert the service plug grip until a click sound is heard.


HINT:
·

For the removal and installation procedures.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>REMOVAL

·

P0A0A92 is also set if the ignition switch is turned to ON with the service plug grip removed. Confirm the conditions when the malfunction occurred.




Result:
Proceed to
OK
NG



OK

4.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CONNECTOR)

NG

INSTALL PARTS CORRECTLY

4.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.
A517678C01
0.042,0.042 0.208,0.208 0.167,0.167 10 true *1
*1 Interlock Connector


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

OK:

The connector is connected correctly.



Result:
Proceed to
OK
NG



OK

5.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

NG

INSTALL PARTS CORRECTLY

5.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>P056014

Result:
Proceed to
OK
NG



OK

6.CHECK HYBRID VEHICLE CONTROL ECU

NG

CONNECT SECURELY

6.CHECK HYBRID VEHICLE CONTROL ECU
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the service plug grip (interlock switch) connector.


c.

Connect the cable to the negative (-) auxiliary battery terminal.


d.

Turn the ignition switch to ON.


e.
A517679C03
0.917,3.833 1.417,4.083 0.5,0.25 1.302,4.417 1.635,4.167 true 0.792,3.313 1.104,3.51 0.313,0.198 10 false *a 1.052,4.313 1.51,4.51 0.458,0.198 10 false ILK 1,3.865 1.458,4.063 0.458,0.198 10 false O220
*a Rear view of wire harness connector
(to Service Plug Grip (Interlock Switch))


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

Standard Voltage:
Tester Connection Condition Specified Condition
O220-1 (ILK) - Body ground Ignition switch ON 11 to 14 V


NOTICE:

Turning the ignition switch to ON with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.



f.

Turn the ignition switch off.


g.

Disconnect the cable from the negative (-) auxiliary battery terminal.


h.

Reconnect the service plug grip (interlock switch) connector.


Result:
Proceed to
OK
NG



OK

7.CHECK SERVICE PLUG GRIP

NG

10.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - SERVICE PLUG GRIP)
7.CHECK SERVICE PLUG GRIP
CAUTION:

Be sure to wear insulated gloves.


a.

Remove the service plug grip.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>REMOVAL


b.
A365596C01
0.115,0.083 0.427,0.24 0.313,0.156 10 false *1
*1 Service Plug Grip


Check the condition of the service plug grip interlock.

OK:

Dirt or foreign matter has not entered the connectors, and there is no evidence of contamination.



Result:
Proceed to
OK
NG



OK

8.CHECK HARNESS AND CONNECTOR (SERVICE PLUG GRIP - BODY GROUND)

NG

REPLACE SERVICE PLUG GRIP

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>REMOVAL


8.CHECK HARNESS AND CONNECTOR (SERVICE PLUG GRIP - BODY GROUND)
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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the service plug grip (interlock switch) connector.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O220-2 (GND) - Body ground Ignition switch off Below 1 Ω



d.

Reconnect the service plug grip (interlock switch) connector.


Result:
Proceed to
OK
NG



OK

9.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

9.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)
a.

Check the connections of each connector.

OK:

Dirt or foreign matter has not entered the connectors, and there is no evidence of contamination.



Result:
Proceed to
OK
NG



OK

REPLACE HYBRID VEHICLE CONTROL ECU

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID VEHICLE CONTROL ECU>REMOVAL


NG

REPAIR OR REPLACE CONNECTOR

10.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the hybrid vehicle control ECU connector.


c.

Disconnect the service plug grip (interlock switch) connector.


d.

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

Standard Resistance:
Tester Connection Condition Specified Condition
I278-32 (ILK) - O220-1 (ILK) Ignition switch off Below 1 Ω



e.

Reconnect the service plug grip (interlock switch) connector.


f.

Reconnect the hybrid vehicle control ECU connector.


Result:
Proceed to
OK
NG



OK

REPLACE HYBRID VEHICLE CONTROL ECU

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID VEHICLE CONTROL ECU>REMOVAL


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR