RM36D0EC _51 Engine / Hybrid System _083048 HYBRID / BATTERY CONTROL _0709511 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 assembly 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 assembly malfunction

·

Service plug malfunction

·

Wire harness malfunction

·

Connector malfunction



INSPECTION DESCRIPTION


A368832E09
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 5.031,3.083 6.74,3.479 1.708,0.396 10 false Hybrid Vehicle Control ECU Assembly 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 Inspection Step
*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 assembly connector.


DTC output due to improper connection or forgetting to install parts. 4 to 6
*b Inspect the detection circuit. DTC output due to an open circuit or improper connection (dirt, foreign matter, etc.). 7 to 11


DESCRIPTION

When the hybrid vehicle control ECU assembly detects that a safety device (interlock) is operated, such as when the service plug grip, inverter cover or rear traction motor cable (floor under wire) 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, 1 on rear traction motor cable (floor under wire) that is connected to the inverter with converter assembly. If the service plug grip, inverter cover, rear traction motor cable (floor under 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. When the safety devices are re-installed correctly, the system will return to normal when the power switch is turned on (IG).

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 assembly

·

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 assembly

·

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 power switch on (IG) and turn the GTS on.

3.

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

4.

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

5.

Turn the power switch on (IG) and turn the GTS on.

6.

With power switch on (IG) 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

A368831E84
4.615,3.135 6.958,3.5 2.344,0.365 10 false Hybrid Vehicle Control ECU Assembly 2.219,2.115 4.479,2.365 2.26,0.25 10 false Service Plug Grip (Interlock Switch) 5.208,1.573 5.667,1.771 0.458,0.198 10 false ILK 3.521,1.594 3.979,1.792 0.458,0.198 10 false ILK 2.823,1.583 3.281,1.781 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 2.229,1.969 2.667,2.188 0.438,0.219 10 false M33 4.615,2.958 4.979,3.188 0.365,0.229 10 false A30 4.969,1.563 5.219,1.781 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 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.

·

As interlock circuit DTCs or other DTCs may be stored when the power switch is turned on (IG) in the following procedure, make sure to clear the DTCs after inspection.



PROCEDURE

1.CHECK DTC OUTPUT (HYBRID CONTROL)
a.

Connect the GTS to the DLC3.


b.

Turn the power switch on (IG).


c.

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


d.

Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes
50001 397
Result:
Result Proceed to
P0A0A13 or P0A0A92 only is output, or DTCs except the ones in the table below are also output. A
Any of the following DTCs are also output. B


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

HINT:
·

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

(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.)





e.

Turn the power switch off.



A

2.CLEAR DTC

B

GO TO DTC CHART (HYBRID CONTROL SYSTEM)

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>DIAGNOSTIC TROUBLE CODE CHART


3.CHECK DTC OUTPUT (HYBRID CONTROL)
a.

Connect the GTS 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.

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



e.

Turn the power switch off.



A

4.CHECK SERVICE PLUG GRIP

B

10.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)
4.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 power switch is turned on (IG) with the service plug grip removed. Confirm the conditions when the malfunction occurred.




Result:
Proceed to
OK
NG



OK

5.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CONNECTOR)

NG

INSTALL PARTS CORRECTLY

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



b.

Remove the No. 1 HV battery cover panel RH.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV BATTERY (for LITHIUM-ION BATTERY [Production date from 2021/08])>REMOVAL


c.
C433541C01
3.052,0.781 3.302,0.958 0.25,0.177 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.



d.

Install the No. 1 HV battery cover panel RH.


Result:
Proceed to
OK
NG



OK

6.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR)

NG

INSTALL PARTS CORRECTLY

6.CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR)

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

Result:
Proceed to
OK
NG



OK

7.CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY

NG

CONNECT SECURELY

7.CHECK HYBRID VEHICLE CONTROL ECU 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 No. 1 HV battery cover panel RH.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV BATTERY (for LITHIUM-ION BATTERY [Production date from 2021/08])>REMOVAL


c.

Disconnect the M33 service plug grip (interlock switch) connector.


d.

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


e.

Turn the power switch on (IG).


f.
C529592C01
0.865,3.51 1.25,3.76 0.385,0.25 2.198,4.229 1.865,3.917 true 0.656,2.667 0.969,2.865 0.313,0.198 10 false *a 2.25,4.146 2.708,4.344 0.458,0.198 10 false ILK 0.938,3.552 1.396,3.75 0.458,0.198 10 false M33
*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
M33-1 (ILK) - Body ground Power switch on (IG) 11 to 14 V


NOTICE:

Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.



g.

Turn the power switch off.


h.

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


i.

Reconnect the M33 service plug grip (interlock switch) connector.


j.

Install the No. 1 HV battery cover panel RH.


Result:
Proceed to
OK
NG



OK

8.CHECK SERVICE PLUG GRIP

NG

11.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ASSEMBLY - SERVICE PLUG GRIP)
8.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

9.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


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



b.

Remove the No. 1 HV battery cover panel RH.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV BATTERY (for LITHIUM-ION BATTERY [Production date from 2021/08])>REMOVAL


c.

Disconnect the M33 service plug grip (interlock switch) connector.


d.
C529592C02
0.865,3.51 1.25,3.76 0.385,0.25 1.219,4.188 1.552,3.896 true 0.656,2.667 0.969,2.865 0.313,0.198 10 false *a 0.885,4.115 1.344,4.313 0.458,0.198 10 false GND 0.948,3.552 1.406,3.75 0.458,0.198 10 false M33
*a Rear view of wire harness connector
(to Service Plug Grip (Interlock Switch))


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

Standard Resistance:
Tester Connection Condition Specified Condition
M33-2 (GND) - Body ground Power switch off Below 1 Ω



e.

Reconnect the M33 service plug grip (interlock switch) connector.


f.

Install the No. 1 HV battery cover panel RH.


Result:
Proceed to
OK
NG



OK

10.CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

10.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 ASSEMBLY

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


NG

REPAIR OR REPLACE CONNECTOR

11.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU 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 A30 hybrid vehicle control ECU assembly connector.


c.

Remove the No. 1 HV battery cover panel RH.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV BATTERY (for LITHIUM-ION BATTERY [Production date from 2021/08])>REMOVAL


d.

Disconnect the M33 service plug grip (interlock switch) connector.


e.

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

A572940C01
1.646,0.688 2.063,0.948 0.417,0.26 4.552,2.885 4.969,3.146 0.417,0.26 5.583,3.167 5.906,3.458 true 1.635,2.104 1.375,2.573 true 0.438,0.469 0.75,0.625 0.313,0.156 10 false *a 4.51,2.281 4.823,2.438 0.313,0.156 10 false *b 1.74,0.729 2.198,0.927 0.458,0.198 10 false A30 4.625,2.927 5.083,3.125 0.458,0.198 10 false M33 5.958,3.375 6.417,3.573 0.458,0.198 10 false ILK 1.281,2.625 1.74,2.823 0.458,0.198 10 false ILK
*a Front view of wire harness connector
(to Hybrid Vehicle Control ECU Assembly) 		*b Rear view of wire harness connector
(to Service Plug Grip (Interlock Switch))


Standard Resistance:
Tester Connection Condition Specified Condition
A30-32 (ILK) - M33-1 (ILK) Power switch off Below 1 Ω



f.

Reconnect the M33 service plug grip (interlock switch) connector.


g.

Install the No. 1 HV battery cover panel RH.


h.

Reconnect the A30 hybrid vehicle control ECU assembly connector.


Result:
Proceed to
OK
NG



OK

REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY

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


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR