P0A0D-351

P112 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A0D-351: High Voltage System Inter-Lock Circuit High

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

DESCRIPTION

A short pin for the interlock switch is provided on the service plug grip and the inverter cover. Therefore, the interlock signal line circuit opens when the service plug grip or the inverter cover is removed.
If the HV control ECU detects an open circuit in the interlock signal line while the vehicle is in motion (vehicle speed above 3 mph [5 km/h]), it stores the information (INF) code 351 in its memory and alerts the driver.
While the vehicle is in motion, the HV control ECU will not shut down the high-voltage system even if an open circuit in the interlock system is detected.






WIRING DIAGRAM





INSPECTION PROCEDURE
CAUTION:
- Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system.
- After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.
HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter.

PROCEDURE

1. CHECK SERVICE PLUG GRIP INSTALLATION
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip has been installed properly.
Standard:
The service plug grip has been installed properly
NG -- CORRECTLY REINSTALL
OK -- Continue to next step.

2. CHECK INVERTER COVER INSTALLATION
(a) Check that the inverter cover has been installed properly.
Standard:
The inverter cover has been installed properly
NG -- CORRECTLY REINSTALL
OK -- Continue to next step.

3. CHECK HYBRID VEHICLE CONTROL ECU (ILK VOLTAGE)




(a) Turn the power switch ON (IG).
(b) Measure the voltage between the terminal of the HV control ECU connector and body ground.
Standard voltage:






NG -- REPLACE HYBRID VEHICLE CONTROL ECU
OK -- Continue to next step.

4. INSPECT SERVICE PLUG GRIP (NO. 2 INTERLOCK SWITCH)
CAUTION: Wear insulated gloves before performing the following operation.




(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state.
(c) Check the connections of the No. 2 interlock switch connector.
Result:
Dirt or foreign objects have entered the connection, or there are remains of them.
(d) Measure the resistance between the terminals of the service plug grip (No.2 interlock switch).
Standard resistance:
Below 1 Ohms
(e) Reinstall the service plug grip Installation.
NG -- REPLACE SERVICE PLUG GRIP
OK -- Continue to next step.

5. INSPECT INVERTER COVER (NO. 1 INTERLOCK SWITCH)
CAUTION: Wear insulated gloves before performing the following operation.




(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state.
(c) Remove the inverter cover Removal.
(d) Check the connections of the No. 1 interlock switch connector.
Result:
Dirt or foreign objects have entered the connection, or there are remains of them.
(e) Measure the resistance between the terminals of the inverter cover (No. 1 interlock switch).
Standard resistance:





(f) Reinstall the inverter cover Installation.
(g) Reinstall the service plug grip Installation.
NG -- REPLACE INVERTER COVER
OK -- Continue to next step.

6. INSPECT INVERTER WITH CONVERTER ASSEMBLY
CAUTION: Wear insulated gloves before performing the following operation.
(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state.
(c) Remove the inverter cover Removal.




(d) Disconnect the I16 No. 1 interlock switch connector.
(e) Check that the ground bolt for the interlock switch is tightened to the specified torque.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(f) Connect terminals A and B as shown in the illustration.
(g) Measure the resistance between the I16 No. 1 interlock switch connector and body ground.
Standard resistance:





(h) Reconnect the No. 1 interlock switch connector.
NG -- REPAIR HARNESS OR CONNECTOR, OR REPLACE INVERTER WITH CONVERTER ASSEMBLY
OK -- Continue to next step.

7. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 2 INTERLOCK SWITCH)
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip and inverter cover have been removed.




(b) Disconnect the H15 HV control ECU connector.




(c) Disconnect the I17 No. 2 interlock switch connector.
(d) Measure the resistance between the wire harness side connectors.
Standard resistance (Check for open):






Standard resistance (Check for short)






(e) Reconnect the No. 2 interlock switch connector.
(f) Reconnect the HV control ECU connector.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

8. CHECK HARNESS AND CONNECTOR (NO. 1 INTERLOCK SWITCH - NO. 2 INTERLOCK SWITCH)
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip and inverter cover have been removed.




(b) Disconnect the I16 No. 1 interlock switch connector.




(c) Disconnect the I17 No. 2 interlock switch connector.
(d) Measure the resistance between the wire harness side connectors.
Standard resistance (Check for open):






Standard resistance (Check for short)






(e) Reconnect the No. 1 interlock switch connector.
(f) Reconnect the No. 2 interlock switch connector.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

9. INSPECT BATTERY PLUG (NO. 2 INTERLOCK SWITCH)
CAUTION: Wear insulated gloves and goggles before performing the following operation.
(a) Remove the HV battery assembly Removal.




(b) Remove the battery plug Removal.
(c) Install the service plug grip to the removed battery plug.
(d) Measure the resistance between the terminals of the battery plug.
Standard resistance:





(e) Remove the service plug grip.
(f) Reinstall the battery plug Installation.
(g) Reinstall the HV battery assembly Installation.
(h) Reinstall the service plug grip Installation.
NG -- REPLACE BATTERY PLUG
OK -- REPLACE HYBRID VEHICLE CONTROL ECU