HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A0D-350, P0A0D-351

DTC Code	DTC Name
P0A0D-350	High Voltage System Inter-Lock Circuit High
P0A0D-351	High Voltage System Inter-Lock Circuit High

DESCRIPTION

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 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 frame wire that is connected to the inverter with converter assembly. The third one is located at the inverter terminal 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 terminal 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)	Wire harness or connector Power Management Control ECU Service plug grip Inverter with converter assembly Frame wire Inverter terminal cover
P0A0D	351	Interlock signal line opens (ILK signal is ON) while the vehicle is being driven

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.

Tech Tips

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

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.

Turn the power switch on (IG) and wait for 5 seconds or more.

PROCEDURE

CHECK DTC OUTPUT (HV)

Connect the intelligent tester to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

Check if DTCs are output.

Result

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

Turn the power switch off.

GO TO DTC CHART Click here

CLEAR DTC (HV)
1. Connect the intelligent tester to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Read and record the DTCs and freeze frame data.
5. Clear DTCs and freeze frame data.
6. Turn the power switch off.
NEXT

RECONFIRM DTC OUTPUT (HV)

Connect the intelligent tester to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

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

Turn the power switch off.

CHECK CONNECTOR CONNECTION CONDITION (INTERLOCK CIRCUIT) Click here

CHECK SERVICE PLUG GRIP

CAUTION:

Be sure to wear insulated gloves.
1. Text in Illustration
  
  *1 Service Plug Grip
  
  Check if the service plug grip is installed correctly.
  
  Standard
  
  The service plug grip is fully pushed in as shown in the illustration.
  Note
  - Insert the service plug grip until a click sound is heard.
  - If "UNLOCK" is printed on the service plug grip, push in the service plug grip until "UNLOCK" is not visible at all.
  Tech Tips
  - For the removal and installation procedures Click here.
  - 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
CHECK INVERTER TERMINAL COVER
CAUTION:

Be sure to wear insulated gloves.
1. Check that the service plug grip is not installed.
  
  Note
  
  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.
2. Check if the inverter terminal cover of the inverter with converter assembly is installed correctly.
  
  OK
  
  The inverter terminal cover is installed correctly.
NG
INSTALL PARTS CORRECTLY

OK
CHECK FRAME WIRE
CAUTION:

Be sure to wear insulated gloves.
1. Check that the service plug grip is not installed.
  
  Note
  
  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.
2. Remove the inverter terminal cover from the inverter with converter assembly.
3. Check if the frame wire T1 is connected correctly.
  
  OK
  
  The frame wire connector is connected correctly.
4. Install the inverter terminal cover from the inverter with converter assembly.
NG
INSTALL PARTS CORRECTLY

OK

Text in Illustration
*1	Service Plug Grip

Standard
The service plug grip is fully pushed in as shown in the illustration.

OK
The inverter terminal cover is installed correctly.

OK
The frame wire connector is connected correctly.

CHECK POWER MANAGEMENT CONTROL ECU

Disconnect connector A59 from the inverter with converter assembly.
Turn the power switch on (IG).

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

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

Standard Voltage

Tester Connection	Switch Condition	Specified Condition
A59-35 (ILKI) - Body ground	Power switch on (IG)	10 to 14 V

Note

Turning the power switch on (IG) with the low voltage connector of the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

Turn the power switch off.
Connect the inverter with converter assembly connector.

CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER) Click here

CHECK INVERTER WITH CONVERTER ASSEMBLY (INTERLOCK)

CAUTION:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.

Note

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.
Disconnect connector A59 from the inverter with converter assembly.

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

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

Standard Resistance

Tester Connection	Switch Condition	Specified Condition
A59-35 (ILKI) - A59-36 (ILKO)	Power switch off	Less than 10 Ω

Note

Do not remove the inverter terminal cover.

Connect the inverter with converter assembly connector.

CHECK INVERTER TERMINAL COVER Click here

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

Install the service plug grip Click here.
Disconnect connector A59 from the inverter with converter assembly.

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

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

Standard Resistance

Tester Connection	Switch Condition	Specified Condition
A59-36 (ILKO) - Body ground	Power switch off	Less than 1 Ω

Connect the inverter with converter assembly connector.

CHECK SERVICE PLUG GRIP Click here

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
CHECK SERVICE PLUG GRIP
1. Remove the service plug grip Click here.
2. Text in Illustration
  
  *1 Service Plug Grip
  
  Check the condition of the service plug grip interlock.
  
  OK
  
  Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.
3. Text in Illustration
  
  *1 Service Plug Grip
  
  Install the service plug grip Click here.
  Note
  - Insert the service plug grip until a click sound is heard.
  - If "UNLOCK" is printed on the service plug grip, push in the service plug grip until "UNLOCK" is not visible at all.
NG
REPLACE SERVICE PLUG GRIP Click here

OK
CHECK HARNESS AND CONNECTOR
1. Check that the service plug grip is not installed.
  
  Note
  
  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.
2. Text in Illustration
  
  *1 Inter Lock Connector
  
  Check that the interlock connector at the service plug grip installation socket is connected correctly.
  
  OK
  
  The connector is connected correctly.
NG
INSTALL PARTS CORRECTLY

OK

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

Text in Illustration
*1	Service Plug Grip

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

Text in Illustration
*1	Service Plug Grip

Text in Illustration
*1	Inter Lock Connector

OK
The connector is connected correctly.

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

CAUTION:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.

Note

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.
Disconnect connector A59 from the inverter with converter assembly.
Disconnect connector c2.

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

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

Standard Resistance

Tester Connection	Switch Condition	Specified Condition
A59-36 (ILKO) - c2-1 (ILK)	Power switch off	Below 1 Ω

Connect the service plug grip connector.
Connect the inverter with converter assembly connector.

REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK INVERTER TERMINAL COVER
CAUTION:

Be sure to wear insulated gloves.
1. Check that the service plug grip is not installed.
  
  Note
  
  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.
2. Remove the inverter terminal cover from the inverter with converter assembly.
3. Check the condition of the inverter terminal cover interlock.
  
  OK
  
  Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.
4. Install the inverter terminal cover from the inverter with converter assembly.
NG
REPLACE INVERTER TERMINAL COVER Click here

OK
CHECK FRAME WIRE (FRAME WIRE CONNECTOR)
CAUTION:

Be sure to wear insulated gloves.
1. Check that the service plug grip is not installed.
  
  Note
  
  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.
2. Remove the inverter terminal cover from the inverter with converter assembly.
3. Disconnect the frame wire T1 from the inverter with converter assembly.
4. Check the frame wire interlock.
  
  OK
  
  Dirt or foreign objects have not entered the connection, and there is no evidence of contamination.
5. Connect the frame wire to the inverter with converter assembly.
6. Install the inverter terminal cover from the inverter with converter assembly.
NG
REPLACE FRAME WIRE Click here

OK

REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

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

Turn the power switch off.
Disconnect connector A59 from the inverter with converter assembly.
Disconnect connector A21 from the power management control ECU.

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

Standard Resistance

Tester Connection	Switch Condition	Specified Condition
A21-32 (ILK) - A59-35 (ILKI)	Power switch off	Below 1 Ω

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

Connect the power management control ECU connector.
Connect the inverter with converter assembly connector.

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE POWER MANAGEMENT CONTROL ECU Click here