- 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.
| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM100000001EKJ2 |
| Model Year Start: 2019 | Model: RAV4 HV | Prod Date Range: [11/2018 - 08/2020] |
| Title: HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for 2WD with NICKEL METAL HYDRIDE BATTERY): P0A0A13,P0A0A92; High Voltage System Interlock Circuit Open; 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020] | ||
|
DTC |
P0A0A13 |
High Voltage System Interlock Circuit Open |
|
DTC |
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
|
System Diagram Location |
Inspection Content |
Reason |
Inspection Step |
|---|---|---|---|
|
*a |
|
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 or inverter cover is removed, it will prohibit hybrid system operation or shut off the system main relay. The 2 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. 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 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 |
|---|---|---|---|---|---|
|
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) |
|
Does not come on |
Master Warning: Comes on |
|
P0A0A92 |
High Voltage System Interlock Performance or Incorrect Operation |
Either of the following conditions is met:
(1 trip detection logic) |
|
Does not come on |
Master Warning: Comes on |
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 here
![2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for 2WD with NICKEL METAL HYDRIDE BATTERY): UTILITY](/t3Portal/stylegraphics/info.gif)
- Connect the Techstream to the DLC3.
- Turn the power switch on (IG) and turn the Techstream on.
- Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
- Turn the power switch off and wait for 2 minutes or more.
- Turn the power switch on (IG) and turn the Techstream on.
- With power switch on (IG) and wait for 5 seconds or more.
- Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.
-
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
CAUTION / NOTICE / HINT
CAUTION:
-
Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
- Inspecting the high-voltage system
- Disconnecting the low voltage connector of the inverter with converter assembly
- Disconnecting the low voltage connector of the HV battery
-
To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
-
After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
-
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.
*a
Without waiting for 10 minutes
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
- 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 Techstream 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
|
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.
- The chart above is listed in inspection order of priority.
- 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.
| B |
|
GO TO DTC CHART (HYBRID CONTROL SYSTEM)
|
|
|
2. |
CLEAR DTC |
Click here
|
|
3. |
CHECK DTC OUTPUT (HYBRID CONTROL) |
(a) Connect the Techstream 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
|
Result |
Proceed to |
|---|---|
|
P0A0A13 or P0A0A92 is output again. |
A |
|
Neither P0A0A13 or P0A0A92 is output again. |
B |
(e) Turn the power switch off.
| B |
|
|
|
4. |
CHECK SERVICE PLUG GRIP |
CAUTION:
Be sure to wear insulated gloves.
|
(a) Check if the service plug grip is installed correctly. NOTICE: Insert the service plug grip until a click sound is heard. HINT:
|
|
| 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 here
|
(c) 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.
| NG |
|
INSTALL PARTS CORRECTLY |
|
|
6. |
CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR) |
Click here
| 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 here
(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) Measure the voltage according to the value(s) in the table below. Standard Voltage:
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.
| NG |
|
|
|
8. |
CHECK SERVICE PLUG GRIP |
CAUTION:
Be sure to wear insulated gloves.
(a) Remove the service plug grip.
Click here
|
(b) 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. |
|
| NG |
|
REPLACE SERVICE PLUG GRIP
|
|
|
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 here
(c) Disconnect the M33 service plug grip (interlock switch) connector.
|
(d) Measure the resistance according to the value(s) in the table below. Standard Resistance:
|
|
(e) Reconnect the M33 service plug grip (interlock switch) connector.
(f) Install the No. 1 HV battery cover panel RH.
| 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.
| OK |
|
REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY
|
| 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 A31 hybrid vehicle control ECU assembly connector.
(c) Remove the No. 1 HV battery cover panel RH.
Click here
(d) Disconnect the M33 service plug grip (interlock switch) connector.
(e) Measure the resistance according to the value(s) in the table below.
|
*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 |
|---|---|---|
|
A31-5 (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 A31 hybrid vehicle control ECU assembly connector.
| OK |
|
REPLACE HYBRID VEHICLE CONTROL ECU ASSEMBLY
|
| NG |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR |
|
|