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Home >> Lexus >> 2024 >> RX 500h >> Repair and Diagnosis >> External Pages >> Different car >> Section 148 (Plug-In Charge Control System - Diagnostic Codes (3 Of 3), Symptom Tests & Circuit Tests) >> PLUG-IN CHARGE CONTROL SYSTEM (for PHEV Model) >> Cannot Lock Charging Connector [10/2024 - ] >> Procedure

Cannot Lock Charging Connector [10/2024 - ]: Procedure

WARNING: This page is about a different car, the 2025 Lexus RX 450h+ and 2024 Lexus RX 450h+. However, it is still accessible from the selected car via links, so may be relevant.
  1. CHECK DTC OUTPUT (HEALTH CHECK) 
    1. Enter the following menus: Health Check.
    2. Check DTCs.

      Result

      Result Proceed to
      No DTCs output A
      DTCs output B
    3. Turn the ignition switch off.

    Result: 

    B 

    GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2023 - ] 

    Result: 

    A 

    See step  2

  2. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY (CHARGING PORT LID OPEN AND CHARGING CONNECTOR LOCK LOCKED) 
    WARNING:

    Be sure to wear insulated gloves.

    HINT: 

    WITH CHARGING PORT LID OPEN AND CHARGING CONNECTOR LOCKED: Status when the charging port lid is opened and the charging cable (electric vehicle charger cable assembly) is connected.

    1. Check that the service plug grip is not installed.
      NOTE:

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

    2. Connect the cable to the negative (-) auxiliary battery terminal.
    3. Unlock of the doors.
    4. Open the charging port lid.
    5. Check that the charging connector lock is unlocked (lock pin is not extended).

      HINT: 

      • If the charging connector lock is locked (the lock pin is extended), unlock it using the charging connector lock emergency release lever.
    6. Connect the charging cable (electric vehicle charger cable assembly), then lock the doors.
      NOTE:

      Make sure to connect the GTS before connecting the charging connector.

      HINT: 

      The charging connector lock is engaged when the doors are locked with the charging connector connected. (If the connector is not fully connected, the charging connector lock function may not operate correctly)

    7. Enter the following menus: Powertrain / Plug-in Control / Data List.

      Powertrain > Plug-in Control > Data List 

      Tester Display
      Charging Connector Connect Status Voltage
      Charging Connector Lock Pin Status
      Charging Connector Lock Motor Unlock Direction Revolution Request Current
      Charging Connector Lock Motor Lock Direction Revolution Request Current
    8. Read the value displayed on the GTS.

      Powertrain > Plug-in Control > Data List 

      Tester Display Measurement Item Normal Condition
      Charging Connector Connect Status Voltage PISW terminal voltage used for checking electric vehicle charger cable assembly connection condition
      (PISW)      		 Charging cable (Electric vehicle charger cable assembly) connected: 0.35 to 2.02 V
      Charging cable (Electric vehicle charger cable assembly) connected and the latch release button (PI switch) engaged: 2.02 to 3.57 V
      Charging Connector Lock Pin Status Charging connector lock pin status
      (CBSW)      		 Charging connector lock pin extended: Lock
      Charging Connector Lock Motor Unlock Direction Revolution Request Current Output of current to operate charging connector lock motor in reverse
      (CBMN)      		 Charging connector lock motor not operated: OFF
      Charging Connector Lock Motor Lock Direction Revolution Request Current Output of current to operate charging connector lock motor forward
      (CBMP)      		 Charging connector lock motor not operated: OFF
      HINT: 
      After the door lock operation, it turns on for approximately 600 ms

      Result

      Result Proceed to
      OK A
      NG
      (PISW)      		 B
      NG
      (CBSW)      		 C
      NG
      (CBMP, CBMN)      		 D
    9. Turn the ignition switch off.
    10. Unlock of the doors and charging connector lock.
    11. Disconnect the charging cable (electric vehicle charger cable assembly).
    12. Close the charging port lid.
    13. Disconnect the cable from the negative (-) auxiliary battery terminal.

    Result: 

    B 

    See step  4

    Result: 

    C 

    See step  9

    Result: 

    D 

    See step  12

    Result: 

    A 

    See step  3

  3. INSPECT CABLE EV CHARGER LOCK ASSEMBLY 

    Refer to INSPECTION [08/2023 - ]

    Result

    Proceed to
    OK
    NG

    Result: 

    OK 

    CAUSE ANALYSIS (USER / ENVIRONMENT RELATED CAUSE) 

    1. Perform cause analysis in the order of "User" and "Environment" categories as specified in the following tables.
      USER RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock/unlock was operated repeatedly Explain to the customer that to protect the charging connector lock motor, if the charging connector lock/unlock was operated repeatedly, operation may be temporarily prohibited.
      Charging connector lock was unlocked using charging connector lock emergency release lever Explain to the customer that the charging connector lock may not operate if the charging connector lock emergency release lever has been operated.
      1. After the charging connector lock emergency release lever has been operated, lock the doors.
      Charging connector lock/unlock operation was attempted after auxiliary battery was replaced or cable disconnected and connected Explain to the customer that charging connector lock/unlock operation may be prohibited after the auxiliary battery has been replaced or the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.
      1. Operate the charging connector lock/unlock again.
      ENVIRONMENT RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock motor temperature high Explain to the customer that, due to the temperature of the charging connector lock motor becoming high, to protect the charging connector lock motor, charging connector lock operation was prohibited.
      1. Wait 3 minutes or more after lock/unlock operation is prohibited, then resume inspection.
      Charging connector lock cannot operate due to foreign matter, ice, etc. Explain to the customer that the charging connector cannot be locked or unlocked if foreign matter, ice, etc. are stuck on the lock pin or charging connector.
    2. Take appropriate action in accordance with the result of the cause analysis.

    Result: 

    NG 

    REPLACE CABLE EV CHARGER LOCK ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

  4. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY (PISW TERMINAL VOLTAGE) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

    2. Disconnect the Hm1 AC charger inlet cable connector.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      Hm1-1 (PISW) - Body ground Ignition switch ON 3.57 to 4.73 V

      Result

      Proceed to
      OK
      NG
    6. Turn the ignition switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal.
    8. Reconnect the AC charger inlet cable connector.

    Result: 

    NG 

    See step  6

    Result: 

    OK 

    See step  5

  5. INSPECT CHARGING CABLE (ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY) (PISW) 

    HINT: 

    Perform the inspection with the charging cable (electric vehicle charger cable assembly) disconnected from the vehicle and external outlet.

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      3 (PISW) - 5 (GND) Latch release button (PI switch) pressed 430 to 530 Ω
      3 (PISW) - 5 (GND) Latch release button (PI switch) not pressed 135 to 165 Ω
      GTY697961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Charging Cable (Electric Vehicle Charger Cable Assembly)
    2. Connect the charging cable (electric vehicle charger cable assembly) to the plug.

      HINT: 

      Make sure not to connect it to the vehicle side charging inlet.

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

      Standard Voltage

      Tester Connection Condition Specified Condition
      3 (PISW) - 5 (GND) Latch release button (PI switch) pressed Below 1 V
      3 (PISW) - 5 (GND) Latch release button (PI switch) not pressed Below 1 V

      Result

      Proceed to
      OK
      NG
    4. Disconnect the charging cable (electric vehicle charger cable assembly) from the plug.

    Result: 

    OK 

    CAUSE ANALYSIS (USER / ENVIRONMENT RELATED CAUSE) 

    1. Perform cause analysis in the order of "User" and "Environment" categories as specified in the following tables.
      USER RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock/unlock was operated repeatedly Explain to the customer that to protect the charging connector lock motor, if the charging connector lock/unlock was operated repeatedly, operation may be temporarily prohibited.
      Charging connector lock was unlocked using charging connector lock emergency release lever Explain to the customer that the charging connector lock may not operate if the charging connector lock emergency release lever has been operated.
      1. After the charging connector lock emergency release lever has been operated, lock the doors.
      Charging connector lock/unlock operation was attempted after auxiliary battery was replaced or cable disconnected and connected Explain to the customer that charging connector lock/unlock operation may be prohibited after the auxiliary battery has been replaced or the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.
      1. Operate the charging connector lock/unlock again.
      ENVIRONMENT RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock motor temperature high Explain to the customer that, due to the temperature of the charging connector lock motor becoming high, to protect the charging connector lock motor, charging connector lock operation was prohibited.
      1. Wait 3 minutes or more after lock/unlock operation is prohibited, then resume inspection.
      Charging connector lock cannot operate due to foreign matter, ice, etc. Explain to the customer that the charging connector cannot be locked or unlocked if foreign matter, ice, etc. are stuck on the lock pin or charging connector.
    2. Take appropriate action in accordance with the result of the cause analysis.

    Result: 

    NG 

    REPLACE CHARGING CABLE (ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY) 

  6. CHECK HARNESS AND CONNECTOR (ELECTRIC VEHICLE CHARGER ASSEMBLY - CHARGING INLET) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

    2. Disconnect the H124 electric vehicle charger assembly connector.
    3. Measure the resistance according to the value(s) in the table below.
      GTY1205360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a AC Charger Inlet Cable
      (Charging Inlet)

      Standard Resistance

      Tester Connection Condition Specified Condition
      m3-3 (PISW) - m3-5 (GND) Ignition switch off 2.3 to 3.0 kΩ
      m3-3 (PISW) - Body ground Ignition switch off 2.3 to 3.0 kΩ
    4. Connect the cable to the negative (-) auxiliary battery terminal.
    5. Turn the ignition switch to ON.
    6. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      m3-3 (PISW) - m3-5 (GND) Ignition switch ON Below 1 V
      m3-3 (PISW) - Body ground Ignition switch ON Below 1 V

      Result

      Proceed to
      OK
      NG
    7. Turn the ignition switch off.
    8. Disconnect the cable from the negative (-) auxiliary battery terminal.
    9. Reconnect the electric vehicle charger assembly connector.

    Result: 

    OK 

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

    Result: 

    NG 

    See step  7

  7. CHECK AC CHARGER INLET CABLE (BODY GROUND TERMINAL CONNECTION CONDITION) 
    1. Check the installation condition of the AC charger inlet cable ground wire mA.

      OK

      The ground wire is securely installed.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    CONNECT SECURELY 

    Result: 

    OK 

    See step  8

  8. CHECK AC CHARGER INLET CABLE 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

    2. Disconnect the Hm1 AC charger inlet cable connector.
      NOTE:

      If the Hm1 connector is disconnected with the auxiliary battery connected, P0D56-15 may be detected. Check that the cable is disconnected from the negative (-) auxiliary battery terminal before proceeding work.

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

      Standard Resistance

      Tester Connection Condition Specified Condition
      m3-3 (PISW) - m3-5 (GND) Ignition switch off 2.3 to 3.0 kΩ
      m3-3 (PISW) - Body ground Ignition switch off 2.3 to 3.0 kΩ
      GTY1205360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a AC Charger Inlet Cable
      (Charging Inlet)
    4. Connect the cable to the negative (-) auxiliary battery terminal.
    5. Turn the ignition switch to ON.
    6. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      m3-3 (PISW) - m3-5 (GND) Ignition switch ON Below 1 V
      m3-3 (PISW) - Body ground Ignition switch ON Below 1 V
      NOTE:

      Turning the ignition switch to ON with the AC charger inlet cable connector disconnected causes DTCs to be stored. Clear the DTCs after performing this inspection.

      Result

      Proceed to
      OK
      NG
    7. Turn the ignition switch off.
    8. Disconnect the cable from the negative (-) auxiliary battery terminal.
    9. Reconnect the AC charger inlet cable connector.

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR (AC CHARGER INLET CABLE - ELECTRIC VEHICLE CHARGER ASSEMBLY) 

    Result: 

    NG 

    REPLACE AC CHARGER INLET CABLE. Refer to  REMOVAL [08/2023 - ] 

  9. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY (CBSW TERMINAL VOLTAGE) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

    2. Disconnect the H35 cable EV charger lock assembly connector.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      H35-9 (CBSW) - Body ground Ignition switch ON 4.5 to 5.5 V

      Result

      Proceed to
      OK
      NG
    6. Turn the ignition switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal.
    8. Reconnect the cable EV charger lock assembly connector.

    Result: 

    NG 

    See step  11

    Result: 

    OK 

    See step  10

  10. INSPECT CABLE EV CHARGER LOCK ASSEMBLY (CHARGING CONNECTOR LOCK DETECTION SWITCH) 

    Refer to INSPECTION [08/2023 - ]

    Result

    Proceed to
    OK
    NG

    Result: 

    OK 

    CAUSE ANALYSIS (USER / ENVIRONMENT RELATED CAUSE) 

    1. Perform cause analysis in the order of "User" and "Environment" categories as specified in the following tables.
      USER RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock/unlock was operated repeatedly Explain to the customer that to protect the charging connector lock motor, if the charging connector lock/unlock was operated repeatedly, operation may be temporarily prohibited.
      Charging connector lock was unlocked using charging connector lock emergency release lever Explain to the customer that the charging connector lock may not operate if the charging connector lock emergency release lever has been operated.
      1. After the charging connector lock emergency release lever has been operated, lock the doors.
      Charging connector lock/unlock operation was attempted after auxiliary battery was replaced or cable disconnected and connected Explain to the customer that charging connector lock/unlock operation may be prohibited after the auxiliary battery has been replaced or the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.
      1. Operate the charging connector lock/unlock again.
      ENVIRONMENT RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock motor temperature high Explain to the customer that, due to the temperature of the charging connector lock motor becoming high, to protect the charging connector lock motor, charging connector lock operation was prohibited.
      1. Wait 3 minutes or more after lock/unlock operation is prohibited, then resume inspection.
      Charging connector lock cannot operate due to foreign matter, ice, etc. Explain to the customer that the charging connector cannot be locked or unlocked if foreign matter, ice, etc. are stuck on the lock pin or charging connector.
    2. Take appropriate action in accordance with the result of the cause analysis.

    Result: 

    NG 

    REPLACE CABLE EV CHARGER LOCK ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

  11. CHECK HARNESS AND CONNECTOR (ELECTRIC VEHICLE CHARGER ASSEMBLY - CABLE EV CHARGER LOCK ASSEMBLY (CBSW)) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

    2. Disconnect the H35 cable EV charger lock assembly connector.
    3. Disconnect the H124 electric vehicle charger assembly connector.
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      H124-59 (CBSW) - H35-9 (CBSW) Ignition switch off Below 1 Ω
      H124-59 (CBSW) or H35-9 (CBSW) - Body ground and other terminals Ignition switch off 10 kΩ or higher

      Result

      Proceed to
      OK
      NG
    5. Reconnect the electric vehicle charger assembly connector.
    6. Reconnect the cable EV charger lock assembly connector.

    Result: 

    OK 

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  12. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY (CBMP, CBMN TERMINAL VOLTAGE) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

    2. Disconnect the H35 cable EV charger lock assembly connector.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the ignition switch to ON.
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      H35-10 (CBMP) - Body ground Ignition switch ON 0 to 1.5 V
      H35-4 (CBMN) - Body ground Ignition switch ON 0 to 1.5 V

      Result

      Proceed to
      OK
      NG
    6. Turn the ignition switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal.
    8. Reconnect the cable EV charger lock assembly connector.

    Result: 

    NG 

    See step  14

    Result: 

    OK 

    See step  13

  13. INSPECT CABLE EV CHARGER LOCK ASSEMBLY (CHARGING CONNECTOR LOCK RELAY) 

    Refer to INSPECTION [08/2023 - ]

    Result

    Proceed to
    OK
    NG

    Result: 

    OK 

    CAUSE ANALYSIS (USER / ENVIRONMENT RELATED CAUSE) 

    1. Perform cause analysis in the order of "User" and "Environment" categories as specified in the following tables.
      USER RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock/unlock was operated repeatedly Explain to the customer that to protect the charging connector lock motor, if the charging connector lock/unlock was operated repeatedly, operation may be temporarily prohibited.
      Charging connector lock was unlocked using charging connector lock emergency release lever Explain to the customer that the charging connector lock may not operate if the charging connector lock emergency release lever has been operated.
      1. After the charging connector lock emergency release lever has been operated, lock the doors.
      Charging connector lock/unlock operation was attempted after auxiliary battery was replaced or cable disconnected and connected Explain to the customer that charging connector lock/unlock operation may be prohibited after the auxiliary battery has been replaced or the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.
      1. Operate the charging connector lock/unlock again.
      ENVIRONMENT RELATED CAUSE

      Possible Cause Action to be Taken
      Charging connector lock motor temperature high Explain to the customer that, due to the temperature of the charging connector lock motor becoming high, to protect the charging connector lock motor, charging connector lock operation was prohibited.
      1. Wait 3 minutes or more after lock/unlock operation is prohibited, then resume inspection.
      Charging connector lock cannot operate due to foreign matter, ice, etc. Explain to the customer that the charging connector cannot be locked or unlocked if foreign matter, ice, etc. are stuck on the lock pin or charging connector.
    2. Take appropriate action in accordance with the result of the cause analysis.

    Result: 

    NG 

    REPLACE CABLE EV CHARGER LOCK ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

  14. CHECK HARNESS AND CONNECTOR (ELECTRIC VEHICLE CHARGER ASSEMBLY - CABLE EV CHARGER LOCK ASSEMBLY (CBMP, CBMN)) 
    WARNING:

    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 ignition switch to ON (READY), unless instructed by the appropriate service information because this may cause a malfunction.

    2. Disconnect the H35 cable EV charger lock assembly connector.
    3. Disconnect the H124 electric vehicle charger assembly connector.
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      H124-8 (CBMP) - H35-10 (CBMP) Ignition switch off Below 1 Ω
      H124-8 (CBMP) or H35-10 (CBMP) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      H124-7 (CBMN) - H35-4 (CBMN) Ignition switch off Below 1 Ω
      H124-7 (CBMN) or H35-4 (CBMN) - Body ground and other terminals Ignition switch off 10 kΩ or higher

      Result

      Proceed to
      OK
      NG
    5. Reconnect the electric vehicle charger assembly connector.
    6. Reconnect the cable EV charger lock assembly connector.

    Result: 

    OK 

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY. Refer to  REMOVAL [08/2023 - ] 

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS AND CONNECTOR 

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