Cannot Lock Charging Connector [12/2023 - ]: Procedure

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 [12/2023 - ] 

Result: 

A 

See step  2

HINT: 

Check that the "Connector Lock" setting is set to "Auto Lock".

Refer to CUSTOMIZE PARAMETERS [12/2023 - ]

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 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. 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

7. Connect the charging cable (electric vehicle charger cable assembly).

   HINT: 

   The connector lock is automatically engaged when the charging connector is connected.

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 charging connector is connected, it turns on for approximately 600 ms

   Result

   Result	Proceed to
   OK	A
   NG (CBSW)	B
   NG (CBMP, CBMN)	C
   NG (PISW)	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  7

Result: 

D 

See step  10

Result: 

A 

See step  3

Refer to INSPECTION [12/2023 - ]

Result

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. Disconnect and then connect the charging connector.
   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. Operate the charging connector lock/unlock again.
   Charging connector lock settings is OFF	Explain to the customer that the charging connector lock will not operate if the "Connector Lock" setting in customize parameters is set to OFF. If using the charging connector lock function, change the "Connector Lock" setting in customize parameters to "Auto Lock" or "Auto Lock & Unlock". Refer to CUSTOMIZE PARAMETERS [12/2023 - ]

   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. 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 [12/2023 - ] 

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 service information because this may cause a malfunction.

2. Disconnect the I53 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
   I53-4 (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  6

Result: 

OK 

See step  5

Refer to INSPECTION [12/2023 - ]

Result

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. Disconnect and then connect the charging connector.
   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. Operate the charging connector lock/unlock again.
   Charging connector lock settings is OFF	Explain to the customer that the charging connector lock will not operate if the "Connector Lock" setting in customize parameters is set to OFF. If using the charging connector lock function, change the "Connector Lock" setting in customize parameters to "Auto Lock" or "Auto Lock & Unlock". Refer to CUSTOMIZE PARAMETERS [12/2023 - ]

   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. 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 [12/2023 - ] 

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 service information because this may cause a malfunction.

2. Disconnect the I53 cable EV charger lock assembly connector.
3. Disconnect the J84 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
   J84-59 (CBSW) - I53-4 (CBSW)	Ignition switch off	Below 1 Ω
   J84-59 (CBSW) or I53-4 (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 [12/2023 - ] 

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

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 service information because this may cause a malfunction.

2. Disconnect the I53 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
   I53-10 (CBMP) - Body ground	Ignition switch ON	0 to 1.5 V
   I53-3 (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  9

Result: 

OK 

See step  8

Refer to INSPECTION [12/2023 - ]

Result

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. Disconnect and then connect the charging connector.
   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. Operate the charging connector lock/unlock again.
   Charging connector lock settings is OFF	Explain to the customer that the charging connector lock will not operate if the "Connector Lock" setting in customize parameters is set to OFF. If using the charging connector lock function, change the "Connector Lock" setting in customize parameters to "Auto Lock" or "Auto Lock & Unlock". Refer to CUSTOMIZE PARAMETERS [12/2023 - ]

   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. 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 [12/2023 - ] 

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 service information because this may cause a malfunction.

2. Disconnect the I53 cable EV charger lock assembly connector.
3. Disconnect the J84 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
   J84-8 (CBMP) - I53-10 (CBMP)	Ignition switch off	Below 1 Ω
   J84-8 (CBMP) or I53-10 (CBMP) - Body ground and other terminals	Ignition switch off	10 kΩ or higher
   J84-7 (CBMN) - I53-3 (CBMN)	Ignition switch off	Below 1 Ω
   J84-7 (CBMN) or I53-3 (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 [12/2023 - ] 

Result: 

NG 

REPAIR OR REPLACE HARNESS AND CONNECTOR 

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 service information because this may cause a malfunction.

2. Disconnect the In1 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
   In1-1 (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  12

Result: 

OK 

See step  11

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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Charging Cable (Electric Vehicle Charger Cable Assembly)

   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

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. Disconnect and then connect the charging connector.
   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. Operate the charging connector lock/unlock again.
   Charging connector lock settings is OFF	Explain to the customer that the charging connector lock will not operate if the "Connector Lock" setting in customize parameters is set to OFF. If using the charging connector lock function, change the "Connector Lock" setting in customize parameters to "Auto Lock" or "Auto Lock & Unlock". Refer to CUSTOMIZE PARAMETERS [12/2023 - ]

   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. 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.
   Non-standard charging cable or problem with charging station	Explain to the customer that if a non-standard charging cable is used or if there is a problem with a charging station, the charging connector may unlock if they press the latch release button (PI switch), even though the unlock switch has not been pressed. Explain to the customer that if a non-standard charging cable is used or if there is a problem with a charging station, the charging connector lock may protrude before the charging connector is fully connected. Use a compatible charging cable or charging station.

2. Take appropriate action in accordance with the result of the cause analysis.

Result: 

NG 

REPLACE CHARGING CABLE (ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY) 

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 service information because this may cause a malfunction.

2. Disconnect the J84 electric vehicle charger assembly connector.
3. Measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	AC Charger Inlet Cable (Charging Inlet)

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   n1-3 (PISW) - n1-5 (GND)	Ignition switch off	2.3 to 3.0 kΩ
   n1-3 (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
   n1-3 (PISW) - n1-5 (GND)	Ignition switch ON	Below 1 V
   n1-3 (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 [12/2023 - ] 

Result: 

NG 

See step  13

1. Check the installation condition of the AC charger inlet cable ground wire nA.

   OK

   The ground wire is securely installed.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

CONNECT SECURELY 

Result: 

OK 

See step  14

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 service information because this may cause a malfunction.

2. Disconnect the In1 AC charger inlet cable connector.
   NOTE:

   If the In1 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	AC Charger Inlet Cable (Charging Inlet)

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   n1-3 (PISW) - n1-5 (GND)	Ignition switch off	2.3 to 3.0 kΩ
   n1-3 (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
   n1-3 (PISW) - n1-5 (GND)	Ignition switch ON	Below 1 V
   n1-3 (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 (INLET AC CHARGER CABLE - ELECTRIC VEHICLE CHARGER ASSEMBLY) 

Result: 

NG 

REPLACE AC CHARGER INLET CABLE. Refer to  REMOVAL [12/2023 - ]