P0D91

What it means

P0D91 is a generic powertrain code for the battery charger coupler lock control circuit being open. It relates to plug-in hybrid and electric vehicles, where a lock holds the charging connector in the inlet during charging. The control unit commanded the lock actuator but saw an open circuit, meaning no continuity in the control wiring or actuator.

Symptoms

• Charging will not start or stops straight away
• Charging cable cannot be released from the inlet, or will not stay locked
• Charging port warning light or message on the dashboard
• Malfunction indicator or hybrid system warning lit
• Reduced or no ability to charge the high-voltage battery

Possible causes

• Open circuit or poor connection in the coupler lock actuator wiring or connectorlikely
• Faulty charge port lock actuator (open motor or solenoid winding)likely
• Corroded or damaged terminals at the charge inlet from water ingress or physical damagepossible
• Blown fuse or loss of supply to the lock circuit, where fittedpossible
• Fault in the charging control unit or driver circuitrare
• Outdated control unit software, only where the manufacturer has issued a bulletin for this faultrare

How to diagnose

1. Read all stored and pending codes and freeze frame data, noting whether other charging or high-voltage codes are present
2. Visually inspect the charge inlet, lock mechanism and cable plug for damage, debris, corrosion or water ingress
3. Check the relevant fuse for the lock circuit; the layout depends on the model
4. Inspect the actuator wiring and connectors for chafing, pushed-out pins, green corrosion or looseness
5. Operate the lock using a bidirectional scan function if supported and listen or watch for movement
6. Following the manufacturer's procedure and with the high-voltage system made safe by a qualified person, check continuity of the control wires and the actuator resistance against the specification
7. Check supply and ground at the actuator connector during a commanded lock, then check for any software updates for the model

How to fix

• Repair or replace damaged wiring and clean or renew corroded connector terminals
• Replace the charge port lock actuator or inlet assembly if it is open circuit
• Replace a blown fuse after finding the reason it failed
• Seal and dry the charge inlet area after water ingress, and renew affected parts
• Update the control unit software only if the manufacturer lists it as a fix for this fault
• Replace the charging control unit only after the wiring and actuator are proven good

Can I keep driving?

Nearby codes

• P0D90GenericBattery Charger Input Frequency Incorrect
• P0D92GenericBattery Charger Coupler Lock Control Circuit Low