DTC    P3004-803    Power Cable Malfunction

for Preparation Click here

DESCRIPTION

WIRING DIAGRAM

INSPECTION PROCEDURE

CAUTION:

1. 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.
   
2. 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.

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).

1. Connect the intelligent tester to the DLC3.
   

2. Turn the power switch on (IG).
   

3. Enter the following menus: Powertrain / Hybrid Control / DTC.
   

4. Check if DTCs are output.
   

   Result:

   Result	Proceed to
   P3004-803 only is output.	A
   Any of the following DTCs are also output.	B
   P0A95-123 is also output.	C

   
   

   DTC No.	Relevant Diagnosis
   P0A1A-151, 155, 156, 658, 659	Generator Control Module
   P0A1B-164, 193, 512, 661, 786	Drive Motor "A" Control Module
   P0A1D-148	Hybrid Powertrain Control Module
   P0A78-266, 267, 586	Drive Motor "A" Inverter Performance
   P0A94-442	DC/DC Converter Performance
   P0ADB-227	Hybrid Battery Positive Contactor Control Circuit Low
   P0ADC-226	Hybrid Battery Positive Contactor Control Circuit High
   P0ADF-229	Hybrid Battery Negative Contactor Control Circuit Low
   P0AE0-228	Hybrid Battery Negative Contactor Control Circuit High
   P0C76-523	Hybrid Battery System Discharge Time Too Long
   P2511-149	ECM/PCM Power Relay Sensor Circuit Intermittent
   P3004-131, 132	Power Cable Malfunction
   P324E-788	MG-ECU Power Relay Intermittent Circuit
   U0110 (all INF codes)*1	Lost Communication with Drive Motor Control Module

   HINT:

   1. *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      
   2. P3004-803 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.
      

5. Turn the power switch off.
   

B	GO TO DTC CHART (HYBRID CONTROL SYSTEM) (Click here)
C	GO TO DTC CHART (P0A95-123) (Click here)

A

1. Connect the intelligent tester to the DLC3.
   

2. Turn the power switch on (IG).
   

3. Enter the following menus: Powertrain / Hybrid Control / DTC.
   

4. Read and record the DTCs and freeze frame data.
   

5. Clear DTCs and freeze frame data.
   

6. Turn the power switch off.
   

NEXT

1. Connect the intelligent tester to the DLC3.
   

2. Turn the power switch on (READY).
   

3. Ensure the safety of the areas in front and at the back of the vehicle.
   

4. Move the shift lever to D and depress both the accelerator pedal and brake pedal at the same time.
   

   HINT:

   1. Depressing both the accelerator pedal and brake pedal at the same time causes the HV battery current to flow and ensures that there is no problem with the high-voltage wiring.
      
   2. Depressing both the accelerator pedal and brake pedal at the same time causes Accelerator and brake depress in the inappropriate operation and history data to be counted.
      

5. Enter the following menus: Powertrain / Hybrid Control / DTC.
   

6. Check if DTCs are output.
   

   Result:

   Result	Proceed to
   P3004-803 is output, or no DTCs are output.	A
   Power switch is not turned on (READY) and P3004- 131 is output.	B

7. Turn the power switch off.
   

B	GO TO DTC CHART (P3004-131) (Click here)

A

1. Check the connections of the power management control ECU connectors.
   

   
   
   
   
   

   Text in Illustration 

   *A

   for LHD

   *B

   for RHD

   OK:

   The connectors are connected securely and there are no contact problems.
   

NG	CONNECT SECURELY

OK

CAUTION:

Be sure to wear insulated gloves.

1. 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.

2. Disconnect connector H3 from the power management control ECU.
   

3. Remove the upper hybrid battery cover sub-assembly (Click here).
   

4. Disconnect connector i3 from the hybrid battery junction block assembly.
   

   HINT:

   Before disconnecting the connector, check whether it is connected securely to the hybrid battery junction block assembly.

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

   Standard Resistance:

   Tester Connection	Switch Condition	Specified Condition
   H3-4 (SMRB) - i3-4 (SMRB)	Power switch off	Below 1 Ω
   H3-2 (SMRG) - i3-1 (SMRG)	Power switch off	Below 1 Ω

   Text in Illustration 

   *a	Rear view of wire harness connector (to Power Management Control ECU)
   *b	Rear view of wire harness connector (to Hybrid Battery Junction Block Assembly)

6. Connect hybrid battery junction block assembly connector.
   

7. Install the upper hybrid battery cover sub-assembly (Click here).
   

8. Connect the power management control ECU connector.
   

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK
REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (Click here)