DTC    P3004-800    Power Cable Malfunction

DTC    P3004-801    Power Cable Malfunction

for Preparation Click here


DESCRIPTION

Refer to the description for DTC P0AE6-225 (Click here).

DTC No.
INF Code
DTC Detection Condition
Trouble Area
P3004
800
Excessive overcurrent occurs during precharge (time from when SMRP turns on until when SMRG turns on).
  1. Wire harness or connector
  2. No. 2 engine wire
  3. Compressor with motor assembly
  4. Inverter with converter assembly
  5. Hybrid battery junction block assembly
  6. Frame wire
  7. Power management control ECU
P3004
801
Minimal overcurrent occurs during precharge (time from when SMRP turns on until when SMRG turns on).

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A08-264 (Click here).
Refer to the wiring diagram for DTC P0AA6-526 (Click here).
Refer to the wiring diagram for DTC P0AE6-225 (Click here).

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.CHECK DTC OUTPUT (HYBRID CONTROL)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (IG).

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

  1. Check if DTCs are output.

    Result:
    Result
    		Proceed to
    P3004-800 or P3004-801 only is output.
    		A
    DTCs shown in Table 1 are output simultaneously.
    		B
    DTCs shown in Table 2 are output simultaneously.
    		C


    Table 1 
    DTC No.
    		Relevant Diagnosis
    P0A09-265
    		DC/DC Converter Status Circuit Low Input
    P0A10-263
    		DC/DC Converter Status Circuit High Input

    Table 2 
    DTC No.
    		Relevant Diagnosis
    P0ABF-123
    		Hybrid Battery Pack Current Sensor Circuit
    P0AC0-123
    		Hybrid Battery Pack Current Sensor Circuit Range / Performance
    P0AC1-123
    		Hybrid Battery Pack Current Sensor Circuit Low
    P0AC2-123
    		Hybrid Battery Pack Current Sensor Circuit High
    P0AFC-123
    		Hybrid Battery Pack Sensor Module
    P0B3D-123
    		Hybrid Battery Voltage Sensor "A" Circuit Low
    P0B42-123
    		Hybrid Battery Voltage Sensor "B" Circuit Low
    P0B47-123
    		Hybrid Battery Voltage Sensor "C" Circuit Low
    P0B4C-123
    		Hybrid Battery Voltage Sensor "D" Circuit Low
    P0B51-123
    		Hybrid Battery Voltage Sensor "E" Circuit Low
    P0B56-123
    		Hybrid Battery Voltage Sensor "F" Circuit Low
    P0B5B-123
    		Hybrid Battery Voltage Sensor "G" Circuit Low
    P0B60-123
    		Hybrid Battery Voltage Sensor "H" Circuit Low
    P0B65-123
    		Hybrid Battery Voltage Sensor "I" Circuit Low
    P0B6A-123
    		Hybrid Battery Voltage Sensor "J" Circuit Low
    P0B6F-123
    		Hybrid Battery Voltage Sensor "K" Circuit Low
    P0B74-123
    		Hybrid Battery Voltage Sensor "L" Circuit Low
    P0B79-123
    		Hybrid Battery Voltage Sensor "M" Circuit Low
    P0B7E-123
    		Hybrid Battery Voltage Sensor "N" Circuit Low
    P0B83-123
    		Hybrid Battery Voltage Sensor "O" Circuit Low
    P308A-123
    		Hybrid Battery Voltage Detection Circuit Open
    U029A-123
    		Lost Communication with Hybrid Battery Pack Sensor Module

    HINT:
    P3004-800 or P3004-801 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.

  1. Turn the power switch off.



B
GO TO DTC CHART (HYBRID CONTROL SYSTEM) (Click here)

C
GO TO DTC CHART (HYBRID BATTERY SYSTEM) (Click here)
A


2.CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)


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


    A237663E01


    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


3.CHECK COMPRESSOR WITH MOTOR ASSEMBLY

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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A216825E01

  1. Disconnect the No. 2 engine wire (air conditioning harness) E2 from the inverter with converter assembly.



    A215631E02

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

    Standard Resistance:
    Tester Connection
    (Tester Probe Polarity)
    		Switch Condition
    		Specified Condition
    E2-1 (ACPB) - E2-2 (ACPE)
    		Power switch off
    		100 kΩ or higher

    Text in Illustration 
    *1
    		Shielded Wire Ground
    *a
    		Front view of No. 2 Engine Wire (Air Conditioning Harness) connector
    (to Inverter with Converter Assembly)

    NOTICE:
    1. Do not use a megohmmeter.
    2. Read the resistance after the value has stabilized.

    HINT:
    The polarities of the tester probes may differ depending on the tester. Use the current output probe of the tester as the positive probe for this measurement. To determine the polarity, use another voltmeter to confirm the current output probe of the tester. When measuring the output of the tester, the voltmeter positive probe indicates the tester current output probe.

  1. Connect the No. 2 engine wire (air conditioning harness) from the inverter with converter assembly.

  1. Install the inverter cover to the inverter with converter assembly.



NG
Go to step 7
OK


4.CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU)

  1. Disconnect connector A62 from the inverter with converter assembly.



    A215725E45

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    A62-12 (NODD) - Body ground
    		Power switch off
    		120 to 140 kΩ

    Text in Illustration 
    *a
    		Front view of wire harness connector
    (to Inverter With Converter Assembly)

  1. Connect the inverter with converter assembly connector.



NG
Go to step 6
OK


5.CHECK FRAME WIRE

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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A215642E06

  1. Disconnect the frame wire (high voltage DC connector) S1 from the inverter with converter assembly.

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



    A215638E07

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    S3-1 (CEI) - S4-1 (CBI)
    		Power switch off
    		10 kΩ or higher

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

  1. Connect the frame wire (high voltage DC connector) to inverter with converter assembly.

  1. Install the inverter cover to the inverter with converter assembly.



NG
Go to step 8
OK

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)  

6.CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)

  1. Disconnect connector A62 from the inverter with converter assembly.

  1. Disconnect connector A19 from power management control ECU.



    A216848E05

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

    Standard Resistance (Check for Open):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A19-21 (NODD) - A62-12 (NODD)
    		Power switch off
    		Below 1 Ω

    Standard Resistance (Check for Short):
    Tester Connection
    		Switch Condition
    		Specified Condition
    A19-21 (NODD) or A62-12 (NODD) - Body ground and other terminals
    		Power switch off
    		10 kΩ or higher

    Text in Illustration 
    *a
    		Rear view of wire harness connector
    (to Power Management Control ECU)
    *b
    		Front view of wire harness connector
    (to Inverter with Converter Assembly)

  1. Connect the power management control ECU connector.

  1. Connect the inverter with converter assembly connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

REPLACE POWER MANAGEMENT CONTROL ECU (Click here)  

7.CHECK NO. 2 ENGINE WIRE

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.



    A209686

  1. Remove the inverter cover from the inverter with converter assembly.



    A216825E01

  1. Disconnect the No. 2 engine wire (air conditioning harness) E2 from the inverter with converter assembly.



    A245320E01

  1. Disconnect the No. 2 engine wire (air conditioning harness) E1 from the compressor with motor assembly.
    Text in Illustration 
    *1
    		Green Lock



    A215631E02

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    E2-1 (ACPB) - E2-2 (ACPE)
    		Power switch off
    		10 kΩ or higher

    Text in Illustration 
    *1
    		Shielded Wire Ground
    *a
    		Front view of No. 2 Engine Wire (Air Conditioning Harness) connector
    (to Inverter with Converter Assembly)

  1. Connect the No. 2 engine wire (air conditioning harness) to the compressor with motor assembly.

  1. Connect the No. 2 engine wire (air conditioning harness) from the inverter with converter assembly.

  1. Install the inverter cover to the inverter with converter assembly.



NG
REPLACE NO. 2 ENGINE WIRE
OK

REPLACE COMPRESSOR WITH MOTOR ASSEMBLY (Click here)  

8.CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

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.

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



    A215638E07

  1. Disconnect the frame wire S3 and S4 from the hybrid battery junction block assembly.



    A215627E04

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    S3-1 (CEI) - S4-1 (CBI)
    		Power switch off
    		10 kΩ or higher

    Text in Illustration 
    *1
    		Hybrid Battery Junction Block Assembly

  1. Connect the frame wire to the hybrid battery junction block assembly.

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



NG
REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (Click here)
OK

REPLACE FRAME WIRE (Click here)