DTC    P3004-132    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
132
The inverter is not precharged.
  1. Hybrid battery junction block assembly
  2. Frame wire
  3. Inverter with converter assembly
  4. Power management control ECU
  5. HV battery
  6. Wire harness or connector

WIRING DIAGRAM

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
    P3004-132 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
    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
    P0AE6-225
    		Hybrid Battery Precharge Contactor Control Circuit Low
    P0AE7-224
    		Hybrid Battery Precharge Contactor Control Circuit High
    P0C76-523
    		Hybrid Battery System Discharge Time Too Long
    P2511-149
    		ECM/PCM Power Relay Sensor Circuit Intermittent
    P3004-131, 800, 801
    		Power Cable Malfunction
    P324E-788
    		MG-ECU Power Relay Intermittent Circuit
    U0110 (all INF codes)*1
    		Lost Communication with Drive Motor Control Module

    Table 2 
    DTC No.
    		Relevant Diagnosis
    P0A95-123
    		High Voltage Fuse
    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 "A" Circuit Low
    P0AC2-123
    		Hybrid Battery Pack Current Sensor "A" 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 Sensor All Circuits Low
    U029A-123
    		Lost Communication with Hybrid Battery Pack Sensor Module

    HINT:
    1. *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
    2. P3004-132 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 FREEZE FRAME DATA (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. Read the freeze frame data of DTC P3004-132.

    Result:

    Result
    		Proceed to
    All of the following conditions are met:
    1. Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VL-Voltage before Boosting) is 50 V or less.
    2. Difference between HV battery voltage (Power Resource VB) and post-boost voltage (VH-Voltage after Boosting) is more than 70 V.
    3. Difference between pre-boost voltage (VL-Voltage before Boosting) and post-boost voltage (VH-Voltage after Boosting) is more than 90 V.
    		A
    In addition to the above conditions, HV battery current (Batt Pack Current Val) is 3 A or more.
    		B
    Other than above
    		C

  1. Turn the power switch off.



B
GO TO DTC CHART (P3004-800) (Click here)

C
Go to step 3
A

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)  

3.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


4.CHECK FRAME WIRE (INVERTER WITH CONVERTER ASSEMBLY SIDE)

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. Check the connection between the frame wire S1 and the inverter with converter assembly.

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

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



NG
CONNECT SECURELY
OK


5.CHECK FRAME WIRE (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY SIDE)

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. Check the connection between the frame wire S4, S3 and the hybrid battery junction block assembly.

Torque:
9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Check for arc marks on the terminals of the frame wire.

    Result:
    Result
    		Proceed to
    The terminals are connected securely and there are no contact problems.
    		There are no arc marks.
    		A
    The terminals are not connected securely and there is a contact problem.
    		There are arc marks.
    		B
    The terminals are not connected securely and there is a contact problem.
    		There are no arc marks.
    		C
    The terminals are connected securely and there are no contact problems.
    		There are arc marks.
    		B

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



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


6.CHECK FRAME WIRE (INVERTER WITH CONVERTER - HYBRID BATTERY JUNCTION BLOCK)

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.

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



    A215642E06

  1. Disconnect the frame wire S1 from the inverter with converter assembly.



    A216851E04

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    S4-1 (CBI) - S1-2 (CBI)
    		Power switch off
    		Below 1 Ω
    S3-1 (CEI) - S1-1 (CEI)
    		Power switch off
    		Below 1 Ω

    Text in Illustration 
    *1
    		Frame Wire (Hybrid Battery Junction Block Assembly Side)
    *a
    		Front view of Frame Wire connector
    (to Inverter with Converter Assembly)

  1. Connect the frame wire from the inverter with converter assembly.

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

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



NG
REPLACE FRAME WIRE (Click here)
OK


7.CHECK CONDITION OF MAIN BATTERY CABLE CONNECTION(S)

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).



    A215635E04

  1. Check the connections between the main battery cables f2, h2 and the hybrid battery junction block assembly.

    OK:
    The connectors are connected securely and not damaged.

  1. Check for arc marks on the terminals of the main battery cable connectors.

    Result:
    Result
    		Proceed to
    The terminals are connected securely and there are no contact problems.
    		There are no arc marks.
    		A
    The terminals are not connected securely and there is a contact problem.
    		There are arc marks.
    		B
    The terminals are not connected securely and there is a contact problem.
    		There are no arc marks.
    		C
    The terminals are connected securely and there are no contact problems.
    		There are arc marks.
    		B

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



B
REPLACE MALFUNCTIONING PARTS

C
CONNECT SECURELY
A


8.CHECK HV BATTERY

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).



    A245323E02

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

    Standard Voltage:
    Tester Connection
    		Switch Condition
    		Specified Condition
    f2-1 (+) - 2
    		Power switch off
    		114 to 190 V
    h2-1 (-) - 1
    		Power switch off
    		54 to 90 V

    CAUTION:
    Do not allow the probes of the electrical tester to contact each other during this inspection.

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



NG
REPLACE HV BATTERY (Click here)
OK


9.CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK)

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. Disconnect connector H3 from the power management control ECU.

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

  1. Disconnect the connector i3 that drives the relay of the hybrid battery junction block assembly.

    HINT:
    Before disconnecting the connector i3 that drives the relay of the hybrid battery junction block assembly, make sure that the connector is securely engaged.



    A213116E40

  1. 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
    H3-3 (SMRP) - i3-3 (SMRP)
    		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)

  1. Connect the hybrid battery junction block assembly connector.

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

  1. Connect the power management control ECU connector.



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


10.INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

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 hybrid battery junction block assembly (Click here).



    A215628E48

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    f2-1 (+) - S4-1 (CBI)
    		Auxiliary battery voltage is applied between terminals i3-4 (SMRB) and i3-2 (GND).
    		Below 1 Ω

    Text in Illustration 
    *1
    		Hybrid Battery Junction Block Assembly

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

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    i3-4 (SMRB) - i3-2 (GND)
    		-40 to 80°C (-40 to 176°F)
    		19.0 to 35.5 Ω

  1. Install the hybrid battery junction block assembly (Click here).



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


11.INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP)

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 hybrid battery junction block assembly (Click here).



    A215628E49

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

    Standard Resistance:
    Tester Connection
    		Switch Condition
    		Specified Condition
    h2-1 (-) - S3-1 (CEI)
    		Auxiliary battery voltage is applied between terminals i3-3 (SMRP) and i3-2 (GND).
    		28.5 to 31.5 Ω

    Text in Illustration 
    *1
    		Hybrid Battery Junction Block Assembly

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

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    i3-3 (SMRP) - i3-2 (GND)
    		-40 to 80°C (-40 to 176°F)
    		112 to 274 Ω

  1. Install the hybrid battery junction block assembly (Click here).



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


12.CHECK FOR INTERMITTENT PROBLEMS

  1. Check for intermittent problems (Click here).


NEXT


13.CLEAR DTC

  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. Read and record the DTCs and freeze frame data.

  1. Clear DTCs and freeze frame data.

  1. Turn the power switch off.


NEXT


14.CHECK DTC OUTPUT (HYBRID CONTROL)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the power switch on (READY).

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

  1. Check if DTCs are output.

    Result:
    Result
    		Proceed to
    No DTCs are output.
    		A
    DTC P3004-131 is output.
    		B
    DTC P3004-132 is output.
    		C

  1. Turn the power switch off.



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

C
REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)
A

REPLACE INVERTER WITH CONVERTER ASSEMBLY (Click here)