DTC    P3004-800    Power Cable Malfunction

DTC    P3004-801    Power Cable Malfunction

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DESCRIPTION


DTC No.
INF Code
DTC Detection Condition
Trouble Area
P3004
800
Excessive overcurrent in high-voltage system
  1. Wire harness or connector
  2. Engine wire No.4
  3. w/ motor compressor assembly
  4. w/ converter inverter assembly
  5. HV relay assembly
  6. Frame wire No.3
  7. Power steering converter assembly
P3004
801
Minimal overcurrent in high-voltage system
  1. Wire harness or connector
  2. Engine wire No.4
  3. w/ motor compressor assembly
  4. w/ converter inverter assembly
  5. HV relay assembly
  6. Frame wire No.3
  7. Power steering converter assembly

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A78-266. (Click here)

INSPECTION PROCEDURE

CAUTION:
  1. Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are working on the high-voltage system.
  2. After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:
At least 5 minutes is required to discharge the high-voltage capacitor inside the w/ converter inverter assembly.

1.READ OUTPUT DTC (HV AND EMPS)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch to the ON position.

  1. Select the following menu items: Powertrain / Hybrid Control and EMPS / DTC.

    Standard:
    DTC is output.



YES
GO TO DTC CHART
NO


2.CHECK WIRE HARNESS AND CONNECTOR (HV CONTROL ECU - MG ECU)

CAUTION:
Be sure to wear insulated gloves.



    A108501E08

  1. Turn the ignition switch off and remove the service plug grip. (Click here)

    NOTICE:
    Do not put the vehicle into the READY-on state with the service plug grip removed as this may cause a malfunction.

  1. Disconnect the H31 connector from the HV control ECU.

  1. Remove the inverter cover. (Click here)

    NOTICE:
    1. Wrap the interlock round terminal for the inverter cover with vinyl tape to prevent it from shorting to ground.
    2. Be sure to prevent water in the reservoir tank from entering the inverter.

  1. Disconnect the I25 connector from the MG ECU.

  1. Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

    HINT:
    Turning the ignition switch to the ON position with the service plug grip and inverter cover removed causes interlock switch system DTC (P0A0D-350) to be output.

    Standard Voltage:
    Tester Connection
    		Specified Condition
    NODD (H31-11) - Body ground
    		Below 1 V

  1. Turn the ignition switch off.

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

    Standard Resistance (Check for open):
    Tester Connection
    		Specified Condition
    NODD (H31-11) - NOFF (I25-33)
    		Below 1 Ω

    Standard Resistance (Check for short):
    Tester Connection
    		Specified Condition
    NODD (H31-11) or NOFF (I25-33) - Body ground
    		10 kΩ or higher



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


3.CHECK W/ MOTOR COMPRESSOR ASSEMBLY

CAUTION:
Be sure to wear insulated gloves.



    A108047E02

  1. Disconnect the engine wire No.4 from the air conditioner wiring harness.



    A108050E01

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    1(+) - 2(-)
    		100 Ω or higher

    NOTICE:
    Connect the tester correctly.



NG
Go to step 5
OK


4.CHECK ENGINE WIRE NO.4

CAUTION:
Be sure to wear insulated gloves.



    A108067E01

  1. Disconnect the engine wire No.4 from the w/ motor compressor assembly.



    A108048E01

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    1 - 2
    		10 kΩ or higher



NG
REPLACE ENGINE WIRE NO.4
OK

REPLACE W/ MOTOR COMPRESSOR ASSEMBLY 

5.CHECK FRAME WIRE NO.3

CAUTION:
Be sure to wear insulated gloves.



    A108522E01

  1. Disconnect the frame wire No.3 (DC cable for the HV battery) from the w/ converter inverter assembly.



    A108046E01

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    1(+) - 2(-)
    		100 Ω or higher

    NOTICE:
    Connect the tester correctly.



OK
REPLACE W/ CONVERTER INVERTER ASSEMBLY
NG


6.CHECK FRAME WIRE NO.3 (W/ CONVERTER INVERTER - HV RELAY ASSEMBLY)

CAUTION:
Be sure to wear insulated gloves.



    A108041E01

  1. Disconnect the frame wire No.3 (DC cable for the w/ converter inverter assembly) from the HV relay assembly.



    A108042E01

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    A - B
    		10 kΩ or higher



NG
REPLACE FRAME WIRE NO.3
OK


7.CHECK HV RELAY ASSEMBLY

CAUTION:
Be sure to wear insulated gloves.



    A108043E01

  1. Disconnect the frame wire No.3 (connector for the power steering converter assembly) from the HV relay assembly.



    A108044E01

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    S45-1 - S44-1
    		10 kΩ or higher



NG
REPLACE HV RELAY ASSEMBLY
OK


8.CHECK FRAME WIRE NO.3 (HV RELAY ASSEMBLY - POWER STEERING CONVERTER)

CAUTION:
Be sure to wear insulated gloves.



    A108064E01

  1. Disconnect the frame wire No.3 (connector for the HV battery) from the power steering converter assembly.



    A108068E01

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    1 - 5
    		10 kΩ or higher



NG
REPLACE FRAME WIRE NO.3
OK

REPLACE POWER STEERING CONVERTER ASSEMBLY