DTC    P3004-131    Power Cable Malfunction

DTC    P3004-132    Power Cable Malfunction

for Preparation Click here


DESCRIPTION


DTC No.
INF Code
DTC Detection Condition
Trouble Area
P3004
131
EV battery fuse is blown out, service plug grip is disconnected, SMR1 and SMR3 remain open, or the system main relay is open.
  1. Main battery cable
  2. Wire harness or connector
  3. HV battery system
  4. HV relay assembly
  5. Main battery cable No.2 (negative side)
  6. Frame wire No.3
  7. w/ converter inverter assembly
  8. HV control ECU
P3004
132
Inverter voltage sensor has a malfunction, or resistance of the system main resistor increases.
  1. Main battery cable
  2. Wire harness or connector
  3. HV battery system
  4. HV relay assembly
  5. Main battery cable No.2 (negative side)
  6. Frame wire No.3
  7. w/ converter inverter assembly
  8. HV control ECU

WIRING DIAGRAM

  1. Refer to the wiring diagrams for DTC P0AA1-224. (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)

  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 / DTC.

  1. Read output DTC. (Click here)

    Result:
    DTC P0A95, P0AA1-244, P0AA2-225, P0AA4-228 or P0AA5-229 is output.



YES
GO TO DTC CHART
NO


2.INSPECT HV RELAY ASSEMBLY (SMR1 AND SYSTEM MAIN RELAY)

CAUTION:
Be sure to wear insulated gloves.



    A108055E05

  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. Remove the HV relay assembly from the vehicle. (Click here)

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    S47-1 - S44-1
    		28.5 to 31.5 Ω
    (when apply battery voltage between terminals CON1 (S48-3) and GND (S48-4))

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    CON1 (S48-3) - GND (S48-4)
    		20 to 60 Ω
    -35 to 80°C (-22 to 176 °F)



NG
REPLACE HV RELAY ASSEMBLY
OK


3.INSPECT HV RELAY ASSEMBLY (SMR3)

CAUTION:
Be sure to wear insulated gloves.



    A108054E06

  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. Remove the HV relay assembly from the vehicle. (Click here)

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    S45-1 - S49-1
    		Below 1 Ω
    (when apply battery voltage between terminals CON3 (S48-2) and GND (S48-4))

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    CON3 (S48-2) - GND (S48-4)
    		20 to 60 Ω
    -35 to 80°C (-22 to 176 °F)



NG
REPLACE HV RELAY ASSEMBLY
OK


4.INSPECT MAIN BATTERY CABLE NO.2 (-)

CAUTION:
Be sure to wear insulated gloves and protective goggles.



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


    A112787E01


    Standard Resistance:

    Tester Connection
    		Specified Condition
    A - B
    		Below 1 Ω

    HINT:
    Check the connections with the main battery cable No.2 (negative side) connected.



NG
REPLACE MAIN BATTERY CABLE NO.2
OK


5.INSPECT MAIN BATTERY CABLE NO.2 (-), HV RELAY ASSEMBLY AND HV BATTERY

CAUTION:
Be sure to wear insulated gloves and protective goggles.

HINT:
Check the connections with the main battery cable No.2 (negative side) connected.



  1. Check that the nut that tightens the main battery cable No.2 (negative side) is properly engaged with the connector on the HV battery terminal (RH side).


    A112788E01

    OK:
    There is no poor connection.

    NOTICE:
    1. The nut that tightens the main battery cable No.2 is not reusable.
    2. Do not overtighten this nut.

  1. Check if the main battery cable No.2 (negative side ) is properly engaged with the connector on the HV relay assembly side.

    OK:
    Connector is connected securely and there is no poor connection.



NG
REPLACE MAIN BATTERY CABLE NO.2, HV RELAY ASSEMBLY OR HV BATTERY
OK


6.INSPECT HV BATTERY

CAUTION:
Be sure to wear insulated gloves and protective goggles.



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


    A112789E01


    Standard Voltage:

    Tester Connection
    		Specified Condition
    A (+) - B (-)
    		40 to 80 V

    NOTICE:
    Connect the tester correctly.



NG
REPLACE HV BATTERY
OK


7.INSPECT HV BATTERY AND HV RELAY ASSEMBLY

CAUTION:
Be sure to wear insulated gloves and protective goggles.

HINT:
Check the connections with the HV battery CTR cable.



  1. Check if the cable on the HV relay assembly side connector in the HV battery CTR is properly engaged.


    A112790E01

    OK:
    Connector is connected securely and there is no poor connection.

  1. Check that the nut that tightens the HV battery CTR cable on the HV battery LH side is not loose.

    OK:
    There is no poor connection.

    NOTICE:
    1. The nut that tightens the main battery cable No.2 is not reusable.
    2. Do not overtighten this nut.



NG
REPLACE HV BATTERY OR HV RELAY ASSEMBLY
OK


8.INSPECT FRAME WIRE NO.3

CAUTION:
Be sure to wear insulated gloves and protective goggles.



    A108522E03

  1. Check that the service plug grip is removed.

  1. Remove the inverter cover. (Click here)

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

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



    A108041E01

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



    A108066E02

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    I22-3 - S44-1
    		Below 1 Ω
    I22-1 - S45-1
    		Below 1 Ω



NG
REPLACE NO.3 WIRE FRAME
OK


9.INSPECT W/ CONVERTER INVERTER ASSEMBLY (VH VOLTAGE)

CAUTION:
Be sure to wear insulated gloves.



    A103665E09

  1. Turn the ignition switch to the ON position.

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

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

    Standard Voltage:
    Tester Connection
    		Specified Condition
    VH (B-31) - GINV (B17)
    		0.3 to 0.7 V



NG
REPLACE W/ CONVERTER INVERTER ASSEMBLY
OK


10.CHECK CONNECTION CODITION OF HV CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT)


    A103658E18

  1. Check the connections of all HV control ECU connectors.

    OK:
    Connectors are connected securely and there is no poor connection.



NG
CONNECT SECURELY
OK


11.CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - HV RELAY ASSEMBLY)

CAUTION:
Be sure to wear insulated gloves and protective goggles.

  1. Check that the service plug grip is removed.

  1. Disconnect the H30 connector from the HV control ECU.

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

    Standard Resistance:
    Tester Connection
    		Specified Condition
    CON1 (H30-3) - CON1 (S48-3)
    		Below 1 Ω
    CON3 (H30-1) - CON3 (S48-2)
    		Below 1 Ω



NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
OK


12.CHECK FOR INTERMINTTENT PROBLEMS

HINT:
After the check, if DTCs P3004-131 and 132 are output again, replace the HV control ECU. If they are not output, replace the HV relay assembly.



NG
REPLACE HV CONTROL ECU
OK

REPLACE HV RELAY ASSEMBLY