HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-132

DTC Code DTC Name
P3004-132 Power Cable Malfunction

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.

  • HV battery junction block

  • Frame wire

  • Inverter with converter assembly

  • Hybrid vehicle control ECU

  • HV battery

  • Wire harness or connector

  • Hybrid vehicle converter

  • HV battery terminal block

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AE6-225 Click here.

INSPECTION PROCEDURE

CAUTION:


  • 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.

  • After disconnecting 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.

Tech Tips

Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE


  1. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P3004-132 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A-151, 155, 156, 658, 659 Generator Control Module
      P0A1B-163, 164, 193, 511, 512, 661, 786, 788 Drive Motor "A" Control Module
      P0A78-266, 267, 586 Drive Motor "A" Inverter Performance
      P0A94-442 DC / DC Converter Performance
      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 Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor Circuit High
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low
      P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High
      P0AFA-123 Hybrid Battery System Voltage Low
      P0AFC (all INF codes) *1 Hybrid Battery Pack Sensor Module
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-800, 801 Power Cable Malfunction
      P3240-443 DC / DC Converter Control Circuit
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module

      Tech Tips


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic flowchart.


      • P3004-132 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.


    B

    GO TO DTC CHART Click here

    A

  2. CHECK FREEZE FRAME DATA


    1. Select the following menu items: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.

    2. Read the freeze frame data of DTC P3004-132.

      Result
      Result Proceed to

      All of the following conditions are met:


      • Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VL-Voltage before Boosting) is 50 V or less.

      • Difference between HV battery voltage (Power Resource VB) and post-boost voltage (VH-Voltage after Boosting) is more than 70 V.

      • Difference between pre-boost voltage (VL-Voltage before Boosting) and post-boost voltage (VH-Voltage after Boosting) is more than 70 V.

      A

      (for LHD)

      B

      (for RHD)
      In addition to the above conditions, HV battery current (Batt Pack Current Val) is 3 A or more. C
      Other than above D

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    GO TO DTC CHART (P3004-800) Click here

    D

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) Click here

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  3. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)


    1. Check the connections of the hybrid vehicle control ECU connectors.

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

    NG

    CONNECT SECURELY

    OK

  4. CHECK CONDITION OF FRAME WIRE CONNECTION(S) (INVERTER WITH CONVERTER ASSEMBLY SIDE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Turn the power switch off.

    2. Remove the service plug grip Click here.

      Note

      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.

    3. Remove the connector cover from the inverter with converter assembly.

      A01GY1RE01

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

      A01GYM3E01
      OK
      The connector is connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  5. CHECK CONDITION OF FRAME WIRE CONNECTION(S) (HV BATTERY JUNCTION BLOCK SIDE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. A01GYUKE02

      Check that the service plug grip is not installed.

    2. Check the connection between the frame wire and the HV battery junction block.

      Specified Condition
      T=9.0 N*m {92 kgf*cm, 80 in.*lbf}

      Tech Tips

      For the removal and installation procedures related to inspection of the frame wire connection, Click here for LHD, Click here for RHD).

    3. 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

    B

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    C

    CONNECT SECURELY

    A

  6. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

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

      A01GYM3E01
    3. A01GYUKE02

      Disconnect the frame wire from the HV battery junction block.

    4. A01GXMAE01

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      g2-1 - g1-1 (CBI) (Positive terminal) Power switch off Below 1 Ω
      g3-1 - g1-2 (CEI) (Negative terminal) Power switch off Below 1 Ω
      Result
      Result Proceed to
      OK A
      NG (for LHD) B
      NG (for RHD) C

    B

    REPLACE FRAME WIRE Click here

    C

    REPLACE FRAME WIRE Click here

    A

  7. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTORS)


    1. Disconnect connectors A76 and E58 from the hybrid vehicle control ECU.

    2. A01H1YGE02

      Disconnect the No. 1 battery pack wire connector.

      Tech Tips


      • Before disconnecting the No. 1 battery pack wire connector, make sure that the connector is securely engaged.

      • Due to the time required to disconnect the HV battery junction block and hybrid vehicle converter connectors, the No. 1 battery pack wire connector resistance check should be performed before these connectors are disconnected.

    3. A01GXNNE04

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      E58-5 (SMRB) - zR3-5 (SMRB) Power switch off Below 1 Ω
    4. A01H29WE02

      Disconnect the No. 2 battery pack wire connector.

      Tech Tips


      • Before disconnecting the No. 2 battery pack wire connector, make sure that the connector is securely engaged.

      • Due to the time required to disconnect the HV battery junction block and hybrid vehicle converter connectors, the No. 2 battery pack wire connector resistance check should be performed before these connectors are disconnected.

    5. A01H0VYE10

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      A76-25 (SMRP) - nS1-11 (SMRP) Power switch off Below 1 Ω

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. 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.

    2. A01GY5G

      Check the connections between the main battery cables and the HV battery junction block.

      OK
      The connectors are connected securely and not damaged.

      Tech Tips

      For the removal and installation procedures related to inspection of the main battery cable connection, Click here.

    3. 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

    B

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    C

    CONNECT SECURELY

    A

  9. CHECK HV BATTERY ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. A01GWHEE02

      Check that the service plug grip is not installed.

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

      Standard voltage
      Tester Connection Switch Condition Specified Condition
      Main battery cable (+) - Service plug grip 1 Power switch off 120 V or higher
      Main battery cable (-) - Service plug grip 2 Power switch off 120 V or higher

      CAUTION:

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


    NG

    REPLACE HV BATTERY ASSEMBLY Click here

    OK

  10. CHECK HARNESS AND CONNECTOR (NO. 1 BATTERY PACK WIRE CONNECTOR - HV BATTERY JUNCTION BLOCK)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

    2. A01GW2B

      Disconnect the low voltage connector that drives the relay of the HV battery junction block.

      Tech Tips

      Before disconnecting the low voltage connector that drives the relay of the HV battery junction block, make sure that the connector is securely engaged.

    3. A01H0KKE05

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      zR3-5 (SMRB) - z38-3 (SMRB) Power switch off Below 1 Ω

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  11. CHECK HARNESS AND CONNECTOR (NO. 2 BATTERY PACK WIRE CONNECTOR - HYBRID VEHICLE CONVERTER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

    2. Disconnect the low voltage connector from the hybrid vehicle converter.

      Tech Tips

      Before disconnecting the low voltage connector of the hybrid vehicle converter, make sure that the connector is securely engaged.

    3. A01GXEHE10

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      nS1-11 (SMRP) - z82-10 (SMRP) Power switch off Below 1 Ω

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  12. CHECK HYBRID BATTERY TERMINAL BLOCK (HV BATTERY JUNCTION BLOCK CONNECTION CONDITION SIDE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

    2. A01GYWB

      Check the connection between the HV battery terminal block and the HV battery junction block.

      Specified Condition
      T=9.0 N*m {92 kgf*cm, 80 in.*lbf}

      Tech Tips

      For the removal and installation procedures related to inspection of the connection of the HV battery terminal block, Click here.

    3. Check for arc marks on the terminals of the HV battery terminal block and HV battery junction block.

      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

    B

    REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA

    C

    CONNECT SECURELY

    A

  13. CHECK HYBRID BATTERY TERMINAL BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


    1. A01GWF1

      Check that the service plug grip is not installed.

    2. Remove the HV battery terminal block from the HV battery pack.

    3. A01H02ZE02

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      A - C Power switch off Below 1 Ω
      B - D Power switch off Below 1 Ω

    NG

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    OK

  14. INSPECT HV BATTERY JUNCTION BLOCK (SMRB)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

    2. Remove the HV battery junction block from the vehicle Click here.

    3. A01GZI8E05

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

      Standard resistance
      Tester Connection Condition Specified Condition
      g2-1 - z30-1 Auxiliary battery voltage is applied between terminals z38-3 (SMRB) and z38-2 (GND). Below 1 Ω

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

      Standard resistance
      Tester Connection Condition Specified Condition
      z38-3 (SMRB) - z38-2 (GND)

      -31 to 176° F

      (-35 to 80°C)

      		 18.8 to 32.1 Ω

    NG

    REPLACE HV BATTERY JUNCTION BLOCK Click here

    OK

  15. CHECK FOR INTERMITTENT PROBLEMS


    1. Check for intermittent problems Click here.


    NEXT

  16. CLEAR DTC


    1. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

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

    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

    4. Clear DTCs and freeze frame data.


    NEXT

  17. CHECK DTC OUTPUT (HV)


    1. Turn the power switch on (READY).

    2. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

    3. Check if DTCs are output.

      Result
      Result Proceed to
      DTC P3004-131 is output. A
      DTC P3004-132 is output, or No DTCs are output.

      B

      (for LHD)

      C

      (for RHD)

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    A

    GO TO DTC CHART (P3004-131) Click here