HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-800, P3004-801

DTC Code DTC Name
P3004-800 Power Cable Malfunction
P3004-801 Power Cable Malfunction

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).

  • Wire harness or connector

  • No. 2 engine wire

  • Compressor with motor assembly

  • Inverter with converter assembly

  • Hybrid battery junction block assembly

  • Frame wire

  • 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.

CAUTION / NOTICE / HINT

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 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.

    Tech Tips

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

Note

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.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

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

    4. 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

      Tech Tips

      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.

    5. 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.

      B001M45E01
      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.

      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.

    2. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

    3. B001L7IE02

      Disconnect the No. 2 engine wire (air conditioning harness) E3 from the inverter with converter assembly.

    4. B001MQEE01
      Text in Illustration
      *1 Shielded Wire Ground
      *a

      Front view of No. 2 Engine Wire (Air Conditioning Harness) connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance

      Tester Connection

      (Tester Probe Polarity)

      		 Switch Condition Specified Condition
      E3-1 (ACPB) - E3-2 (ACPE) Power switch off 100 kΩ or higher

      Note


      • Do not use a megohmmeter.

      • Read the resistance after the value has stabilized.

      Tech Tips

      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.

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

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


    NG

    CHECK NO. 2 ENGINE WIRE Click here

    OK

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


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

    2. Disconnect connector A19 from power management control ECU.

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

      B001LGQE01
      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)

    4. Connect the power management control ECU connector.

    5. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  5. CHECK POWER MANAGEMENT CONTROL ECU

    CAUTION:

    Be sure to wear insulated gloves.


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

      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.

    2. Connect the cable to the negative (-) auxiliary battery terminal.

    3. Turn the power switch on (IG).

    4. B001NBHE02
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      A19-21(NODD) - H3-6(E1) Power switch on (IG) Less than 1.5 V

    5. Turn the power switch off.

    6. Disconnect the cable from the negative (-) auxiliary battery terminal.


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  6. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

      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.

    2. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

    3. B001LA2E02

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

    4. Remove the upper hybrid battery cover sub-assembly Click here.

    5. B001MDJE02

      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

    6. Install the upper hybrid battery cover sub-assembly Click here.

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

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


    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 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.

      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.

    2. B001LYD

      Remove the inverter cover from the inverter with converter assembly.

    3. B001L7IE02

      Disconnect the No. 2 engine wire (air conditioning harness) E3 from the inverter with converter assembly.

    4. B001NBZE02
      Text in Illustration
      *1 Green Lock

      Disconnect the No. 2 engine wire (air conditioning harness) E1 from the compressor with motor assembly.

    5. B001MQEE01
      Text in Illustration
      *1 Shielded Wire Ground
      *a

      Front view of No. 2 Engine Wire (Air Conditioning Harness) connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      E3-1 (ACPB) - E3-2 (ACPE) Power switch off 10 kΩ or higher
      Result
      Result Proceed to
      OK (for 2ZR-FXE) A
      OK (for 5ZR-FXE) B
      NG C

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

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

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


    A

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY (2ZR-FXE) Click here

    B

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY (5ZR-FXE) Click here

    C

    REPLACE NO. 2 ENGINE WIRE

  8. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


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

      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.

    2. Remove the upper hybrid battery cover sub-assembly Click here.

    3. B001MDJE02

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

    4. B001MMCE02
      Text in Illustration
      *1 Hybrid Battery Junction Block Assembly

      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

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

    6. Install the upper hybrid battery cover sub-assembly Click here.


    OK

    REPLACE FRAME WIRE Click here

    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here