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

DTC Code DTC Name
P3004-800 High Voltage Power Resource
P3004-801 High Voltage Power Resource

DTC SUMMARY

MALFUNCTION DESCRIPTION

The power management control ECU monitors the high-voltage wiring between the HV battery and inverter with converter assembly and detects a short circuit malfunction or high-voltage system operation malfunction.

The cause of this malfunction may be one of the following:


  1. Battery current sensor (IB) circuit malfunction


    • Battery current sensor (IB) malfunction

    • Motor generator control ECU (MG ECU) malfunction

    • Communication (wire harness) malfunction

  2. High voltage system malfunction


    • HV battery malfunction

    • Hybrid battery junction block assembly malfunction

    • Inverter with converter assembly malfunction

    • Air conditioner system malfunction

    • High-voltage wire harness malfunction

    • High-voltage connector or connection malfunction

  3. Low-voltage circuit (12 V) malfunction


    • Power management control ECU malfunction

    • Low voltage wire harness malfunction

    • Low voltage connector malfunction

INSPECTION DESCRIPTION
A01I41YE01
System Diagram Range Inspection Content Reason Inspection Step
*a Check wire harness connector connection condition between power management control ECU and inverter with converter assembly

Check that DCDC can be cut off during precharge.


  • Check for open or short circuit in NODD line.

  • Check that NODD terminal voltage is sufficiently low during DCDC operation command.

 2, 3 , 4
*b Check high-voltage wiring connection condition of the air conditioner compressor with motor assembly Check for short circuit 5, 7
*c Check hybrid battery junction block assembly Check for short circuit 6, 9

DESCRIPTION

Refer to the description for DTC P0AE6-225 Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P3004 800

High-voltage circuit malfunctions between the HV battery and inverter with converter assembly.

Excessive overcurrent occurs during precharge (time from when SMRP turns on until SMRG turns on).

(1 trip detection logic)

  • Wire harness or connector

  • No. 4 engine wire

  • Compressor with motor assembly

  • Inverter with converter assembly

  • Hybrid battery junction block assembly

  • No. 4 floor wire

  • Power management control ECU
801

High-voltage circuit malfunctions between the HV battery and inverter with converter assembly.

Minimal overcurrent occurs during precharge (time from when SMRP turns on until when SMRG turns on).

(1 trip detection logic)
Related Data List
DTC No. Data List
P3004-800

  • VH-Voltage after Boosting

  • Power Resource VB
P3004-801

The following items can be helpful when performing repairs:

Data List


WIRING DIAGRAM


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 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.

  • If P3004-800 or P3004-801 are output, do not repeatedly turn the power switch on (READY), off.

Tech Tips

After the repair, clear the DTCs, perform the following procedure and check that the same DTC (including pending DTC) is not output.


  1. Turn the power switch off and wait for 30 seconds or more.

  2. Turn the power switch on (READY) and wait for 30 seconds or more.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the Techstream to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P3004-800 or P3004-801 only is output, or DTCs except the ones in the tables below are also output. A
      Any of the DTCs in table 1 below are also output. B
      Any of the DTCs in table 2 below are also output. C
      Table 1
      Relevant DTC
      P0A09-265 DC / DC Converter Status Circuit Low Input
      P0A10-263 DC / DC Converter Status Circuit High Input
      P0A94-172, 553, 554, 555, 556, 557 DC / DC Converter Performance
      Table 2
      Malfunction Content Relevant DTC
      Microcomputer malfunction P0AFC-123 Hybrid Battery Pack Sensor Module
      Power source circuit malfunction P0ABF-123 Hybrid Battery Pack Current Sensor Circuit
      Communication system malfunction U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module
      Sensor and actuator circuit malfunction 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
      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
      P0B88-123 Hybrid Battery Voltage Sensor "P" Circuit Low
      P0B8D-123 Hybrid Battery Voltage Sensor "Q" Circuit Low
      P0B92-123 Hybrid Battery Voltage Sensor "R" Circuit Low
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low

      Tech Tips


      • P3004-800 or P3004-801 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    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. A01I61A

      Check the connector connections and contact pressure of the relevant terminals for the power management control ECU connectors Click here.

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

    NG

    CONNECT SECURELY

    OK

  3. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    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. Check the connection condition of the low voltage connector of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter Click here.

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector does not pull out.

      A01I3MYE01
      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

      Tech Tips

      When connecting the connector, insert it with the locking lever in the raised position. Rotate the lever downward and make sure that the connector is pulled into its socket. When the locking lever is in its fully closed position, a click will be heard as its locking claws engage. After the click is heard, pull up on the connector to confirm that it is properly connected.


    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  4. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - 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. A01I3RP

      Disconnect the A13 inverter with converter assembly connector.

    3. Disconnect the A38 power management control ECU connector.

    4. A01I61FE14
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A13-5 (NODD) - A38-23 (NODD) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A13-5 (NODD) or A38-23 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Reconnect the A38 power management control ECU connector.

    6. Reconnect the A13 inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  5. CHECK POWER MANAGEMENT CONTROL ECU (NODD)

    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. A01I53YE80
      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
      A38-23 (NODD) - I3-6 (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 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. A01I614E01

      Disconnect connector G2 of the No. 4 engine wire (air conditioning harness) from the inverter with converter assembly.

    3. A01I2T0E02
      Text in Illustration
      *a

      Front view of No. 4 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
      G2-1 (ACPE) (Negative probe) - G2-2 (ACPB) (Positive probe) 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.

    4. Connect the No. 4 engine wire (air conditioning harness) to the inverter with converter assembly.


    NG

    CHECK NO. 4 ENGINE WIRE Click here

    OK

  7. CHECK NO. 4 FLOOR 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. A01I5ZB

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

    3. A01I4JQE04

      Disconnect connector Q1 of the No. 4 floor wire from the inverter with converter assembly.

    4. Remove the No. 4 hybrid battery shield panel Click here.

    5. A01I5ULE01

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      Q2-1 (CBI) - Q3-1 (CEI) Power switch off 10 kΩ or higher

    6. Install the No. 4 hybrid battery shield panel.

    7. Connect the No. 4 floor wire.

    8. Install the connector cover assembly.


    NG

    CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  8. CHECK NO. 4 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. A01I614E01

      Disconnect connector G2 of the No. 4 engine wire (air conditioning harness) from the inverter with converter assembly.

    3. A01I3BJE01
      Text in Illustration
      *1 Green Lock

      Disconnect connector G1 of the No. 4 engine wire (air conditioning harness) from the compressor with motor assembly.

    4. A01I2T0E02
      Text in Illustration
      *a

      Front view of No. 4 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
      G2-1 (ACPE) - G2-2 (ACPB) Power switch off 10 kΩ or higher

    5. Connect the No. 4 engine wire (air conditioning harness) to the compressor with motor assembly.

    6. Connect the No. 4 engine wire (air conditioning harness) to the inverter with converter assembly.


    NG

    REPLACE NO. 4 ENGINE WIRE

    OK

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

  9. 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 No. 4 hybrid battery shield panel Click here.

    3. A01I5G7E04

      Disconnect connector Q2 and connector Q3 of the No. 4 floor wire from the hybrid battery junction block assembly.

    4. A01I36RE01

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      Q3-1 (CEI) - Q2-1 (CBI) Power switch off 10 kΩ or higher

    5. Connect the No. 4 floor wire.

    6. Install the No. 4 hybrid battery shield panel.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

    REPLACE NO. 4 FLOOR WIRE Click here