HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-803

DTC Code DTC Name
P3004-803 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 an open circuit malfunction.

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

Tech Tips


  • This DTC is differentiated from P3004-131 based on detection timing (after power switch is turned on (READY)). If P3004-131 is also output at the same time, first perform troubleshooting for P3004-131.

  • If there is a SMRG stuck open malfunction, only P3004-803 is output.


  1. Inside of inverter voltage sensor (VH or VL) circuit malfunction


    • Voltage sensor (VH or VL) 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

    • High-voltage wire harness malfunction

    • High-voltage connector or connection malfunction

  3. Low-voltage circuit (12 V) malfunction


    • Power management control ECU malfunction

    • Hybrid battery junction block assembly malfunction

    • Low voltage wire harness malfunction

    • Low voltage connector malfunction

DESCRIPTION

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

DTC No. INF Code DTC Detection Condition Trouble Area
P3004 803

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

When the power switch is on (READY), both "VL-Voltage before Boosting" and "VH-Voltage after Boosting" drop abnormally.

The EV electric battery fuse is blown, the service plug grip is removed, SMRB or SMRG remains open, or the high voltage cable has an open circuit.

(1 trip detection logic)

  • Hybrid battery junction block assembly

  • Wire harness or connector
Related Data List
DTC No. Data List
P3004-803

  • VL-Voltage before Boosting

  • VH-Voltage after Boosting

  • Power Resource VB

The following items can be helpful when performing repairs:

Data List


WIRING DIAGRAM

Refer to the wiring diagram for the HV battery high-voltage line circuit 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 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.

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


  1. Turn the power switch on (READY) and wait for 30 seconds or more. If the DTC is not output again, drive the vehicle according to the freeze frame data item "Vehicle Spd" for approximately 5 minutes.

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
      P3004-803 only is output, or DTCs except the ones in the table below are also output.. A
      Any of the following DTCs including pending DTCs are also output. B
      P0A95-123 is also output. C
      Malfunction Content Relevant DTC
      Microcomputer malfunction P0A1A-151, 155, 156, 658, 659 Generator Control Module
      P0A1B-164, 193, 512, 661, 786 Drive Motor "A" Control Module
      P0A1D-148 Hybrid Powertrain Control Module
      P324E-788 MG-ECU Power Relay Intermittent Circuit
      Power source circuit malfunction P2511-149 ECM/PCM Power Relay Sensor Circuit Intermittent
      Communication system malfunction U0110 (all INF codes)*1 Lost Communication with Drive Motor Control Module "A"
      Sensor and actuator circuit malfunction P0A78-266, 267, 586 Drive Motor "A" Inverter Performance
      P0A94-442 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      System malfunction P3004-131, 132 High Voltage Power Resource

      Tech Tips


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

      • P3004-803 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 (P0A95-123) Click here

    A

  2. CLEAR DTC


    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. Clear DTCs and freeze frame data.

    5. Turn the power switch off.


    NEXT

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the Techstream to the DLC3.

    2. Turn the power switch on (READY).

    3. Ensure the safety of the areas in front and at the back of the vehicle.

    4. Move the shift lever to D and depress both the accelerator pedal and brake pedal at the same time.

      Tech Tips


      • Depressing both the accelerator pedal and brake pedal at the same time causes the HV battery current to flow and ensures that there is no problem with the high-voltage wiring.

      • Depressing both the accelerator pedal and brake pedal at the same time causes Accelerator and brake depressing in the inappropriate operation and history data to be counted.

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

    6. Check if DTCs are output.

      Result
      Result Proceed to
      P3004-803 is output, or no DTCs are output. A
      Power switch is not turned on (READY) and P3004- 131 is output. B

      Tech Tips

      Because P3004-131 uses 2-trip detection logic, the DTC detection conditions need to be met 2 times.

    7. Turn the power switch off.


    B

    GO TO DTC CHART (P3004-131) Click here

    A

  4. 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

  5. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - 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. Disconnect the I3 power management control ECU connector.

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

    4. Disconnect the O9 hybrid battery junction block assembly connector.

      Tech Tips

      Before disconnecting the connector, check whether it is connected securely to the hybrid battery junction block assembly.

    5. A01I2N0E05
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Power Management Control ECU)
      *b

      Rear view of wire harness connector

      (to 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
      I3-4 (SMRB) - O9-1 (SMRB) Power switch off Below 1 Ω
      I3-2 (SMRG) - O9-3 (SMRG) Power switch off Below 1 Ω

    6. Reconnect the O9 hybrid battery junction block assembly connector.

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

    8. Reconnect the I3 power management control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here