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 SMRG turns on).

  • Wire harness or connector

  • Air conditioning harness assembly

  • With motor compressor assembly

  • Inverter with converter assembly

  • HV battery junction block

  • Frame wire

  • Hybrid vehicle converter

  • Power steering converter

  • Frame wire No. 3

  • HV battery terminal block

  • HV vehicle control ECU
P3004 801 Minimal overcurrent occurs during precharge (time from when SMRP turns on until SMRG turns on).

WIRING DIAGRAM


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 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
      P3004-800 or P3004-801 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A09-265 DC / DC Converter Status Circuit Low Input
      P0A10-263 DC / DC Converter Status Circuit High Input
      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
      P0AFA-123 Hybrid Battery System Voltage Low
      P0AFC (all INF codes) *1 Hybrid Battery Pack Sensor Module
      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.


      • P3004-800 or P3004-801 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 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

  3. CHECK WITH MOTOR COMPRESSOR ASSEMBLY

    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. Disconnect the air conditioning harness assembly from the inverter with converter assembly.

      A000WX4E01
      *1 for LHD:
      *2 for RHD:
    4. A000Z5LE03
      *a Air Conditioning Harness Assembly
      *b Shielded Wire Ground

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

      Standard resistance

      Tester Connection

      (Tester Probe Polarity)

      		 Switch Condition Specified Condition
      j1-1 (Negative probe) - j1-2 (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.


    NG

    CHECK AIR CONDITIONING HARNESS ASSEMBLY Click here

    OK

  4. CHECK FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


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

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

      A000YZ3E01
      *1 for LHD:
      *2 for RHD:

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

      A000VIJE01
      *1 for LHD:
      *2 for RHD:
    4. A000VQNE02
      *1 Frame Wire (HV Battery Junction Block Side)

      Disconnect the frame wire from the HV battery junction block.

    5. A000ZE2E03
      *1 Frame Wire (HV Battery Junction Block Side)
      *2 Red Mark
      *3 Shielded Wire Ground

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      g2-1 - g3-1 Power switch off 10 kΩ or higher
      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

  5. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE HYBRID VEHICLE CONTROL ECU)


    1. Turn the power switch off.

    2. A000YI9E02
      *1 No. 2 Battery Pack Wire Connector
      *2 A Side
      *3 B Side

      Disconnect the No. 2 battery pack wire connector Click here.

    3. A000Y4LE02
      *1 No. 2 Battery Pack Wire Connector
      *2 nS1
      *3 A Side
      *4 B Side

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      nS1-14 (NODD) - Body ground Power switch off 120 to 140 kΩ

    NG

    CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 2 BATTERY PACK WIRE CONNECTOR) Click here

    OK

  6. 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

      For the removal and installation procedures related to the low voltage connector of the hybrid vehicle converter, Click here.

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

      A000TQ0E01
      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      nS1-14 (NODD) - z82-9 (NODD) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      nS1-14 (NODD) or z82-9 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. CHECK HV CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000WMXE03
      *1 Hybrid Vehicle Converter

      Disconnect the 3 high-voltage connectors of the hybrid vehicle converter from the HV battery junction block.

    3. A000Z8NE02
      *1 Hybrid Vehicle Converter

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

      Standard resistance

      Tester Positive Lead

      (Tester Probe Polarity)

      		 Switch Condition Specified Condition
      High voltage + z58 (Positive probe) - High voltage - z59 (Negative probe) Power switch off 500 kΩ or higher
      High voltage + z58 (Positive probe) - High voltage precharge z60 (Negative probe) Power switch off 10 MΩ 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.


    NG

    REPLACE HV CONVERTER Click here

    OK

  8. CHECK HYBRID BATTERY TERMINAL BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000Y57

      Disconnect the high-voltage connectors from the HV battery junction block.

    3. A00105S

      Disconnect the connector for the power steering converter from the HV battery junction block.

    4. A000W7DE03

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      A - B Power switch off 10 kΩ or higher

    NG

    CHECK HV BATTERY JUNCTION BLOCK Click here

    OK

  9. CHECK POWER STEERING CONVERTER WIRE (HV BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the frame wire No. 3 (connector for the HV battery) from the power steering converter.

    2. A000ZKHE03
      *1 CBP
      *2 CEP

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      z28-1 (CBP) - z28-5 (CEP) Power switch off 10 kΩ or higher

    NG

    REPLACE POWER STEERING CONVERTER WIRE

    OK

  10. CHECK POWER STEERING CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000Z9KE02
      *1 CEP
      *2 CBP

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      z28-1 (CBP) (Positive probe) - z28-5 (CEP) (Negative probe) Power switch off 400 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.

      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    C

    REPLACE POWER STEERING CONVERTER Click here

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


    1. Disconnect connector A76 from the hybrid vehicle control ECU.

      A000VBEE01

    2. Turn the power switch off.

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

      Standard resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      A76-26 (NODD) - nS1-14 (NODD) Power switch off Below 1 Ω
      Standard resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      A76-26 (NODD) or nS1-14 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher

    OK

    REPLACE HYBRID VEHICLE CONTROL ECU Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  12. CHECK AIR CONDITIONING HARNESS ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. A000TPTE01
      *1 Green Lock

      Check that the service plug grip is not installed.

    2. Disconnect the air conditioning harness assembly from the with motor compressor assembly.

    3. A000Z5LE03
      *a Air Conditioning Harness Assembly
      *b Shielded Wire Ground

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      j1-1 - j1-2 Power switch off 10 kΩ or higher

    OK

    REPLACE WITH MOTOR COMPRESSOR ASSEMBLY Click here

    NG

    REPLACE AIR CONDITIONING HARNESS ASSEMBLY

  13. CHECK HV BATTERY JUNCTION BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


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

    2. A000VGD

      Remove the HV battery terminal block.

    3. Disconnect the connector for the power steering converter from the HV battery junction block.

    4. A000TFZE02
      *1 Battery Carrier

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

      Standard resistance
      Tester Connection Switch Condition Specified Condition
      g2-1 - g3-1 Power switch off 10 kΩ or higher

    OK

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    NG

    REPLACE HV BATTERY JUNCTION BLOCK Click here