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

DESCRIPTION

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

DTC No. 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 floor wire (air conditioning harness) (for LHD)

  • Air conditioning harness (for RHD)

  • Compressor with motor assembly

  • Inverter with converter assembly

  • Hybrid battery junction block assembly

  • No. 4 floor wire

  • Power management control ECU
P3004-801

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)

  • Wire harness or connector

  • No. 4 floor wire (air conditioning harness) (for LHD)

  • Air conditioning harness (for RHD)

  • Compressor with motor assembly

  • Inverter with converter assembly

  • Hybrid battery junction block assembly

  • No. 4 floor wire

  • Power management control ECU
Related Data List
DTC No. Data List
P3004-800

  • VH-Voltage after Boosting

  • Power Resource VB
P3004-801

Use the following items as references when performing repairs.


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 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, 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 GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.

      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
      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
      P0B88-123 Hybrid Battery Voltage Sensor "P" Circuit Low
      P0B8D-123 Hybrid Battery Voltage Sensor "Q" Circuit Low
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module

      Tech Tips

      P3004-800 or P3004-801 may be stored due to a malfunction which causes the DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. 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. B002B9CE01
      Text in Illustration
      *A for LHD
      *B for RHD

      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 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.

      B002B6BE01
      Text in Illustration
      *A for LHD *B for RHD

      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.

      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. Disconnect the A39*1 or A75*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD

    3. Disconnect the A35 power management control ECU connector.

    4. B002BCTE02
      Text in Illustration
      *A for LHD
      *B for RHD
      *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)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A39-5 (NODD) - A35-23 (NODD) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A75-5 (NODD) - A35-23 (NODD) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A39-5 (NODD) or A35-23 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A75-5 (NODD) or A35-23 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Reconnect the A35 power management control ECU connector.

    6. Reconnect the A39*1 or A75*2 inverter with converter assembly connector.


      • *1: for LHD

      • *2: for RHD


    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. B002C0BE02
      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 Switch Condition Specified Condition
      A35-23 (NODD) - N91-6 (E1) Power switch on (IG) Below 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. B002BRUE02
      Text in Illustration
      *A for LHD
      *B for RHD

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

    3. B002BRIE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of air conditioning harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      for LHD

      Tester Connection

      (Tester Probe Polarity)

      		 Switch Condition Specified Condition
      V3-1 (ACPE) (Negative probe) - V3-2 (ACPB) (Positive probe) Power switch off 100 kΩ or higher
      for RHD

      Tester Connection

      (Tester Probe Polarity)

      		 Switch Condition Specified Condition
      f1-1 (ACPE) (Negative probe) - f1-2 (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. Reconnect the air conditioning harness to the inverter with converter assembly.


    NG

    CHECK HARNESS AND CONNECTOR (AIR CONDITIONING HARNESS) 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. B002BMGE01
      Text in Illustration
      *A for LHD
      *B for RHD

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

    3. B002BXDE03
      Text in Illustration
      *A for LHD
      *B for RHD

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

    4. B002BR3E02
      Text in Illustration
      *a

      Front view of No. 4 floor wire 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
      V2-1 (CBI) - V2-2 (CEI) Power switch off 10 kΩ or higher

    5. Reconnect the No. 4 floor wire to the inverter with converter assembly.

    6. Install the connector cover assembly.


    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    NG

  8. CHECK HV 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 vehicle battery shield sub-assembly Click here.

    3. B002BHB

      Remove the No. 4 floor wire from the hybrid battery junction block assembly.

    4. B002BIME02

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      V5-1 (CBI) - V4-1 (CEI) Power switch off 10 kΩ or higher

    5. Connect the No. 4 floor wire to the hybrid battery junction block assembly.

    6. Install the No. 4 hybrid vehicle battery shield sub-assembly.


    OK

    REPLACE NO. 4 FLOOR WIRE Click here

    NG

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

  9. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING HARNESS)

    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. B002BRUE02
      Text in Illustration
      *A for LHD
      *B for RHD

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

    3. A000NBN

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

    4. B002BRIE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of air conditioning harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      for LHD
      Tester Connection Switch Condition Specified Condition
      V3-1 (ACPE) - V3-2 (ACPB) Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      f1-1 (ACPE) - f1-2 (ACPB) Power switch off 10 kΩ or higher

    5. Reconnect the air conditioning harness to the compressor with motor assembly.

    6. Reconnect the air conditioning harness to the inverter with converter assembly.

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

    A

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

    B

    REPLACE NO. 4 FLOOR WIRE Click here

    C

    REPLACE AIR CONDITIONING HARNESS