HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-803

DTC Code	DTC Name
P3004-803	High Voltage Power Resource

DESCRIPTION

Refer to the description for DTC P0AE6-225.

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DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	Warning Indicate
P3004-803	High Voltage Power Resource	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	Does not come on	Master Warning Light: Comes on

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P3004-803

High Voltage Power Resource

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

Does not come on

Master Warning Light:

Comes on

Related Data List
DTC No.	Data List
P3004-803	VL-Voltage before Boosting VH-Voltage after Boosting Power Resource VB

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AE6-225.

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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.

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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.

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Tech Tips

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

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

CHECK DTC OUTPUT (HYBRID CONTROL)

Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes

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

Relevant DTC
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
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
P2511-149	ECM/PCM Power Relay Sensor Circuit Intermittent
P3004-131, 132	High Voltage Power Resource
P324E-788	MG-ECU Power Relay Intermittent Circuit
U0110 (all INF codes)*1	Lost Communication with Drive Motor Control Module "A"

Tech Tips

*1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
P3004-803 may be stored due to a malfunction which causes the DTCs in the preceding table to be stored. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a reproduction test to check that no DTCs are output.

Turn the power switch off.

GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

GO TO DTC CHART (P0A95-123) Click here

CLEAR DTC

Result

Proceed to
NEXT

Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
Read and record the DTCs and freeze frame data.

Powertrain > Hybrid Control > Trouble Codes
Clear the DTCs and freeze frame data.

Powertrain > Hybrid Control > Clear DTCs

Turn the power switch off.

Result

Proceed to
NEXT

CHECK DTC OUTPUT (HYBRID CONTROL)

Connect the GTS to the DLC3.
Turn the power switch on (READY).
Tech Tips
- If the power switch could not be turned on (READY), turn the power switch off and check for DTCs after turning the power switch on (READY) again.
- Because P3004-131 uses 2 trip detection logic, the DTC detection conditions need to be met 2 times.
Ensure the safety of the areas in front and at the back of the vehicle.
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 Depress" in the inappropriate operation and history data to be counted.
Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes

Result

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

Turn the power switch off.

GO TO DTC CHART (P3004-131) Click here

CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)

Result

Proceed to
OK
NG

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

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

for LHD

for RHD

Result

Proceed to
OK
NG

CONNECT SECURELY

CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY)

CAUTION:

Be sure to wear insulated gloves.

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.
Disconnect the K32 power management control ECU connector.
Remove the upper hybrid battery cover sub-assembly.

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Rear view of wire harness connector

(to Power Management Control ECU)

Rear view of wire harness connector

(to Hybrid Battery Junction Block Assembly)

Disconnect the k2 hybrid battery junction block assembly connector.

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

Standard Resistance

Tester Connection	Condition	Specified Condition
K32-4 (SMRB) - k2-4 (SMRB)	Power switch off	Below 1 Ω
K32-2 (SMRG) - k2-1 (SMRG)	Power switch off	Below 1 Ω

Reconnect the k2 hybrid battery junction block assembly connector.
Install the upper hybrid battery cover sub-assembly.

Reconnect the K32 power management control ECU connector.

Result

Proceed to
OK
NG

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

REPAIR OR REPLACE HARNESS OR CONNECTOR