HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-131

DTC Code DTC Name
P3004-131 High Voltage Power Resource

DTC SUMMARY


  1. MALFUNCTION DESCRIPTION

    The hybrid vehicle 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:


      Inside of inverter voltage sensor (VH) circuit malfunction

    • Voltage sensor (VH) malfunction

    • Motor generator control ECU (MG ECU) malfunction

    • Communication (wire harness) malfunction


      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


      Low-voltage circuit (12 V) malfunction

    • Hybrid vehicle control ECU malfunction

    • Hybrid battery junction block assembly malfunction

    • Low voltage wire harness malfunction

    • Low voltage connector malfunction

  2. INSPECTION DESCRIPTION

    B002KOYE02
    System Diagram Range Inspection Content Reason Inspection Step
    *a Check connection condition and wire harness continuity between hybrid vehicle control ECU and hybrid battery junction block assembly In order to check whether connectors are connected properly and to check for an open circuit in the SMRP and SMRB primary lines 3 to 6
    *b Check system main relay Check whether SMRB and SMRP stuck OFF 7, 8
    *c Check connection condition and high-voltage cable continuity between hybrid battery junction block assembly and inverter with converter assembly Check for open circuit and defective connection (arc marks) due to looseness 9, 10, 11
    *d Check high-voltage cable and connection condition between HV battery and hybrid battery junction block assembly Check for open circuit and defective connection (arc marks) due to looseness 12
    *e Check HV battery Check whether HV battery voltage has drastically dropped below normal range 13

DESCRIPTION

Refer to the description for DTC P0AE6-225.

Click here

The hybrid vehicle control ECU monitors the high-voltage wiring between the HV battery and the inverter with converter assembly and detects the following malfunction.

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P3004-131 High Voltage Power Resource

Although an SMR on request was sent when the power switch is operated, the voltage after boosting did not increase.

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

The EV electric battery fuse is blown, the service plug grip is removed, the system main resistor is blown, SMRG is turned off, SMRP or SMRB remains open, or the high-voltage cable has an open circuit.

(2 trip detection logic)

  • Hybrid battery junction block assembly

  • No. 2 frame wire

  • Inverter with converter assembly

  • HV battery

  • Wire harness or connector

 Does not come on

Master Warning Light:

Comes on
Related Data List
DTC No. Data List
P3004-131

  • VH-Voltage after Boosting

  • Power Resource VB

The following items can be helpful when performing repairs:


WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AA6-526.

Click here

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

Click here

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.

  • When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

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.


      Powertrain > Hybrid Control > Trouble Codes
      Result
      Result Proceed to
      P3004-131 (including pending DTC) only is output, or DTCs except the ones in the tables below are also output. A
      Any of the following DTCs including pending DTCs in table 1 below are also output. B
      Any of the DTCs in table 2 below are also output. C
      Table 1
      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
      P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low
      P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      System malfunction P3004-800, 801 High Voltage Power Resource
      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 P0A95-123 High Voltage Fuse
      P0AC0-123 Hybrid Battery Pack Current Sensor Circuit Range / Performance
      P0AC1-123 Hybrid Battery Pack Current Sensor "A" Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor "A" 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


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

      • P3004-131 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 FREEZE FRAME DATA (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. Read the freeze frame data of DTC P3004-131.

      Tech Tips

      In the freeze frame data, read the items "VH-Voltage after Boosting", "Power Resource VB" and "VL-Voltage before Boosting".

      Result
      Result Proceed to

      Both of the following conditions are met:


      • Post-boost voltage (VH-Voltage after Boosting) is below 50 V.

      • Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VL-Voltage before Boosting) is 40 V or less.

      		 A
      Except above B

    5. Turn the power switch off.


    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

  3. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

    Result
    Proceed to
    OK
    NG

    1. A01CQIMC01
      *A for LHD
      *B for RHD

      Check the connector connections and contact pressure of the relevant terminals for the hybrid vehicle control ECU connectors.

      Click here

      OK
      The connectors are connected securely and there are no contact pressure problems.
      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  4. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HYBRID BATTERY PACK WIRE 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

    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. B002IRF

      Check the connection condition of the No. 2 hybrid battery pack wire connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

      Click here

      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

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  5. CHECK CONNECTOR CONNECTION CONDITION (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY CONNECTOR)

    Result
    Proceed to
    OK
    NG

    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. 2 hybrid vehicle battery shield reinforcement.

      Click here

    3. B002IJY

      Check the connector connections and contact pressure of the relevant terminals for the hybrid battery junction block assembly connector.

      Click here

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

    4. Install the No. 2 hybrid vehicle battery shield reinforcement.

      Result
      Proceed to
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  6. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE 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 I115 hybrid vehicle control ECU connector.

    3. Remove the No. 2 hybrid vehicle battery shield reinforcement.

      Click here

    4. B002K92C96
      *a

      Rear view of wire harness connector

      (to Hybrid Vehicle Control ECU)
      *b

      Rear view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)

      Disconnect the y1 hybrid battery junction block assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      I115-4 (SMRB) - y1-4 (SMRB) Power switch off Below 1 Ω
      I115-3 (SMRP) - y1-3 (SMRP) Power switch off Below 1 Ω

    6. Reconnect the y1 hybrid battery junction block assembly connector.

    7. Install the No. 2 hybrid vehicle battery shield reinforcement.

    8. Reconnect the I115 hybrid vehicle control ECU connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    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 hybrid battery junction block assembly.

      Click here

    3. B002KQNC55
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      t5-1 (CBI) - x2-1 (+) Auxiliary battery voltage is applied between terminals y1-4 (SMRB) and y1-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      y1-4 (SMRB) - y1-2 (GND) -40 to 80°C (-40 to 176°F) 18.4 to 36.3 Ω

    5. Install the hybrid battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  8. INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRP)

    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 hybrid battery junction block assembly.

      Click here

    3. B002KQNC58
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      t6-1 (CEI) - x3-1 (-) Auxiliary battery voltage is applied between terminals y1-3 (SMRP) and y1-2 (GND) 28.5 to 31.5 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      y1-3 (SMRP) - y1-2 (GND) -40 to 80°C (-40 to 176°F) 112 to 274 Ω

    5. Install the hybrid battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  9. CHECK INVERTER WITH CONVERTER ASSEMBLY (NO. 2 FRAME WIRE CONNECTION CONDITION)

    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. B002HXI

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

    3. B002JFA

      Check that the bolt for the No. 2 frame wire is tightened to the specified torque, the No. 2 frame wire is connected securely, and there are no contact problems.

      Specified Condition
      T=8.0 N*m (82 kgf*cm, 71 in.*lbf)

    4. Disconnect the No. 2 frame wire from the inverter with converter assembly.

    5. Check for arc marks on the terminals of the No. 2 frame wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Reconnect the No. 2 frame wire.

    7. Install the connector cover assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  10. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (NO. 2 FRAME WIRE CONNECTION CONDITION)

    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. 2 hybrid vehicle battery shield reinforcement.

      Click here

    3. B002IZP

      Check that the nut for the No. 2 frame wire is tightened to the specified torque, the No. 2 frame wire is connected securely, and there are no contact problems.

      Specified Condition
      T=9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Disconnect the No. 2 frame wire from the hybrid battery junction block assembly.

    5. Check for arc marks on the terminals of the No. 2 frame wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Install the No. 2 hybrid vehicle battery shield reinforcement.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  11. CHECK NO. 2 FRAME WIRE (INVERTER WITH CONVERTER ASSEMBLY - 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. 2 hybrid vehicle battery shield reinforcement.

      Click here

    3. B002IZP

      Disconnect the No. 2 frame wire from the hybrid battery junction block assembly.

    4. B002HXI

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

    5. B002JFA

      Disconnect the No. 2 frame wire from the inverter with converter assembly.

    6. B002J62C03
      *a

      No. 2 Frame Wire

      (Inverter with Converter Assembly Side)
      *b

      No. 2 Frame Wire

      (Hybrid Battery Junction Block Assembly Side)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      t2-1 (CBI) - t5-1 (CBI) Power switch off Below 1 Ω
      t2-2 (CEI) - t6-1 (CEI) Power switch off Below 1 Ω

    7. Reconnect the No. 2 frame wire.

    8. Install the connector cover assembly.

    9. Install the No. 2 hybrid vehicle battery shield reinforcement.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 2 FRAME WIRE Click here

    OK

  12. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV BATTERY HIGH VOLTAGE CONNECTOR CONNECTION CONDITION)

    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. 2 hybrid vehicle battery shield reinforcement.

      Click here

    3. B002KFG

      Check the connector connection condition between the 2 HV battery high voltage connectors and the hybrid battery junction block assembly.

    4. Disconnect the 2 HV battery high voltage connectors from the hybrid battery junction block assembly.

    5. Check for arc marks on the terminals of the HV battery high voltage terminals.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Reconnect the 2 HV battery high voltage connectors.

    7. Install the No. 2 hybrid vehicle battery shield reinforcement.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  13. CHECK HV BATTERY

    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. 2 hybrid vehicle battery shield reinforcement.

      Click here

    3. Disconnect the 2 HV battery high voltage connectors from the hybrid battery junction block assembly.

    4. B002K91C02
      *a

      Front view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)
      *b

      Service Plug Grip Removed

      (Service Plug Grip Connecting Terminals)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      x2-1 (+) - Service plug terminal 1 Power switch off 96 V or higher
      x3-1 (-) - Service plug terminal 2 Power switch off 108 V or higher

      CAUTION:

      Do not allow the probes of the electrical tester to contact each other during this inspection.

    5. Reconnect the 2 HV battery high voltage connectors.

    6. Install the No. 2 hybrid vehicle battery shield reinforcement.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY Click here

    OK

  14. CHECK FOR INTERMITTENT PROBLEMS


    1. Check for intermittent problems.

      Click here

      Result
      Proceed to
      Problem symptom does not recur.
      Problem symptom recurs.

      Tech Tips


      • Since 2 trip detection logic is used, the DTC detection condition must be met twice.

      • If DTC P3004-131 is output again after performing the inspection, replace the inverter with converter assembly. If DTC P3004-131 is not output again, replace the hybrid battery junction block assembly.


    Problem symptom does not recur.

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    Problem symptom recurs.

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here