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

DTC SUMMARY

MALFUNCTION DESCRIPTION

The hybrid vehicle control ECU monitors the high-voltage wiring between the HV battery and inverter with converter assembly and detects a short circuit malfunction or high-voltage system operation malfunction.

The cause of this malfunction may be one of the following:
- Battery current sensor (IB) malfunction
- Motor generator control ECU (MG ECU) malfunction
- Communication (wire harness) malfunction
- HV battery malfunction
- Hybrid battery junction block assembly malfunction
- Inverter with converter assembly malfunction
- Air conditioner system malfunction
- High-voltage wire harness malfunction
- High-voltage connector or connection malfunction
- Hybrid vehicle control ECU malfunction
- Low voltage wire harness malfunction
- Low voltage connector malfunction

INSPECTION DESCRIPTION

System Diagram Location	Inspection Content	Reason	Inspection Step
*a	Check wire harness connector connection condition between hybrid vehicle control ECU and inverter with converter assembly	Check that DCDC can be cut off during precharge. Check for open or short circuit in NODD line. Check that NODD terminal voltage is sufficiently low during DCDC operation command.	2 to 5
*b	Check high-voltage wiring connection condition of the air conditioner compressor with motor assembly	Check for short circuit	6, 8
*c	Check hybrid battery junction block assembly	Check for short circuit	7, 9

System Diagram Location

Inspection Content

Reason

Inspection Step

Check wire harness connector connection condition between hybrid vehicle control ECU and inverter with converter assembly

Check that DCDC can be cut off during precharge.

Check for open or short circuit in NODD line.
Check that NODD terminal voltage is sufficiently low during DCDC operation command.

2 to 5

Check high-voltage wiring connection condition of the air conditioner compressor with motor assembly

Check for short circuit

6, 8

Check hybrid battery junction block assembly

Check for short circuit

7, 9

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
P3004-800	High Voltage Power Resource	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 Engine wire Compressor with motor assembly Inverter with converter assembly Hybrid battery junction block assembly No. 2 frame wire Hybrid vehicle control ECU	Does not come on	Master Warning Light: Comes on
P3004-801	High Voltage Power Resource	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 SMRG turns on). (1 trip detection logic)	Wire harness or connector Engine wire Compressor with motor assembly Inverter with converter assembly Hybrid battery junction block assembly No. 2 frame wire Hybrid vehicle control ECU	Does not come on	Master Warning Light: Comes on

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Warning Indicate

P3004-800

High Voltage Power Resource

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
Engine wire
Compressor with motor assembly
Inverter with converter assembly
Hybrid battery junction block assembly
No. 2 frame wire
Hybrid vehicle control ECU

Does not come on

Master Warning Light:

Comes on

P3004-801

High Voltage Power Resource

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 SMRG turns on).

(1 trip detection logic)

Wire harness or connector
Engine wire
Compressor with motor assembly
Inverter with converter assembly
Hybrid battery junction block assembly
No. 2 frame wire
Hybrid vehicle control ECU

Does not come on

Master Warning Light:

Comes on

Related Data List
DTC No.	Data List
P3004-800	VH-Voltage after Boosting Power Resource VB
P3004-801	VH-Voltage after Boosting Power Resource VB

The following items can be helpful when performing repairs:

Data List

VL-Voltage before Boosting
Power Resource IB
Ready Signal

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0A08-264.

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Refer to the wiring diagram for DTC P0AA6-526.

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CAUTION / NOTICE / HINT

CAUTION:

If this DTC is output, do not turn the power switch on (READY) until the repair has been completed. This DTC means an excessive amperage flow through the system main resistor. The system main resistor may overheat and be damaged if the power switch is turned on (READY) repeatedly before repair.
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.

Click here
If P3004-800 or P3004-801 are output, do not repeatedly turn the power switch on (READY), off.

Tech Tips

After the repair, clear the DTCs, perform the following procedure and check that the same DTC (including pending DTC) is not output.

Turn the power switch off and wait for 30 seconds or more.
Turn the power switch on (READY) and wait for 30 seconds or more.

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
P3004-800 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
Relevant DTC
P0A09-265	DC / DC Converter Status Circuit Low Input
P0A10-263	DC / DC Converter Status Circuit High Input
P0A94-169, 170, 171, 172, 553, 554, 555, 556, 557	DC / DC Converter Performance

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	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
	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

P3004-800 or P3004-801 may be output as a result of the malfunction indicated by the DTCs above.

The chart above is listed in inspection order of priority.
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.)

Turn the power switch off.

GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

Result

Proceed to
OK
NG

*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

CONNECT SECURELY

CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY 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.

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.

Check the 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

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.

CONNECT SECURELY

REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - HYBRID VEHICLE CONTROL ECU)

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 A59 inverter with converter assembly connector.
Disconnect the A60 hybrid vehicle control ECU connector.

Front view of wire harness connector

(to Inverter with Converter Assembly)

Rear view of wire harness connector

(to Hybrid Vehicle Control ECU)

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

Standard Resistance (Check for Open)

Tester Connection	Condition	Specified Condition
A59-5 (NODD) - A60-25 (NODD)	Power switch off	Below 1 Ω

Standard Resistance (Check for Short)

Tester Connection	Condition	Specified Condition
A59-5 (NODD) or A60-25 (NODD) - Body ground and other terminals	Power switch off	10 kΩ or higher

Reconnect the A60 hybrid vehicle control ECU connector.

Reconnect the A59 inverter with converter assembly connector.

Result

Proceed to
OK
NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

CHECK HYBRID VEHICLE CONTROL ECU

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.
Connect the cable to the negative (-) auxiliary battery terminal.
Turn the power switch on (IG).

*a	Component with harness connected (Hybrid Vehicle Control ECU)

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

Standard Voltage

Tester Connection	Condition	Specified Condition
A60-25 (NODD) - I115-6 (E1)	Power switch on (IG)	Less than 1.5 V

Turn the power switch off.

Disconnect the cable from the negative (-) auxiliary battery terminal.

Result

Proceed to
OK
NG

REPLACE HYBRID VEHICLE CONTROL ECU Click here

CHECK COMPRESSOR WITH MOTOR 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 engine wire (air conditioning harness) from the inverter with converter assembly.

*a	Engine wire (Air Conditioning Harness) (Inverter with Converter Assembly Side)

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

Standard Resistance

Tester Connection

(Tester Probe Polarity)

Condition

Specified Condition

C47-1 (ACPE) (Negative probe) - C47-2 (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.

Reconnect the engine wire (air conditioning harness).

Result

Proceed to
OK
NG

CHECK ENGINE WIRE (AIR CONDITIONING HARNESS) Click here

CHECK NO. 2 FRAME WIRE

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

*a	No. 2 frame wire (Inverter with Converter Assembly Side)

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

Standard Resistance

Tester Connection	Condition	Specified Condition
t2-1 (CBI) - t2-2 (CEI)	Power switch off	10 kΩ or higher

Reconnect the No. 2 frame wire.

Install the connector cover assembly.

Result

Proceed to
OK
NG

REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

CHECK NO. 2 FRAME WIRE Click here

CHECK ENGINE WIRE (AIR CONDITIONING HARNESS)

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 engine wire (air conditioning harness) from the inverter with converter assembly.
Disconnect the engine wire (air conditioning harness) from the compressor with motor assembly.

Click here

*a	Engine Wire (Air Conditioning Harness) (Inverter with Converter Assembly Side)

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

Standard Resistance

Tester Connection

(Tester Probe Polarity)

Condition

Specified Condition

C47-1 (ACPE) (Negative probe) - C47-2 (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

Reconnect the engine wire (air conditioning harness) to the compressor with motor assembly.

Reconnect the engine wire (air conditioning harness) to the inverter with converter assembly.

Result

Proceed to
OK
NG

REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

REPLACE ENGINE WIRE

CHECK NO. 2 FRAME WIRE

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

Click here
Disconnect the No. 2 frame wire from the hybrid battery junction block assembly.
Remove the connector cover assembly from the inverter with converter assembly.
Disconnect the No. 2 frame wire from the inverter with converter assembly.

*a	No. 2 frame wire (Inverter with Converter Assembly Side)

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

Standard Resistance

Tester Connection	Condition	Specified Condition
t2-1(CBI) - t2-2(CEI)	Power switch off	10 kΩ or higher

Reconnect the No. 2 frame wire.

Install the connector cover assembly.

Result

Proceed to
OK
NG

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

REPLACE NO. 2 FRAME WIRE Click here