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HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-800, P3004-801

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Info Added 2017-08-02

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DTC Code DTC Name
P3004-800 High Voltage Power Resource
P3004-801 High Voltage Power Resource
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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 when SMRG turns on).

  • Wire harness or connector

  • No. 4 engine wire

  • Compressor with motor assembly

  • Inverter with converter assembly

  • Hybrid battery junction block assembly

  • Frame wire

  • Hybrid vehicle control ECU assembly
801 Minimal overcurrent occurs during precharge (time from when SMRP turns on until when SMRG turns on).
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WIRING DIAGRAM


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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 (Click here).

    Tip:

    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).

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PROCEDURE


  1. Click here

    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 following DTCs in table 1 below are also output. B
      Any of the following DTCs in table 2 below are also output. C
      Table 1. 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. 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
      P0B92-123 Hybrid Battery Voltage Sensor "R" Circuit Low
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module
      Tip:

      P3004-800 or P3004-801 may be stored due to a malfunction which causes the DTCs in either 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.

    5. Turn the power switch off.


  2. Click here

    CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU ASSEMBLY CONNECTOR)


    1. A0005OEE01

      Check the connector connections and contact pressure of the relevant terminals for the hybrid vehicle control ECU assembly connectors (Click here).

      Table 3. Text in Illustration
      *A for LHD
      *B for RHD
      OK
      The connectors are connected securely and there are no contact pressure problems.

  3. Click here

    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. A00046KE03

      Check the connector connections and contact pressure of the low voltage connectors of the inverter with converter assembly (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 connectors are connected securely and there are no contact pressure problems.
      Tip:

      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.


  4. Click here

    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. A0007J0E03

      Disconnect the E2 inverter with converter assembly connector.

    3. A0005O4E03

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

      Standard Resistance

      Tester Connection

      (Tester Probe Polarity)

      		 Condition Specified Condition
      E2-1 (ACPE) (Negative probe) - E2-2 (ACPB) (Positive probe) Power switch off 100 kΩ or higher
      Table 4. Text in Illustration
      *a

      Front view of No. 4 engine wire (Air Conditioning Harness) connector

      (to Inverter with Converter Assembly)
      Note:

      • Do not use a megohmmeter.

      • Read the resistance after the value has stabilized.

      Tip:

      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 E2 inverter with converter assembly connector.


  5. Click here

    CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - HYBRID VEHICLE CONTROL ECU 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 A13 inverter with converter assembly connector.

    3. Disconnect the A78 hybrid vehicle control ECU assembly connector.

    4. A0005B2E02

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      A13-5 (NODD) - A78-25 (NODD) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      A13-5 (NODD) or A78-25 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher
      Table 5. Text in Illustration
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      *b

      Rear view of wire harness connector

      (to Hybrid Vehicle Control ECU Assembly)

    5. Reconnect the A78 hybrid vehicle control ECU assembly connector.

    6. Reconnect the A13 inverter with converter assembly connector.


    • OKClick here
    • NG

      REPAIR OR REPLACE HARNESS OR CONNECTOR

  6. Click here

    CHECK HYBRID VEHICLE CONTROL ECU ASSEMBLY (NODD)

    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. A0006GQE02

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      A78-25 (NODD) - H211-6 (E1) Power switch on (IG) Less than 1.5 V
      Table 6. Text in Illustration
      *a

      Component with harness connected

      (Hybrid Vehicle Control ECU Assembly)

    5. Turn the power switch off.

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


  7. Click here

    CHECK FRAME 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. A0004W1

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

    3. A0006GSE03

      Disconnect the S1 inverter with converter assembly connector.

    4. Remove the No. 4 hybrid battery shield panel (Click here).

    5. A0005XKE04

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S2-1 (CBI) - S3-1 (CEI) Power switch off 10 kΩ or higher

    6. Install the No. 4 hybrid battery shield panel.

    7. Reconnect the S1 inverter with converter assembly connector.

    8. Install the connector cover assembly.


  8. Click here

    CHECK NO. 4 ENGINE 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. A0007J0E03

      Disconnect the E2 inverter with converter assembly connector.

    3. A000970E03

      Disconnect the E1 compressor with motor assembly connector (Click here).

    4. A0005O4E03

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      E2-1 (ACPE) - E2-2 (ACPB) Power switch off 10 kΩ or higher
      Table 7. Text in Illustration
      *a

      Front view of No. 4 engine wire (Air Conditioning Harness) connector

      (to Inverter with Converter Assembly)

    5. Reconnect the E1 compressor with motor assembly connector.

    6. Reconnect the E2 inverter with converter assembly connector.


    • OK

      REPLACE COMPRESSOR WITH MOTOR ASSEMBLY (Click here)

    • NG

      REPLACE NO. 4 ENGINE WIRE

  9. Click here

    CHECK 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. 4 hybrid battery shield panel (Click here).

    3. A0005XKE04

      Disconnect the S2 and S3 hybrid battery junction block assembly connectors.

    4. A0004MXE03

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S3-1 (CEI) - S2-1 (CBI) Power switch off 10 kΩ or higher

    5. Reconnect the S2 and S3 hybrid battery junction block assembly connectors.

    6. Install the No. 4 hybrid battery shield panel.