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

DTC Code DTC Name
P3004-800 Power Cable Malfunction
P3004-801 Power Cable Malfunction

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

  • No. 3 wire frame

  • Power steering converter assembly

  • Power management control ECU
P3004 801 Minimal overcurrent occurs during precharge (time from when SMRP turns on until when SMRG turns on).

WIRING DIAGRAM


INSPECTION PROCEDURE

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 disconnecting 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.

Tech Tips

Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE


  1. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P3004-800or P3004-801 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A09-265 DC/DC Converter Status Circuit Low Input
      P0A10-263 DC/DC Converter Status Circuit High Input

      Tech Tips

      P3004-800 or P3004-801 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART Click here

    A

  2. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      P3004-800or P3004-801 only is output. A
      Any of the following DTCs are also output. B
      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
      P308A-123 Hybrid Battery Voltage Detection Circuit Open

      Tech Tips

      P3004-800 or P3004-801 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

    5. Turn the power switch off.


    B

    GO TO DTC CHART Click here

    A

  3. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)


    1. Check the connections of the power management control ECU connectors.

      A01NF3IE01
      Text in Illustration
      *1 for LHD *2 for RHD
      OK
      The connectors are connected securely and there are no contact problems.

    NG

    CONNECT SECURELY

    OK

  4. 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. A01NEKJ

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

    3. A01NF9OE01

      Disconnect the No. 4 engine wire (air conditioning harness) e2 from the inverter with converter assembly.

    4. A01NFOVE01
      Text in Illustration
      *1

      No. 4 Engine Wire

      (Air Conditioning Harness)
      *2 Shielded Wire Ground

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

      Standard Resistance

      Tester Connection

      (Tester Probe Polarity)

      		 Switch Condition Specified Condition
      e2-1 (ACPB) - e2-2 (ACPE) 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.

    5. Connect the No. 4 engine wire (air conditioning harness) from the inverter with converter assembly.

    6. Install the inverter terminal cover to the inverter with converter assembly.


    NG

    CHECK NO. 4 ENGINE WIRE Click here

    OK

  5. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU)


    1. Disconnect connector A79 from the inverter with converter assembly.

    2. A01NH3DE37
      Text in Illustration
      *1

      Front view of wire harness 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
      A79-24 (NODD) - Body ground Power switch off 120 to 140 kΩ

    3. Connect the inverter with converter assembly connector.


    NG

    CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER) Click here

    OK

  6. CHECK NO. 3 WIRE FRAME

    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. A01NEKJ

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

    3. A01NDA0

      Disconnect the No. 3 wire frame (high voltage DC connector) g1 from the inverter with converter assembly.

    4. Remove the No. 1 battery cover lid Click here.

    5. A01NDUKE01

      Disconnect the connector g6 from the hybrid battery junction block assembly.

    6. A01NFUIE03
      Text in Illustration
      *1 No. 3 Wire Frame
      *2 Red Mark

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g3-1 - g2-1 Power switch off 10 kΩ or higher

    7. Connect the hybrid battery junction block assembly connector.

    8. Install the No. 1 battery cover lid Click here.

    9. Connect the No. 3 wire frame (high voltage DC connector) to inverter with converter assembly.

    10. Install the inverter terminal cover to the inverter with converter assembly.


    NG

    CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  7. CHECK NO. 3 WIRE FRAME (HYBRID BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER)

    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. 1 battery cover lid Click here.

    3. A01NDUKE01

      Disconnect the connector g6 from the hybrid battery junction block assembly.

    4. Disconnect connector g7 from the power steering converter assembly.

    5. A01NDJ1E01

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g7-1 (CBP) - g7-5 (CEP) Power switch off 10 kΩ or higher

    6. Connect the power steering converter assembly connector.

    7. Connect the hybrid battery junction block assembly connector.

    8. Install the No. 1 battery cover lid Click here.


    NG

    REPLACE NO. 3 WIRE FRAME Click here

    OK

  8. CHECK POWER STEERING CONVERTER 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 connector g7 from the power steering converter assembly.

    3. A01NFH8E01

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

      Standard Resistance

      Tester Connection

      Tester Probe Polarity)

      		 Switch Condition Specified Condition

      g7-1 (CBP) (Positive prove) -

      g7-5 (CEP) (Negative prove)

      		 Power switch off 400 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. Connect the power steering converter assembly connector.


    NG

    REPLACE POWER STEERING CONVERTER ASSEMBLY Click here

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  9. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER)


    1. Disconnect connector A79 from the inverter with converter assembly.

    2. Disconnect connector A80 from power management control ECU.

    3. A01NFSUE01
      Text in Illustration
      *1

      Rear view of wire harness connector

      (Power Management Control ECU)
      *2 Inverter with Converter Assembly

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

      Standard Resistance (Check for open)
      Tester Connection Switch Condition Specified Condition
      A80-21 (NODD) - A79-24 (NODD) Power switch off Below 1 Ω
      Standard Resistance (Check for short)
      Tester Connection Switch Condition Specified Condition
      A80-21 (NODD) or A79-24 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher
      Result
      Result Proceed to
      OK (for LHD) A
      OK (for RHD) B
      NG C

    4. Connect the power management control ECU connector.

    5. Connect the inverter with converter assembly connector.


    B

    REPLACE POWER MANAGEMENT CONTROL ECU (for RHD) Click here

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

    REPLACE POWER MANAGEMENT CONTROL ECU (for LHD) Click here

  10. 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. A01NEKJ

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

    3. A01NF9OE01

      Disconnect the No. 4 engine wire (air conditioning harness) e2 from the inverter with converter assembly.

    4. A01NDU9E02
      Text in Illustration
      *1 Green Lock

      Disconnect the No. 4 engine wire (air conditioning harness) e1 from the compressor with motor assembly.

    5. A01NFOVE01
      Text in Illustration
      *1

      No. 4 Engine Wire

      (Air Conditioning Harness)
      *2 Shielded Wire Ground

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      e2-1 (ACPB) - e2-2 (ACPE) Power switch off 10 kΩ or higher

    6. Connect the No. 4 engine wire (air conditioning harness) to the compressor with motor assembly.

    7. Connect the No. 4 engine wire (air conditioning harness) from the inverter with converter assembly.

    8. Install the inverter terminal cover to the inverter with converter assembly.


    NG

    REPLACE NO. 4 ENGINE WIRE

    OK

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

  11. 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. 1 battery cover rid Click here.

    3. A01NDUKE01

      Disconnect the connector g6 from the hybrid battery junction block assembly.

    4. A01NFUIE02

      Disconnect the No. 3 wire frame g2 and g3 from the hybrid battery junction block assembly.

    5. A01NEBDE01
      Text in Illustration
      *1 Hybrid Battery Junction Block Assembly

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      g2-1 - g3-1 Power switch off 10 kΩ or higher

    6. Connect the No. 3 wire frame to the hybrid battery junction block assembly.

    7. Connect the hybrid battery junction block assembly connector.

    8. Install the No. 1 battery cover rid Click here.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

    REPLACE NO. 3 WIRE FRAME Click here