HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-803

DTC Code DTC Name
P3004-803 Power Cable Malfunction

DESCRIPTION

Refer to the description for DTC P0AE6-225 Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P3004 803 While the power switch is on (READY), the electric battery fuse in the service plug grip is burned out, the service plug grip is removed, or SMRB or SMRG is open.

  • Hybrid battery junction block assembly

  • Wire harness or connector

WIRING DIAGRAM

Refer to wiring diagram for DTC P0AE6-225 Click here.

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
      P3004-803 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A-151, 155, 658, 659 Generator Control Module
      P0A1B-164, 193, 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 HV CPU Power Relay Sense Circuit Intermittent No Continuity
      P3004-131 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 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
      P3004-803 only is output. A
      P0A95-123 is also output. B

    5. Turn the power switch off.


    B

    GO TO DTC CHART Click here

    A

  3. CLEAR DTC (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. Read and record the DTCs and freeze frame data.

    5. Clear DTCs and freeze frame data.

    6. Turn the power switch off.


    NEXT

  4. CHECK DTC OUTPUT (HV)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (READY).

    3. Ensure the safety of the areas in front and at the back of the vehicle.

    4. Move the shift lever to the D position 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 depressing in the inappropriate operation and history data to be counted.

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

    6. Check if DTCs are output.

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

    7. Turn the power switch off.


    B

    GO TO DTC CHART Click here

    A

  5. 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

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

    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 F97 from the power management control ECU.

    3. Remove the battery cover sub-assembly Click here.

    4. Disconnect connector z34 from the hybrid battery junction block assembly.

      Tech Tips

      Before disconnecting the connector, check whether it is connected securely to the hybrid battery junction block assembly.

    5. A01NF1EE07
      Text in Illustration
      *1 Power Management Control ECU
      *2 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
      F97-4 (SMRB) - z34-4 (SMRB) Power switch off Below 1 Ω
      F97-2 (SMRG) - z34-1 (SMRG) Power switch off Below 1 Ω

    6. Connect hybrid battery junction block assembly connector.

    7. Install the battery cover sub-assembly Click here.

    8. Connect the power management control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here