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

DESCRIPTION

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

DTC No. INF Code DTC Detection Condition Trouble Area
P3004 800

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

  • No. 4 engine wire

  • Compressor with motor assembly

  • Inverter with converter assembly

  • Hybrid battery junction block assembly

  • Frame wire

  • Hybrid vehicle control ECU
801

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 when SMRG turns on).

(1 trip detection logic)
Related Data List
DTC No. Data List
P3004-800

  • VH-Voltage after Boosting

  • Power Resource VB
P3004-801

The following items can be helpful when performing repairs:


WIRING DIAGRAM


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.

Note

After turning the ignition 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 ignition switch off and wait for 30 seconds or more.

  2. Turn the ignition switch to 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 ignition switch to ON (IG).

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

    4. Check if DTCs are output.

      Result
      Result Proceed to
      Only P3004-800 or P3004-801 is output, or DTCs other than the ones in the table below are also output. A
      DTCs shown in Table 1 are output simultaneously. B
      DTCs shown in Table 2 are output simultaneously. C
      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
      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
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module

      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 ignition 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 CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)


    1. A01V0I0E02
      Text in Illustration
      *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.

    NG

    CONNECT SECURELY

    OK

  3. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A004GGV

      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.

      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.


    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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A004EQ3

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

    3. A004G00

      Remove the inverter cover from the inverter with converter assembly.

    4. A004E55E02

      Disconnect the No. 2 engine wire (air conditioning harness) connector from the inverter with converter assembly.

    5. A004E9BE01
      Text in Illustration
      *a

      No. 2 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)

      		 Switch Condition Specified Condition
      D2-2 (ACPE) (Negative probe) - D2-1 (ACPB) (Positive probe) Ignition 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.

    6. Connect the No. 2 engine wire (air conditioning harness) to the inverter with converter assembly.

    7. Install the inverter cover.

    8. Install the inverter terminal cover.


    NG

    CHECK NO. 2 ENGINE WIRE Click here

    OK

  5. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the hybrid vehicle control ECU connector.

    3. Disconnect the inverter with converter assembly connector.

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

      A004FKNE02
      Standard Resistance (Check for Open)
      Tester Connection Switch Condition Specified Condition
      A33-12 (NODD) - A26-25 (NODD) Ignition switch off Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Switch Condition Specified Condition
      A33-12 (NODD) or A26-25 (NODD) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Hybrid Vehicle Control ECU)
      *b

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

    5. Connect the inverter with converter assembly connector.

    6. Connect the hybrid vehicle control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. CHECK HYBRID VEHICLE CONTROL ECU

    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 ignition switch to 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 ignition switch to ON (IG).

    4. A004E7NE02
      Text in Illustration
      *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
      A26-25(NODD) - F55-6(E1) Ignition switch ON (IG) Less than 1.5 V

    5. Turn the ignition switch off.

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


    NG

    REPLACE HYBRID VEHICLE CONTROL ECU Click here

    OK

  7. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A004EQ3

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

    3. A004G00

      Remove the inverter cover from the inverter with converter assembly.

    4. A004FYPE02

      Disconnect the frame wire connector from the inverter with converter assembly.

    5. A004FTOE01
      Text in Illustration
      *a

      Frame Wire

      (Inverter With Converter Assembly Side)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      L1-2 (CBI) - L1-1 (CEI) Ignition switch off 10 kΩ or higher

    6. Connect the frame wire.

    7. Install the inverter cover.

    8. Install the inverter terminal cover.


    OK

    REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS Click here

    NG

    CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

  8. CHECK NO. 2 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A004EQ3

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

    3. A004G00

      Remove the inverter cover from the inverter with converter assembly.

    4. A004E55E02

      Disconnect the No. 2 engine wire (air conditioning harness) connector from the inverter with converter assembly.

    5. A004E39E02

      Disconnect the No. 2 engine wire (air conditioning harness) connector from the compressor with motor assembly Click here.

    6. A004E3DE01
      Text in Illustration
      *a

      No. 2 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 Switch Condition Specified Condition
      D2-1 (ACPB) - D2-2 (ACPE) Ignition switch off 10 kΩ or higher

    7. Connect the No. 2 engine wire (air conditioning harness) to the compressor with motor assembly.

    8. Connect the No. 2 engine wire (air conditioning harness) to the inverter with converter assembly.

    9. Install the inverter cover.

    10. Install the inverter terminal cover.


    OK

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

    NG

    REPLACE NO. 2 ENGINE WIRE

  9. 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 ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 1 hybrid vehicle battery cover panel LH Click here.

    3. A004F2GE02

      Disconnect connector L4 and connector L3 of the frame wire from the hybrid battery junction block assembly.

    4. A004GBXE01

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      L3-1 (CEI) - L4-1 (CBI) Ignition switch off 10 kΩ or higher

    5. Connect the frame wire.

    6. Install the No. 1 hybrid vehicle battery cover panel LH.


    OK

    REPLACE FRAME WIRE Click here

    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here