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HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-803

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DTC Code DTC Name
P3004-803 Power Cable Malfunction
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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 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
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WIRING DIAGRAM

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

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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 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 intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / DTC.

    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
      P0A95-123 is also output. C
      DTC No. Relevant Diagnosis
      P0A1A-151, 155, 156, 658, 659 Generator Control Module
      P0A1B-164, 193, 512, 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 ECM/PCM Power Relay Sensor Circuit Intermittent
      P3004-131, 132 Power Cable Malfunction
      P324E-788 MG-ECU Power Relay Intermittent Circuit
      U0110 (all INF codes)*1 Lost Communication with Drive Motor Control Module
      Tip:

      • *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.


  2. Click here

    CLEAR DTC


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / DTC.

    4. Read and record the DTCs and freeze frame data.

    5. Clear DTCs and freeze frame data.

    6. Turn the power switch off.


  3. Click here

    CHECK DTC OUTPUT (HYBRID CONTROL)


    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 D and depress both the accelerator pedal and brake pedal at the same time.

      Tip:

      • 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 depress in the inappropriate operation and history data to be counted.

    5. Enter the following menus: Powertrain / Hybrid Control / DTC.

    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.


  4. Click here

    CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)


    1. A003Y7QE01

      Check the connections of the power management control ECU connectors.

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

  5. Click here

    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 H3 from the power management control ECU.

    3. Remove the upper hybrid battery cover sub-assembly (Click here).

    4. Disconnect connector i3 from the hybrid battery junction block assembly.

      Tip:

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

    5. A003ZL1E41

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      H3-4 (SMRB) - i3-4 (SMRB) Power switch off Below 1 Ω
      H3-2 (SMRG) - i3-1 (SMRG) Power switch off Below 1 Ω
      Table 2. Text in Illustration
      *a

      Rear view of wire harness connector

      (to Power Management Control ECU)
      *b

      Rear view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)

    6. Connect hybrid battery junction block assembly connector.

    7. Install the upper hybrid battery cover sub-assembly (Click here).

    8. Connect the power management control ECU connector.


  6. Click here

    GO TO DTC CHART (HYBRID CONTROL SYSTEM)Click here

  7. Click here

    GO TO DTC CHART (P3004-131)Click here

  8. Click here

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLYClick here

  9. Click here

    CONNECT SECURELY

  10. Click here

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  11. Click here

    GO TO DTC CHART (P0A95-123)Click here