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 Excessive overcurrent occurs during precharge (time from when SMRP turns on until SMRG turns on).

  • Wire harness or connector

  • No. 4 floor wire (air conditioning harness)*1

  • Air conditioning harness*2

  • Compressor with motor assembly

  • Inverter with converter assembly

  • Power steering converter wire

  • Power steering converter assembly

  • Hybrid battery junction block assembly

  • No. 4 floor wire

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

PROCEDURE


  1. 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 if DTCs are output.

      Result
      Result Proceed to
      P3004-800 or P3004-801 only is 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
      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
      P0B97-123 Hybrid Battery Voltage Sensor "S" Circuit Low
      P0B9C-123 Hybrid Battery Voltage Sensor "T" Circuit Low
      P0BA1-123 Hybrid Battery Voltage Sensor "U" 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 power 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 (POWER MANAGEMENT CONTROL ECU CONNECTOR)


    1. A01FQC6E01
      Text in Illustration
      *A for LHD
      *B for RHD

      Check the connector connections and contact pressure of the relevant terminals for the power management control ECU connectors Click here.

      OK
      The connectors are connected securely and there are no contact pressure problems.

    NG

    CONNECT SECURELY

    OK

  3. 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. for LHD:


      1. Disconnect the connector of the No. 4 floor wire (air conditioning harness) from the inverter with converter assembly.

        A01FTG5

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

        A01FUUGE09
        Standard Resistance

        Tester Connection

        (Tester Probe Polarity)

        		 Switch Condition Specified Condition
        V3-1 (ACPE) (Negative probe) - V3-2 (ACPB) (Positive probe) Power switch off 100 kΩ or higher
        Text in Illustration
        *a

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

        (to Inverter with Converter Assembly)

        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.

      3. Connect the No. 4 floor wire (air conditioning harness) to the inverter with converter assembly.

    3. for RHD:


      1. Disconnect the connector of the air conditioning harness from the inverter with converter assembly.

        A01FRLD

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

        A01FUUGE11
        Standard Resistance

        Tester Connection

        (Tester Probe Polarity)

        		 Switch Condition Specified Condition
        f1-1 (ACPE) (Negative probe) - f1-2 (ACPB) (Positive probe) Power switch off 100 kΩ or higher
        Text in Illustration
        *a

        Front view of air conditioning harness connector

        (to Inverter with Converter Assembly)

        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.

      3. Connect the air conditioning harness to the inverter with converter assembly.


    NG

    CHECK HARNESS AND CONNECTOR Click here

    OK

  4. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the connector from the inverter with converter assembly.

    3. Disconnect the connector from the power management control ECU.

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

      A01FQEPE01
      Text in Illustration
      *A for LHD *B for RHD
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

      		 *b

      Rear view of wire harness connector

      (to Power Management Control ECU)
      Standard Resistance (Check for Open)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A39-5 (NODD) - A35-23 (NODD) Power switch off Below 1 Ω
      for RHD
      Tester Connection Switch Condition Specified Condition
      A75-5 (NODD) - A35-23 (NODD) Power switch off Below 1 Ω
      Standard Resistance (Check for Short)
      for LHD
      Tester Connection Switch Condition Specified Condition
      A39-5 (NODD) or A35-23 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher
      for RHD
      Tester Connection Switch Condition Specified Condition
      A75-5 (NODD) or A35-23 (NODD) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Connect the power management control ECU connector.

    6. Connect the inverter with converter assembly connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Connect the cable to the negative (-) auxiliary battery terminal.

    2. Turn the power switch on (IG).

    3. A01FVQXE10
      Text in Illustration
      *a

      Component with harness connected

      (Power Management Control ECU)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A35-23 (NODD) - N91-6 (E1) Power switch on (IG) Below 1.5 V

    4. Turn the power switch off.

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


    NG

    REPLACE POWER MANAGEMENT CONTROL ECU Click here

    OK

  6. CHECK NO. 4 FLOOR 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. A01FRDPE01
      Text in Illustration
      *A for LHD
      *B for RHD

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

    3. A01FUXUE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Disconnect the connector of the No. 4 floor wire from the inverter with converter assembly.

    4. Remove the No. 4 hybrid vehicle battery shield sub-assembly Click here.

    5. A01FUBA

      Disconnect the connector of the power steering converter wire from the hybrid battery junction block assembly.

    6. A01FT15E01

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      V5-1 (CBI) - V4-1 (CEI) Power switch off 10 kΩ or higher

    7. Connect the power steering converter wire.

    8. Install the No. 4 hybrid vehicle battery shield sub-assembly.

    9. Connect the No. 4 floor wire.

    10. Install the connector cover assembly.


    NG

    CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  7. CHECK POWER STEERING CONVERTER 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. Remove the No. 4 hybrid vehicle battery shield sub-assembly Click here.

    3. A01FUBA

      Disconnect the connector of the power steering converter wire from the hybrid battery junction block assembly.

    4. Remove the ECU bracket Click here.

    5. Disconnect the connector of the power steering converter wire from the power steering converter assembly.

    6. A01FVADE01
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Power Steering Converter Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      q2-1 (CBP) - q2-5 (CEP) Power switch off 10 kΩ or higher

    7. Connect the power steering converter wire to the power steering converter assembly.

    8. Install the ECU bracket.

    9. Connect the power steering converter wire to the hybrid battery junction block assembly.

    10. Install the No. 4 hybrid vehicle battery shield sub-assembly.


    NG

    REPLACE POWER STEERING CONVERTER WIRE 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. Remove the ECU bracket Click here.

    3. Disconnect the connector of the power steering converter wire from the power steering converter assembly.

    4. A01FTE1E01
      Text in Illustration
      *a

      Component without harness connected

      (Power Steering Converter Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      q2-1 (CBP) - q2-5 (CEP) Power switch off 400 kΩ or higher

    5. Connect the power steering converter wire.

    6. Install the ECU bracket.


    NG

    REPLACE POWER STEERING CONVERTER ASSEMBLY Click here

    OK

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  9. CHECK HARNESS AND 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. for LHD:


      1. Disconnect the connector of the No. 4 floor wire (air conditioning harness) from the inverter with converter assembly.

        A01FTG5

      2. Disconnect the connector of the No. 4 floor wire (air conditioning harness) from the compressor with motor assembly.

        A01FV15E01
        Text in Illustration
        *1 Green Lock

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

        A01FUUGE09
        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        V3-1 (ACPE) - V3-2 (ACPB) Power switch off 10 kΩ or higher
        Text in Illustration
        *a

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

        (to Inverter with Converter Assembly)

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

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

    3. for RHD:


      1. Disconnect the connector of the air conditioning harness from the inverter with converter assembly.

        A01FRLD

      2. Disconnect the connector of the air conditioning harness from the compressor with motor assembly.

        A01FV15E01
        Text in Illustration
        *1 Green Lock

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

        A01FUUGE12
        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        f1-1 (ACPE) - f1-2 (ACPB) Power switch off 10 kΩ or higher
        Text in Illustration
        *a

        Front view of air conditioning harness connector

        (to Inverter with Converter Assembly)

      4. Connect the air conditioning harness to the compressor with motor assembly.

      5. Connect the air conditioning harness to the inverter with converter assembly.

      Result
      Result Proceed to
      OK A
      NG (for LHD) B
      NG (for RHD) C

    B

    REPLACE NO. 4 FLOOR WIRE Click here

    C

    REPLACE AIR CONDITIONING HARNESS

    A

    REPLACE COMPRESSOR WITH MOTOR ASSEMBLY Click here

  10. 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 vehicle battery shield sub-assembly Click here.

    3. A01FT15

      Disconnect the No. 4 floor wire from the hybrid battery junction block assembly.

    4. A01FUP5E01

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      V4-1 (CEI) - V5-1 (CBI) Power switch off 10 kΩ or higher

    5. Connect the No. 4 floor wire.

    6. Install the No. 4 hybrid vehicle battery shield sub-assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

    REPLACE NO. 4 FLOOR WIRE Click here