HYBRID CONTROL SYSTEM, Diagnostic DTC:P3004-131

DTC Code DTC Name
P3004-131 High Voltage Power Resource

DESCRIPTION

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

The power management control ECU monitors the high-voltage wiring between the HV battery and the inverter with converter assembly and detects the following malfunction.

DTC No. INF Code DTC Detection Condition Trouble Area
P3004 131

One of the following occurs during pre-charge (the time from when SMRP turns on until SMRG turns on):


  • EV battery fuse in the service plug grip has an open circuit

  • Service plug grip is not installed

  • SMRP remains open

  • SMRB remains open

  • Precharge resistor has an open circuit

  • High voltage cable has an open circuit

  • Hybrid battery junction block assembly

  • No. 4 floor wire

  • Inverter with converter assembly

  • HV battery

  • Wire harness or connector

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.

  • When disposing of an HV battery, make sure to return it through an authorized collection agent that is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

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
      P3004-131 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
      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
      P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low
      P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P2511-149 HV CPU Power Relay Sense Circuit Intermittent No Continuity
      P3004-800, 801 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"
      Table 2
      DTC No. Relevant Diagnosis
      P0A95-123 High Voltage Fuse
      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
      P0B94-123 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


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • P3004-131 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 FREEZE FRAME DATA (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. Read the freeze frame data of DTC P3004-131.

      Result
      Result Proceed to

      Both of the following conditions are met:


      • Post-boost voltage (VH-Voltage after Boosting) is below 50 V.

      • Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VL-Voltage before Boosting) is 40 V or less.

      		 A
      Other than above B

    5. Turn the power switch off.


    B

    Click here

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  3. 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

  4. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HYBRID BATTERY PACK WIRE 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. Remove the front luggage compartment trim cover Click here.

    3. A01FQ7K

      Check the connector connections and contact pressure of the relevant terminals for the No. 2 hybrid battery pack wire connector Click here.

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

    4. Install the front luggage compartment trim cover.


    NG

    CONNECT SECURELY

    OK

  5. CHECK INVERTER WITH CONVERTER ASSEMBLY (NO. 4 FLOOR WIRE CONNECTOR CONNECTION CONDITION)

    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

      Check the connector connection condition between the No. 4 floor wire and the inverter with converter assembly.

      Specified Condition
      8.0 N*m (82 kgf*cm, 71 in.*lbf)

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

    5. Check for arc marks on the terminals of the No. 4 floor wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the No. 4 floor wire to the inverter with converter assembly.

    7. Install the connector cover assembly to the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  6. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (NO. 4 FLOOR WIRE CONNECTOR CONNECTION CONDITION)

    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

      Check that the nuts for the No. 4 floor wire are tightened to the specified torque, the No. 4 floor wire is connected securely, and there are no contact problems.

      Specified Condition
      9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Check for arc marks on the terminals of the No. 4 floor wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

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


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  7. CHECK NO. 4 FLOOR WIRE (INVERTER WITH CONVERTER ASSEMBLY - 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. 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. A01FU0XE01
      Text in Illustration
      *a

      Front view of No. 4 floor wire connector

      (to Inverter with Converter Assembly)
      *b

      Component with harness connected

      (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
      V2-1 (CBI) - V5-1 (CBI) Power switch off Below 1 Ω
      V2-2 (CEI) - V4-1 (CEI) Power switch off Below 1 Ω

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

    7. Connect the No. 4 floor wire to the inverter with converter assembly.

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


    NG

    REPLACE NO. 4 FLOOR WIRE Click here

    OK

  8. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (HV BATTERY HIGH VOLTAGE TERMINAL CONNECTOR CONNECTION CONDITION)

    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 upper hybrid battery cover sub-assembly Click here.

    3. A01FVW1

      Check the connection condition between the HV battery high voltage terminal connector and the hybrid battery junction block assembly Click here.

    4. Disconnect the HV battery high voltage terminal connectors.

    5. Check for arc marks on the terminals of the HV battery high voltage terminal connectors.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the HV battery high voltage terminal connectors.

    7. Install the upper hybrid battery cover sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  9. CHECK HV BATTERY

    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 upper hybrid battery cover sub-assembly Click here.

    3. A01FRQ3E01
      Text in Illustration
      *a

      Component with harness connected

      (Hybrid Battery Junction Block Assembly)
      *b Service Plug Grip Terminal

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      y2-1 (+) - Service plug grip terminal 2 Power switch off 204 V or higher
      x1-1 (-) - Service plug grip terminal 1 Power switch off 36 V or higher

      CAUTION:

      Do not allow the probes of the electrical tester to contact each other during this inspection.

    4. Install the upper hybrid battery cover sub-assembly.


    NG

    REPLACE HV BATTERY Click here

    OK

  10. CHECK HARNESS AND CONNECTOR (NO. 2 HYBRID BATTERY PACK WIRE CONNECTOR - POWER MANAGEMENT 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the front luggage compartment trim cover Click here.

    3. Disconnect the No. 2 hybrid battery pack wire connector.

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

    5. A01FS7CE04
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to No. 2 Hybrid Battery Pack Wire Connector)
      *b

      Rear view of wire harness connector

      (to Power Management Control ECU)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      Tm1-5 (SMRB) - N91-4 (SMRB) Power switch off Below 1 Ω
      Tm1-7 (SMRP) - N91-3 (SMRP) Power switch off Below 1 Ω

    6. Connect the power management control ECU connector.

    7. Connect the No. 2 hybrid battery pack wire connector.

    8. Install the front luggage compartment trim cover.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  11. CHECK HARNESS AND CONNECTOR (NO. 2 HYBRID BATTERY PACK WIRE CONNECTOR - 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 front luggage compartment trim cover Click here.

    3. Disconnect the No. 2 hybrid battery pack wire connector.

    4. Remove the upper hybrid battery cover sub-assembly Click here.

    5. Disconnect the connector 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.

    6. A01FTD4E04
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to No. 2 Hybrid Battery Pack Wire Connector)
      *b

      Rear view of wire harness connector

      (to 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
      Tm1-5 (SMRB) - m3-4 (SMRB) Power switch off Below 1 Ω
      Tm1-7 (SMRP) - m3-3 (SMRP) Power switch off Below 1 Ω

    7. Connect the hybrid battery junction block assembly connector.

    8. Install the upper hybrid battery cover sub-assembly.

    9. Connect the No. 2 hybrid battery pack wire connector.

    10. Install the front luggage compartment trim cover.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  12. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    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 hybrid battery junction block assembly Click here.

    3. A01FS16E46
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      V5-1 (CBI) - y2-1 (+) Auxiliary battery voltage is applied between terminals m3-4 (SMRB) and m3-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      m3-4 (SMRB) - m3-2 (GND) -40 to 80°C (-40 to 176°F) 18.4 to 36.3 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  13. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP)

    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 hybrid battery junction block assembly Click here.

    3. A01FS16E47
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      V4-1 (CEI) - x1-1 (-) Auxiliary battery voltage is applied between terminals m3-3 (SMRP) and m3-2 (GND) 28.5 to 31.5 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      m3-3 (SMRP) - m3-2 (GND) -40 to 80°C (-40 to 176°F) 112 to 274 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  14. CHECK FOR INTERMITTENT PROBLEMS


    1. Check for intermittent problems Click here.

      Tech Tips


      • Since 2 trip detection logic is used, the DTC detection condition must be met twice.

      • If DTC P3004-131 is output again after performing the inspection, replace the hybrid vehicle converter. If DTC P3004-131 is not output again, replace the hybrid battery junction block assembly.


    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here