СИСТЕМА УПРАВЛЕНИЯ ГИБРИДНОЙ СИСТЕМОЙ, Diagnostic DTC:P3004-132

DTC Code DTC Name
P3004-132 High Voltage Power Resource

DESCRIPTION

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

DTC No. DTC Detection Condition Trouble Area
P3004-132

Although an SMR on request was sent when the power switch is operated, the voltage did not increase after boosting.

High-voltage circuit malfunctions between the HV battery and inverter with converter assembly.

The EV electric battery fuse is blown, the service plug grip is removed, the system main resistor is blown, SMRP or SMRB remains open, or the high-voltage cable has an open circuit.

(1 trip detection logic)

  • Hybrid battery junction block assembly

  • No. 4 floor wire

  • Inverter with converter assembly

  • Power management control ECU

  • Wire harness or connector

  • HV battery

  • Wire harness or connector
Related Data List
DTC No. Data List
P3004-132

  • VH-Voltage after Boosting

  • Power Resource VB

Use the following items as references when performing repairs.


WIRING DIAGRAM

Refer to the wiring diagram for DTC P0AA6-526 Click here.

Refer to the 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 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 who 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.

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


  1. Turn the power switch off and wait for 30 seconds or more.

  2. Turn the power switch 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 power switch on (IG).

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

    4. Check for DTCs.

      Result
      Result Proceed to
      P3004-132 only is output, or DTCs except the ones in the tables below are also output. A
      Any of the following DTCs including pending DTCs in table 1 below are also output. B
      Any of the DTCs in Table 2 below are also output. 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 Low
      P0ADF-229 Hybrid Battery Positive Contactor Control Circuit High
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE6-225 Hybrid Battery Negative Contactor Control Circuit High
      P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High
      P0C76-523 Hybrid Battery Precharge Contactor Control Circuit Low
      P2511-149 ECM/PCM Power Relay Sensor Circuit Intermittent
      P3004-131, 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 "A" Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor "A" 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
      D0B8D-123 Hybrid Battery Voltage Sensor "Q" 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.

      • P3004-132 may be stored due to a malfunction which causes the DTCs in the preceding tables to be stored. In this case, first troubleshoot the output DTCs in the preceding tables. 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 P3004-132.

      Result
      Result Proceed to

      All of the following conditions are met:


      • Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VL-Voltage before Boosting) is 33 V or less.

      • Difference between HV battery voltage (Power Resource VB) and post-boost voltage (VH-Voltage after Boosting) is more than 30 V.

      • Difference between pre-boost voltage (VL-Voltage before Boosting) and post-boost voltage (VH-Voltage after Boosting) is more than 42 V.

      		 A
      In addition to the above conditions, HV battery current (Batt Pack Current Val) is 3 A or more. B
      Except above C

    5. Turn the power switch off.


    B

    GO TO DTC CHART (P3004-800) Click here

    C

    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. A01FU0R

      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. A01FVXAE01
      Text in Illustration
      *A for LHD
      *B for RHD

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

    3. A01FPZ5E01
      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. Reconnect 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 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. A01FVUL

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

    3. A01FVUL

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

    4. A01FVXAE01
      Text in Illustration
      *A for LHD
      *B for RHD

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

    5. A01FPZ5E01
      Text in Illustration
      *A for LHD
      *B for RHD

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

    6. A01FQE6E02
      Text in Illustration
      *1 Shield Ground
      *2 Red Mark
      *a

      No. 4 Floor Wire

      (Inverter with Converter Assembly Side)
      *b

      No. 4 Floor Wire

      (Hybrid Battery Junction Block Assembly Side)

      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

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

    8. Reconnect the No. 4 floor wire to the hybrid battery junction block assembly.

    9. Install the connector cover assembly.

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


    NG

    REPLACE NO. 4 FLOOR WIRE Click here

    OK

  8. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (HV BATTERY HIGH VOLTAGE TERMINAL 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 hybrid battery junction block assembly Click here.

    3. A01FS16E48
      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


    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. A01FUWME01
      Text in Illustration
      *a

      Component with harness connected

      (Hybrid Battery Junction Block Assembly)
      *b Service Plug Grip Disconnected (Service Plug Grip Connecting Terminals)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      y2-1 (+) - Service plug terminal 1 Power switch off 102 V or higher
      w2-1 (-) - Service plug terminal 2 Power switch off 90 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 mT1 No. 2 hybrid battery pack wire connector.

    4. Disconnect the N91 power management control ECU connector.

    5. A01FVC5E04
      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
      mT1-4 (SMRB) - N91-4 (SMRB) Power switch off Below 1 Ω
      mT1-2 (SMRP) - N91-3 (SMRP) Power switch off Below 1 Ω

    6. Reconnect the N91 power management control ECU connector.

    7. Reconnect the mT1 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 mT1 No. 2 hybrid battery pack wire connector.

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

    5. Disconnect the m3 hybrid battery junction block assembly connector.

    6. A01FRLBE04
      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
      mT1-4 (SMRB) - m3-4 (SMRB) Power switch off Below 1 Ω
      mT1-2 (SMRP) - m3-3 (SMRP) Power switch off Below 1 Ω

    7. Reconnect the m3 hybrid battery junction block assembly connector.

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

    9. Reconnect the mT1 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. A01FS16E48
      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. A01FS16E49
      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) - w2-1 (-) 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

    Click here


    NEXT

  15. CLEAR DTC


    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 and record the DTCs and freeze frame data.

    5. Clear the DTCs and freeze frame data.

    6. Turn the power switch off.


    NEXT

  16. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (READY).

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

    4. Check for DTCs.

      Result
      Result Proceed to
      No DTCs are output. A
      DTC P3004-131 is output. B
      DTC P3004-132 is output. C

      Tech Tips

      Because P3004-131 uses 2-trip detection logic, the DTC detection conditions need to be met 2 times.

    5. Turn the power switch off.


    B

    GO TO DTC CHART (P3004-131) Click here

    C

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here