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Home >> Lexus >> 2007 >> RX 400h AWD >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Vehicle Control (P310) - RX400H - DTC P0AA1-231 Through U0424-537 >> DTC P3004-131 Power Cable Malfunction; DTC P3004-132 Power Cable Malfunction >> Inspection Procedure

Inspection Procedure

CAUTION:
  • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are working on the high-voltage system.
  • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:

At least 5 minutes is required to discharge the high-voltage capacitor inside the w/ converter inverter assembly.

  1. READ OUTPUT DTC (HV) 
    1. Connect the intelligent tester to the DLC3.
    2. Turn the ignition switch to the ON position.
    3. Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES.
    4. Read output DTC. (See DTC CHECK / CLEAR )

      Result: 

      DTC P0A95, P0AE6-225, P0AE7-224, P0AE0-228 or P0ADF-229 is output 

    YES: GO TO  DTC CHART 

    NO: Go to next step 

  2. INSPECT HV RELAY ASSEMBLY (SMR1 AND SYSTEM MAIN RELAY) 
    CAUTION: Be sure to wear insulated gloves.
    1. Turn the ignition switch off and remove the service plug grip. (See HYBRID CONTROL SYSTEM )
      NOTE: Do not put the vehicle into the READY-on state with the service plug grip removed as this may cause a malfunction.
    2. Remove the HV relay assembly from the vehicle. (See REMOVAL )
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      S47-1 - S44-1 28.5 to 31.5 Ω (when apply battery voltage between terminals CON1 (S48-3) and GND (S48-4))
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      CON1 (S48-3) - GND (S48-4) 20 to 60 Ω -35 to 80°C (-22 to 176°F)

    NG: REPLACE HV RELAY ASSEMBLY 

    Fig 1: Inspecting HV Relay Assembly (SMR1 And System Main Relay)
    G05278781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  3. INSPECT HV RELAY ASSEMBLY (SMR3) 
    CAUTION: Be sure to wear insulated gloves.
    1. Turn the ignition switch off and remove the service plug grip. (See HYBRID CONTROL SYSTEM )
      NOTE: Do not put the vehicle into the READY-on state with the service plug grip removed as this may cause a malfunction.
    2. Remove the HV relay assembly from the vehicle. (See REMOVAL )
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      S45-1 - S49-1 Below 1 Ω (when apply battery voltage between terminals CON3 (S48-2) and GND (S48-4))
    4. Measure the resistance according to the value(s) in the table below.
      Fig 2: Inspecting HV Relay Assembly (SMR3)
      G05278782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      CON3 (S48-2) - GND (S48-4) 20 to 60 Ω -35 to 80°C (-22 to 176°F)

    NG: REPLACE HV RELAY ASSEMBLY 

    OK: Go to next step 

  4. INSPECT MAIN BATTERY CABLE NO.2 (-) 
    CAUTION: Be sure to wear insulated gloves and protective goggles.
    1. Measure the resistance according to the value(s) in the table below.
      Fig 3: Identifying HV Relay Assembly, Main Battery Cable No 2 And HV Battery RH
      G05201662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      A - B Below 1 Ω

      HINT:

      Check the connections with the main battery cable No.2 (negative side) connected.

    NG: REPLACE MAIN BATTERY CABLE NO.2 

    OK: Go to next step 

  5. INSPECT MAIN BATTERY CABLE NO.2 (-), HV RELAY ASSEMBLY AND HV BATTERY 
    CAUTION: Be sure to wear insulated gloves and protective goggles.

    HINT:

    Check the connections with the main battery cable No.2 (negative side) connected.

    1. Check that the nut that tightens the main battery cable No.2 (negative side) is properly engaged with the connector on the HV battery terminal (RH side).
      Fig 4: HV Relay Assembly, Main Battery Cable No 2 And HV Battery RH With Torque Specifications
      G05201663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK: There is no poor connection. 

      NOTE:
      • The nut that tightens the main battery cable No.2 is not reusable.
      • Do not overtighten this nut.
    2. Check if the main battery cable No.2 (negative side) is properly engaged with the connector on the HV relay assembly side.

      OK: Connector is connected securely and there is no poor connection. 

    NG: REPLACE MAIN BATTERY CABLE NO.2, HV RELAY ASSEMBLY OR HV BATTERY 

    OK: Go to next step 

  6. INSPECT HV BATTERY 
    CAUTION: Be sure to wear insulated gloves and protective goggles.
    1. Measure the voltage according to the value(s) in the table below.
      Fig 5: Identifying HV Relay Assembly, HV Battery RH And HV Battery CTR
      G05201664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      A (+) - B (-) 40 to 80 V
      NOTE: Connect the tester correctly.

    NG: REPLACE HV BATTERY 

    OK: Go to next step 

  7. INSPECT HV BATTERY AND HV RELAY ASSEMBLY 
    CAUTION: Be sure to wear insulated gloves and protective goggles.

    HINT:

    Check the connections with the HV battery CTR cable.

    1. Check if the cable on the HV relay assembly side connector in the HV battery CTR is properly engaged.
      Fig 6: HV Relay Assembly, HV Battery RH And HV Battery CTR With Torque Specifications
      G05201665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK: Connector is connected securely and there is no poor connection. 

    2. Check that the nut that tightens the HV battery CTR cable on the HV battery LH side is not loose.

      OK: There is no poor connection. 

      NOTE:
      • The nut that tightens the main battery cable No.2 is not reusable.
      • Do not overtighten this nut.

    NG: REPLACE HV BATTERY OR HV RELAY ASSEMBLY 

    OK: Go to next step 

  8. INSPECT FRAME WIRE NO.3 
    CAUTION: Be sure to wear insulated gloves and protective goggles.
    1. Check that the service plug grip is removed.
    2. Remove the inverter cover. (See INVERTER WITH CONVERTER )
      NOTE: Wrap the interlock round terminal for the inverter cover with vinyl tape to prevent it from shorting to ground. Be sure to prevent water in the reservoir tank from entering the inverter.
    3. Disconnect the frame wire No.3 (DC cable for the HV battery) from the w/ converter inverter assembly.
      Fig 7: Identifying DC Cable For HV Battery From W/ Converter Inverter Assembly
      G05201612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the frame wire No.3 (DC cable for the w/ converter inverter assembly) from the HV relay assembly.
      Fig 8: Identifying Frame Wire No.3 From HV Relay Assembly
      G05201667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      I21-3 - S44-1 Below 1 Ω
      I21-1 - S45-1 Below 1 Ω

    NG: REPLACE NO.3 WIRE FRAME 

    Fig 9: Identifying I21 Frame Wire Connector Terminal
    G05278789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  9. INSPECT W/ CONVERTER INVERTER ASSEMBLY (VH VOLTAGE) 
    CAUTION: Be sure to wear insulated gloves.
    1. Turn the ignition switch to the ON position.

      HINT:

      Turning the ignition switch to the ON position with the service grip and inverter cover removed causes interlock switch system DTC (P0A0D-350) to be output.

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

      Standard Voltage 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      VH (B-31) - GINV (B-17) 0.3 to 0.7 V

    NG: REPLACE W/ CONVERTER INVERTER ASSEMBLY 

    Fig 10: Identifying MG ECU Connectors
    G05201669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  10. CHECK CONNECTION CONDITION OF HV CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) 
    1. Check the connections of all HV control ECU connectors.

      OK: Connectors are connected securely and there is no poor connection. 

    NG: CONNECT SECURELY 

    Fig 11: Identifying HV Control ECU Connector
    G05201226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  11. CHECK HARNESS AND CONNECTOR (HV CONTROL ECU - HV RELAY ASSEMBLY) 
    CAUTION: Be sure to wear insulated gloves and protective goggles.
    1. Check that the service plug grip is removed.
    2. Disconnect the H30 connector from the HV control ECU.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      CON1 (H30-3) - COM (S48-3) Below 1 Ω
      CON3 (H30-1) - CON3 (S48-2) Below 1 Ω

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  12. CHECK FOR INTERMITTENT PROBLEMS 

    HINT:

    After the check, if DTCs P3004-131 and 132 are output again, replace the HV control ECU. If they are not output, replace the HV relay assembly.

    NG: REPLACE HV CONTROL ECU 

    OK: REPLACE HV RELAY ASSEMBLY 

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