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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 P3004-800 Power Cable Malfunction; DTC P3004-801 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 AND EMPS) 
    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 and EMPS / DTC INFO / CURRENT CODES.

      Standard: 

      DTC is output. 

    YES: GO TO  DTC CHART 

    NO: Go to next step 

  2. CHECK WIRE HARNESS AND CONNECTOR (HV CONTROL ECU - MG ECU) 
    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. Disconnect the H34 connector from the HV control ECU.
    3. 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.
    4. Disconnect the I21 connector from the MG ECU.
    5. Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

      HINT:

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

      Fig 1: Disconnecting H34 Connector From HV Control ECU
      G05278792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      NODD (H34-11) - Body ground Below 1 V
    6. Turn the ignition switch off.
    7. Measure the resistance according to the value(s) in the table below.

      Standard Resistance (Check for open) 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      NODD (H34-11) - NODD (I21-33) Below 1 Ω

      Standard Resistance (Check for short) 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      NODD (H34-11) or NODD (I21-33) - Body ground 10 kΩ or higher

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  3. CHECK W/ MOTOR COMPRESSOR ASSEMBLY 
    CAUTION: Be sure to wear insulated gloves.
    1. Disconnect the engine wire No.4 from the air conditioner wiring harness.
      Fig 2: Disconnecting Engine Wire No 4 From Air Conditioner Wiring Harness
      G05278793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      1(+) - 2(-) 100 Ω or higher
      NOTE: Connect the tester correctly.

    NG: GO TO step   5 

    Fig 3: Identifying Engine Wire Connector
    G05278794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  4. CHECK ENGINE WIRE NO.4 
    CAUTION: Be sure to wear insulated gloves.
    1. Disconnect the engine wire No.4 from the w/ motor compressor assembly.
      Fig 4: Disconnecting Engine Wire No 4 From W/ Motor Compressor Assembly
      G05201584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      1 - 2 10 kΩ or higher

    NG: REPLACE ENGINE WIRE NO.4 

    Fig 5: Identifying Engine Wire No 4 Connector
    G05201675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE W/ MOTOR COMPRESSOR ASSEMBLY 

  5. CHECK FRAME WIRE NO.3 
    CAUTION: Be sure to wear insulated gloves.
    1. Disconnect the frame wire No.3 (DC cable for the HV battery) from the w/ converter inverter assembly.
      Fig 6: Identifying Frame Wire No 3
      G05201676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      1(+) - 2(-) 100 Ω or higher
      NOTE: Connect the tester correctly.

      OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY 

      Fig 7: Identifying Frame Wire No 3 Connector
      G05201677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: Go to next step 

  6. CHECK FRAME WIRE NO.3 (W/ CONVERTER INVERTER - HV RELAY ASSEMBLY) 
    CAUTION: Be sure to wear insulated gloves.
    1. Disconnect the frame wire No.3 (DC cable for the w/ converter inverter assembly) from the HV relay assembly.
      Fig 8: Locating Frame Wire No.3
      G05201667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 - S44-1 10 kΩ or higher

    NG: REPLACE FRAME WIRE NO.3 

    Fig 9: Identifying HV Relay S45 And S44 Connector Terminal
    G05278717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  7. CHECK HV RELAY ASSEMBLY 
    CAUTION: Be sure to wear insulated gloves.
    1. Disconnect the frame wire No.3 (connector for the power steering converter assembly) from the HV relay assembly.
      Fig 10: Disconnecting Frame Wire No.3 Connector For Power Steering Converter Assembly
      G05278801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 - S44-1 10 kΩ or higher

    NG: REPLACE HV RELAY ASSEMBLY 

    Fig 11: Identifying HV Relay S45 And S44 Connector Terminal
    G05278719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  8. CHECK FRAME WIRE NO.3 (HV RELAY ASSEMBLY - POWER STEERING CONVERTER) 
    CAUTION: Be sure to wear insulated gloves.
    1. Disconnect the frame wire No. 3 (connector for the HV battery) from the power steering converter assembly.
      Fig 12: Disconnecting Frame Wire No.3 (Connector For HV Battery) From Power Steering Converter Assembly
      G05278803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      1 - 5 10 kΩ or higher

    NG: REPLACE FRAME WIRE NO.3 

    Fig 13: Identifying Power Steering Converter Assembly Connector Terminal
    G05278804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE POWER STEERING CONVERTER ASSEMBLY 

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