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Home >> Lexus >> 2009 >> GS 450h >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Vehicle Control (Diagnostic Codes (P0AE6-225 - U0424-537)) >> Hybrid Control System >> DTC P3004-132: Power Cable Malfunction >> Procedure

DTC P3004-132: Power Cable Malfunction: Procedure

  1. CHECK DTC OUTPUT 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      DTC No. Related Part
      P0A95 Electric vehicle fuse circuit
      P0AE7-224, P0AE6-225 SMRP control line circuit
      P0ADC-226, P0ADB-227 SMRB control line circuit
      P0A1F, P3105, P0AFA Battery smart unit circuit, VB sensor circuit
      P0ABF, P0AC0, P0AC1, P0AC2 IB sensor circuit
      P3004-131, 800, 801 High-voltage power source line circuit
      P0A1A-156, 658, 151, 155, 659, P0A1B-511, 164, 163, 512, 193, 786, 788, 659, 661
      P0A78-266, 267, 523, 586, P0A94-442      		 VH sensor circuit

    YES → GO TO DTC CHART 

    NO: Go to next step 

  2. CHECK FREEZE FRAME DATA 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    4. Read output DTCs.
    5. Read the freeze frame data for DTC P3004-132.

      Result

      Result Proceed to
      Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VL-Voltage before Boosting) is 60 V or less, difference between HV battery voltage (Power Resource VB) and post-boost voltage (VH-Voltage after Boosting) is more than 80 V, and difference between pre-boost voltage (VL-Voltage before Boosting) and post-boost voltage (VH-Voltage after Boosting) is more than 100 V. A
      HV battery current (IB) is 3 A or more. B
      Other than above C

    B → GO TO INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P3004-800) 

    A → See step   14 

    C: Go to next step 

  3. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) 
    1. Check the connections of the hybrid vehicle control ECU connectors.
      Fig 1: Checking Connector Connection Condition (HV Control ECU Connector)
      GTY146608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  4. CHECK CONDITION OF FRAME WIRE CONNECTION(S) (INVERTER WITH CONVERTER ASSEMBLY SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Turn the power switch off and remove the service plug grip. Refer to PRECAUTION .
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Remove the connector cover assembly from the inverter with converter assembly. Refer to COMPONENTS .
      Fig 2: Locating Connector Cover Assembly
      GTY146942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the connection between the frame wire and the inverter with converter assembly.
      Fig 3: Identifying Frame Wire & Inverter
      GTY134578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  5. CHECK CONDITION OF FRAME WIRE CONNECTION(S) (HV RELAY ASSEMBLY SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      Fig 4: Locating Frame Wire Connection
      GTY140932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the connection between the frame wire and the HV relay assembly.

      HINT: 

      For the removal and installation procedures related to inspection of the frame wire connection. Refer to COMPONENTS .

      Torque: 9.0 N*m (92 kgf*cm, 81 in.*lbf) 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  6. CHECK FRAME WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Disconnect the frame wire from the inverter with converter assembly. Refer to COMPONENTS .
      Fig 5: Identifying Frame Wire & Inverter
      GTY134578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the frame wire from the HV relay assembly. Refer to COMPONENTS .
      Fig 6: Disconnecting Frame Wire From HV Relay Assembly
      GTY146866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      Fig 7: Identifying Red Mark On Frame Wire Frame Wire
      GTY145565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      w1-1 - w4-1 Below 1 Ω
      w1-2 - w5-1 Below 1 Ω

    NG → REPLACE FRAME WIRE 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Disconnect connector A54 from the hybrid vehicle control ECU.
    3. Disconnect the battery pack wire connector. Refer to COMPONENTS .
      Fig 8: Locating Battery Pack Wire Connector
      GTY146871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • Before disconnecting the battery pack wire connector, make sure that the connector is securely engaged.
      • Due to the time required to disconnect the HV relay assembly and hybrid vehicle converter connectors, the battery pack wire resistance check should be performed before these connectors are disconnected.
    4. Measure the resistance according to the value(s) in the table below.
      Fig 9: Identifying A54 And VN1 Connectors Terminals
      GTY145560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      SMRP (VN1-8) - SMRP (A54-123) Below 1 Ω
      CON2 (VN1-3) - SMRB (A54-41) Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  8. CHECK CONDITION OF MAIN BATTERY CABLE CONNECTION(S) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      Fig 10: Identifying Main Battery Cable & Connectors
      GTY138539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the main battery cable and the connectors for damage, poor connections or other contact problems.

      Result

      Result Proceed to
      The connectors are connected securely and there are no contact problems. A
      The connectors are not connected securely. B
      HV relay assembly connector is damaged. C
      Main battery cable is damaged. D

      HINT: 

      The main battery cable and HV battery are supplied as one unit.

    D → See step   15 

    C → See step   16 

    B → CONNECT SECURELY 

    A: Go to next step 

  9. CHECK HV BATTERY ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      Fig 11: Identifying Z23 & Z25 Connectors
      GTY132567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below.

      Standard voltage

      Terminal Specified Condition
      z23-1 - Service plug grip terminal A 114 to 119 V
      z25-1 - Service plug grip terminal B 126 to 210 V
      WARNING:

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

    NG → See step   15 

    OK: Go to next step 

  10. CHECK HARNESS AND CONNECTOR (HV RELAY ASSEMBLY - BATTERY PACK WIRE CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Disconnect connector N6 from the HV relay assembly. Refer to COMPONENTS .
      Fig 12: Identifying N6 Connector
      GTY141366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Before disconnecting the HV relay connector, make sure that the connector is securely engaged.

    3. Measure the resistance according to the value(s) in the table below.
      Fig 13: Identifying Battery Pack Wire Connector N6
      GTY133209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      CON2 (VN1-3) - SMRB (N6-3) Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      Fig 14: Identifying Hybrid Vehicle Converter & N1 Connector
      GTY126759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Before disconnecting the hybrid vehicle converter connector, make sure that the connector is securely engaged.

    2. Measure the resistance according to the value(s) in the table below.
      Fig 15: Identifying VN1 & N1 Connectors
      GTY124688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      SMRP (VN1-8) - SMRP (N1-4) Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  12. INSPECT HV RELAY ASSEMBLY (SMRB) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Remove the HV relay assembly from the vehicle. Refer to COMPONENTS .
    3. Measure the resistance according to the value(s) in the table below.
      Fig 16: Identifying W4, Z23 & N6 Connectors
      GTY125989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      w4-1 - z23-1 Below 1 Ω
      (When battery voltage is applied between terminals N6-2 and N6-3)
    4. Measure the resistance according to the value(s) in the table below.

      Standard resistance

      Tester Connection Specified Condition
      SMRB (N6-3) - GND (N6-2) 18.8 to 32.1 Ω at -35 to 80°C (-31 to 176°F)

    NG → See step   16 

    OK: Go to next step 

  13. CHECK FOR INTERMITTENT PROBLEMS 
    1. Connect the Techstream to the DLC3.
    2. Check for intermittent problems. Refer to CHECK FOR INTERMITTENT PROBLEMS .
    3. Clear the DTCs.
    4. Turn the power switch on (READY).
    5. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    6. Check if DTCs are output.

      Result

      Result Proceed to
      DTC P3004-131 is output (SMRP may remain off). A
      DTC P3004-132 is output. B
      No DTC is output. C

    B → See step   17 

    A → GO TO INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P3004-131) 

    C → See step   17 

  14. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  COMPONENTS 
  15. REPLACE HV BATTERY ASSEMBLY. Refer to  COMPONENTS 
  16. REPLACE HV RELAY ASSEMBLY. Refer to  COMPONENTS 
  17. REPLACE HYBRID VEHICLE CONVERTER. Refer to  COMPONENTS 
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