DTC P3004-800: Power Cable Malfunction; DTC P3004-801: Power Cable Malfunction: Procedure

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
   P0A09-265, P0A10-263	Hybrid vehicle converter circuit
   P0AFA, P0A1F, P3105	VB sensor circuit, battery smart unit circuit
   P0ABF, P0AC0, P0AC1, P0AC2	IB sensor circuit

YES → GO TO DTC CHART 

NO: Go to next step 

1. Check the connections of the hybrid vehicle control ECU connectors.
   Fig 1: Checking Connector Connection Condition (HV Control ECU Connector)

   Courtesy 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 

1. Turn the power switch off and remove the service plug grip. Refer to PRECAUTION
   Fig 2: Identifying Service Plug Grip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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. Disconnect the air conditioning harness from the inverter with converter assembly.
3. Measure the resistance according to the value(s) in the table below.
   Fig 3: Identifying Air Conditioning Harness Assembly Connector W9

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   w9-1 - w9-2	100 kΩ or more

   NOTE:

   • Make sure that the tester probes are connected to the correct terminals.
   • Do not use a megohmmeter.
   • Read the resistance after the value has stabilized.

OK → See step   5 

NG: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 4: Identifying Air Conditioning Harness Assembly And Compressor With Motor Assembly Lock

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the air conditioning harness from the with motor compressor assembly. Refer to COMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 5: Identifying Air Conditioning Harness Assembly Connector Terminal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   w9-1 - w9-2	10 kΩ or more

NG → REPLACE AIR CONDITIONING HARNESS ASSEMBLY 

OK → See step   14 

1. Check that the service plug grip is not installed.
2. Remove the connector cover assembly from the inverter with converter assembly. Refer to COMPONENTS .
   Fig 6: Identifying Connector Cover Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the frame wire from the inverter with converter assembly. Refer to COMPONENTS .
   Fig 7: Locating Connections Of High Voltage Connectors Of Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disconnect the frame wire from the HV relay assembly. Refer to COMPONENTS .
   Fig 8: Disconnecting Frame Wire From HV Relay Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Measure the resistance according to the value(s) in the table below.
   Fig 9: Identifying Red Mark On Frame Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   w4-1 - w5-1	10 kΩ or more

NG → REPLACE FRAME WIRE 

OK: Go to next step 

1. Turn the power switch off.
   Fig 10: Locating Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the battery pack wire connector. Refer to COMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 11: Checking Harness And Connector (VN1 Battery Pack Wire)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   NODD (VN1-6) - Body ground	120 to 140 kΩ

NG → See step   10 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 12: Identifying Hybrid Vehicle Converter & N1 Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect connector N1 from the hybrid vehicle converter. Refer to COMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 13: Identifying N1 Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance (Check for open)

   Tester Connection	Specified Condition
   NODD (VN1-6) - NODD (N1-2)	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Specified Condition
   NODD (VN1-6) or NODD (N1-2) - Body ground	10 kΩ or more

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the 3 high voltage connectors of the hybrid vehicle converter from the HV relay assembly.
   Fig 14: Identifying Hybrid Vehicle Converter & High Voltage Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the resistance according to the value(s) in the table below.
   Fig 15: Identifying Hybrid Vehicle Converter, Z10, Z11 & Z12 Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   z11-1 - z10-1	500 kΩ or more
   z11-1 - z12-1	10 MΩ or more

   NOTE:

   • Do not use a megohmmeter.
   • Make sure that the tester probes are connected to the correct terminals.
   • Read the resistance after the value has stabilized.

NG → See step   12 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 16: Identifying HV Relay Assembly & High Voltage Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the high voltage connectors from the HV relay assembly.
3. Measure the resistance according to the value(s) in the table below.
   Fig 17: Locating HV Relay Assembly Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   w5-1 - w4-1	10 kΩ or more

NG → See step   11 

OK → See step   13 

1. Disconnect connector A54 from the hybrid vehicle control ECU.
   Fig 18: Checking Harness And Connectors A54 HV Control ECU & VN1 Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the power switch off.
3. Measure the resistance according to the value(s) in the table below.

   Standard resistance (Check for open)

   Tester Connection	Specified Condition
   NODD (A54-55) - NODD (VN1-6)	Below 1 Ω

   Standard resistance (Check for short)

   Tester Connection	Specified Condition
   NODD (A54-55) or NODD (VN1-6) - Body ground	10 kΩ or more

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   15