DTC P3004-132: 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

   Result	Proceed to
   P3004-132 only is output.	A
   Any of the following DTCs are also output.	B

   DTC No.	Relevant Diagnosis
   P0A1A-151, 155, 156, 658, 659	Generator Control Module
   P0A1B-163, 164, 193, 511, 512, 661, 786, 788	Drive Motor "A" Control Module
   P0A1F (all INF codes) *1	Battery Energy Control Module
   P0A78-266, 267, 523, 586	Drive Motor "A" Inverter Performance
   P0A94-442	DC / DC Converter Performance
   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 Circuit Low
   P0AC2-123	Hybrid Battery Pack Current Sensor Circuit High
   P0ADB-227	Hybrid Battery Positive Contactor Control Circuit Low
   P0ADC-226	Hybrid Battery Positive Contactor Control Circuit High
   P0AE6-225	Hybrid Battery Precharge Contactor Control Circuit Low
   P0AE7-224	Hybrid Battery Precharge Contactor Control Circuit High
   P0AFA-123	Hybrid Battery System Voltage Low
   P3004-800, 801	Power Cable Malfunction
   P3240-443	DC / DC Converter Control Circuit
   U029A-123	Lost Communication with Hybrid Battery Pack Sensor Module

   HINT: 

   • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic flowchart.
   • P3004-132 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

B → See step   20 

A: Go to next step 

1. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
2. 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 50 V or less. Difference between HV battery voltage (Power Resource VB) and post-boost voltage (VH-Voltage after Boosting) is more than 70 V. Difference between pre-boost voltage (VL-Voltage before Boosting) and post-boost voltage (VH-Voltage after Boosting) is more than 70 V.	A
   In addition to the above conditions, HV battery current (Batt Pack Current Val) is 3 A or more.	B
   Other than above	C

C → See step   3 

B → See step   18 

A → See step   26 

1. Check the connections of the hybrid vehicle control ECU connectors.
   Fig 1: Identifying Hybrid Vehicle Control ECU Connectors

   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.
2. 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 information because this may cause a malfunction.

3. Remove the connector cover from the inverter with converter assembly.
   Fig 2: Locating Connector Cover Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the connection between the frame wire and the inverter with converter assembly.
   Fig 3: Locating DC Connector Of Inverter

   Courtesy 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 

1. Check that the service plug grip is not installed.
   Fig 4: Locating Frame Wire Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the connection between the frame wire and the HV battery junction block.

   Specified Condition

   T=9.0 N*m {92 kgf*cm, 80 in.*lbf}

   HINT: 

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

3. Check for arc marks on the terminals of the frame 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

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the frame wire (high voltage DC connector) from the inverter with converter assembly.
   Fig 5: Locating DC Connector Of Inverter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the frame wire from the HV battery junction block.
   Fig 6: Locating Frame Wire Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Measure the resistance according to the value(s) in the table below.
   Fig 7: Identifying Frame Wire HV Battery Junction Block And Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   g2-1 - g1-1 (CBI) (Positive terminal)	Power switch off	Below 1 Ω
   g3-1 - g1-2 (CEI) (Negative terminal)	Power switch off	Below 1 Ω

NG → See step   21 

OK: Go to next step 

1. Disconnect connectors A74 and E55 from the hybrid vehicle control ECU.
2. Disconnect the battery pack wire connector.
   Fig 8: Locating Battery Pack Wire Connector

   Courtesy 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 battery junction block and hybrid vehicle converter connectors, the battery pack wire resistance check should be performed before these connectors are disconnected.
3. Measure the resistance according to the value(s) in the table below.
   Fig 9: Checking Harness And Connector (Hybrid Vehicle Control ECU - Battery Pack Wire Connector)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   E55-5 (SMRB) - zR2-3 (CON2)	Power switch off	Below 1 Ω
   A74-25 (SMRP) - zR2-8 (SMRP)	Power switch off	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Check the connections between the main battery cables and the HV battery junction block.
   Fig 10: Locating High Voltage Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The connectors are connected securely and not damaged.

   HINT: 

   For the removal and installation procedures related to inspection of the main battery cable connection. Refer to REMOVAL .

3. Check for arc marks on the terminals of the main battery cable connectors.

   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

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 11: Identifying Battery Pack Wire Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Measure the voltage according to the value(s) in the table below.

   Standard voltage

   Tester Connection	Switch Condition	Specified Condition
   Main battery cable (+) - Service plug grip 1	Power switch off	120 to 200 V
   Main battery cable (-) - Service plug grip 2	Power switch off	120 to 200 V

   WARNING:

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

NG → See step   22 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the low voltage connector that drives the relay of the HV battery junction block.

   HINT: 

   Before disconnecting the low voltage connector that drives the relay of the HV battery junction block, make sure that the connector is securely engaged.

   Fig 12: Locating Low Voltage Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the resistance according to the value(s) in the table below.
   Fig 13: Checking Harness And Connector (Battery Pack Wire - HV Battery Junction Block)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   zR2-3 (CON2) - z38-3 (CON2)	Power switch off	Below 1 Ω

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 low voltage connector from the hybrid vehicle converter.
   Fig 14: Locating Low Voltage Connector Of Hybrid Vehicle Converter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

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

3. Measure the resistance according to the value(s) in the table below.
   Fig 15: Checking Harness And Connector (Battery Pack Wire Connector - Hybrid Vehicle Converter)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   zR2-8 (SMRP) - z35-4 (SMRP)	Power switch off	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Check the connection between the HV battery terminal block and the HV battery junction block.
   Fig 16: Locating HV Battery Junction Block Connection

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

   T=9.0 N*m {92 kgf*cm, 80 in.*lbf}

   HINT: 

   For the removal and installation procedures related to inspection of the connection of the HV battery terminal block. Refer to REMOVAL .

3. Check for arc marks on the terminals of the HV battery terminal block and HV battery junction block.

   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

C → CONNECT SECURELY 

B → REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA 

A: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 17: Locating HV Battery Junction Block Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the HV battery terminal block from the HV battery pack.
3. Measure the resistance according to the value(s) in the table below.
   Fig 18: Locating HV Battery Terminal Block Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   A - C	Power switch off	Below 1 Ω
   B - D	Power switch off	Below 1 Ω

NG → See step   25 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Remove the HV battery junction block from the vehicle. Refer to REMOVAL .
3. Measure the resistance according to the value(s) in the table below.
   Fig 19: Inspecting HV Battery Junction Block (SMRB)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Condition	Specified Condition
   g2-1 - z30-1	Auxiliary battery voltage is applied between terminals z38-3 (CON2) and z38-2 (GND).	Below 1 Ω

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

   Standard resistance

   Tester Connection	Condition	Specified Condition
   z38-3 (CON2) - z38-2 (GND)	-31 to 176°F (-35 to 80°C)	18.8 to 32.1 Ω

NG → See step   23 

OK: Go to next step 

1. Check for intermittent problems. Refer to CHECK FOR INTERMITTENT PROBLEMS .

NEXT: Go to next step 

1. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
2. Read and record the DTCs and freeze frame data.
3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
4. Clear DTCs and freeze frame data.

NEXT: Go to next step 

1. Turn the power switch on (READY).
2. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
3. 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 DTCs are output.	C

B → See step   19 

A → See step   24 

C → See step   19