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

CHECK DTC OUTPUT (HV)

Connect the Techstream to the DLC3.
Turn the power switch on (IG).
Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

Check if DTCs are output.

Result

Result	Proceed to
P3004-800 or P3004-801 only is output.	A
Any of the following DTCs are also output.	B

DTC No.	Relevant Diagnosis
P0A09-265	DC / DC Converter Status Circuit Low Input
P0A10-263	DC / DC Converter Status Circuit High Input
P0A1F (all INF codes) *1	Battery Energy Control Module
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
P0AFA-123	Hybrid Battery System Voltage Low
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.

P3004-800 or 801 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 13

A: Go to next step

CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)
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

CHECK WITH MOTOR COMPRESSOR ASSEMBLY

WARNING:

Be sure to wear insulated gloves.

Turn the power switch off.
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.
Disconnect the air conditioning harness assembly from the inverter with converter assembly.

Fig 2: Locating Air Conditioning Harness Assembly Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 3: Identifying j1 Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection (Tester Probe Polarity)	Switch Condition	Specified Condition
j1-1 (Negative prove) - j1-2 (Positive prove)	Power switch off	100 kΩ or higher

NOTE:

Do not use a megohmmeter.
Read the resistance after the value has stabilized.

HINT:

The polarities of the tester probes may differ depending on the tester. Use the current output probe of the tester as the positive probe for this measurement. To determine the polarity, use another voltmeter to confirm the current output probe of the tester. When measuring the output of the tester, the voltmeter positive probe indicates the tester current output probe.

NG → See step 12

OK: Go to next step

CHECK FRAME WIRE

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.
Remove the connector cover from the inverter with converter assembly.

Fig 4: Locating Connector Cover Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
Disconnect the frame wire from the HV battery junction block.

Fig 6: Locating Frame Wire Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 7: Identifying Frame Wire HV Battery Junction Block

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection	Switch Condition	Specified Condition
g2-1 - g3-1	Power switch off	10 kΩ or higher

NG → See step 14

OK: Go to next step

CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE HYBRID VEHICLE CONTROL ECU)

Turn the power switch off.
Disconnect the battery pack wire connector. Refer to REMOVAL .

Fig 8: Locating Battery Pack Wire Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 9: Identifying zR2 Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection	Switch Condition	Specified Condition
zR2-6 (NODD) - Body ground	Power switch off	120 to 140 kΩ

NG → See step 11

OK: Go to next step

CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR - HYBRID VEHICLE CONVERTER)

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.
Disconnect the low voltage connector from the hybrid vehicle converter.

Fig 10: Locating Low Voltage Connector Of Hybrid Vehicle Converter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

For the removal and installation procedures related to the low voltage connector of the hybrid vehicle converter. Refer to REMOVAL .

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

Fig 11: Checking Harness And Connector (Battery Pack Wire Connector - Hybrid Vehicle Converter)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance (Check for open)

Tester Connection	Switch Condition	Specified Condition
zR2-6 (NODD) - z35-2 (NODD)	Power switch off	Below 1 Ω

Standard resistance (Check for short)

Tester Connection	Switch Condition	Specified Condition
zR2-6 (NODD) or z35-2 (NODD) - Body ground and other terminals	Power switch off	10 kΩ or higher

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step

CHECK HYBRID VEHICLE CONVERTER

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.
Disconnect the 3 high voltage connectors of the hybrid vehicle converter from the HV battery junction block.

Fig 12: Identifying Hybrid Vehicle Converter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 13: Locating z58, z59 And z60 Connectors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Positive Lead (Tester Probe Polarity)	Switch Condition	Specified Condition
High voltage + z59 (Positive prove) - High voltage - z58 (Negative prove)	Power switch off	500 kΩ or higher
High voltage + z59 (Positive prove) - High voltage precharge z60 (Negative prove)	Power switch off	10 MΩ or higher

NOTE:

Do not use a megohmmeter.
Read the resistance after the value has stabilized.

HINT:

NG → See step 16

OK: Go to next step

CHECK HYBRID BATTERY TERMINAL BLOCK

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.
Disconnect the high voltage connectors from the HV battery junction block.

Fig 14: Locating High Voltage Connectors For HV Battery Junction Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the connector for the power steering converter from the HV battery junction block.

Fig 15: Locating Connector For Power Steering Converter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 16: Locating Connector Terminals For Power Steering Converter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection	Switch Condition	Specified Condition
A - B	Power switch off	10 kΩ or higher

NG → See step 22

OK: Go to next step

CHECK POWER STEERING CONVERTER WIRE (HV BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER)

WARNING:

Be sure to wear insulated gloves.

Disconnect the frame wire No. 3 (connector for the HV battery) from the power steering converter.

Fig 17: Locating Connector For HV Battery
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 18: Identifying Z28 Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

Tester Connection	Switch Condition	Specified Condition
z28-1 (CBP) - z28-5 (CEP)	Power switch off	10 kΩ or higher

NG → See step 20

OK: Go to next step

CHECK POWER STEERING CONVERTER

WARNING:

Be sure to wear insulated gloves.

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

Fig 19: Identifying z28 Connector Terminals (CEP And CBP)

Standard resistance

Tester Connection	Switch Condition	Specified Condition
z28-1 (CBP) (Positive prove) - z28-5 (CEP) (Negative prove)	Power switch off	400 kΩ or higher

NOTE:

Do not use a megohmmeter.
Read the resistance after the value has stabilized.

HINT:

NG → See step 21

OK → See step 17

CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)

Disconnect connector A74 from the hybrid vehicle control ECU.

Fig 20: Checking Harness And Connector (Hybrid Vehicle Control ECU - Battery Pack Wire Connector)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the power switch off.

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

Standard resistance (Check for open)

Tester Connection	Switch Condition	Specified Condition
A74-26 (NODD) - zR2-6 (NODD)	Power switch off	Below 1 Ω

Standard resistance (Check for short)

Tester Connection	Switch Condition	Specified Condition
A74-26 (NODD) or zR2-6 (NODD) - Body ground and other terminals	Power switch off	10 kΩ or higher

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK → See step 19

CHECK AIR CONDITIONING HARNESS ASSEMBLY

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.

Fig 21: Checking Air Conditioning Harness Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the air conditioning harness assembly from the with motor compressor assembly.

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

Fig 22: Identifying j1 Connector Terminals

Standard resistance

Tester Connection	Switch Condition	Specified Condition
j1-1 - j1-2	Power switch off	10 kΩ or higher

NG → REPLACE AIR CONDITIONING HARNESS ASSEMBLY

OK → See step 18

GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART
REPLACE FRAME WIRE. Refer to REMOVAL
REPLACE HV BATTERY JUNCTION BLOCK. Refer to REMOVAL
REPLACE HYBRID VEHICLE CONVERTER. Refer to REMOVAL
REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to REMOVAL
REPLACE WITH MOTOR COMPRESSOR ASSEMBLY. Refer to REMOVAL
REPLACE HYBRID VEHICLE CONTROL ECU. Refer to REMOVAL
REPLACE POWER STEERING CONVERTER WIRE. Refer to REMOVAL
REPLACE POWER STEERING CONVERTER. Refer to REMOVAL

CHECK HV BATTERY JUNCTION BLOCK

WARNING:

Be sure to wear insulated gloves.

Check that the service plug grip is not installed.
Remove the HV battery terminal block.

Fig 23: Locating HV Battery Junction Block Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the connector for the power steering converter from the HV battery junction block.

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

Fig 24: Identifying g3 And g2 Connector Terminals

Standard resistance

Tester Connection	Switch Condition	Specified Condition
g2-1 - g3-1	Power switch off	10 kΩ or higher

NG → See step 15

OK → See step 23

REPLACE HYBRID BATTERY TERMINAL BLOCK. Refer to REMOVAL