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Home >> Lexus >> 2010 >> HS 250h >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control (Diagnostic Codes (P0AA6-526 - U0424-537) & Circuit Tests) >> Hybrid Control System >> DTC P3004-131: Power Cable Malfunction >> Procedure

DTC P3004-131: Power Cable Malfunction: Procedure

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

      Result

      Result Proceed to
      P3004-131 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-129, 150 Battery Energy Control Module
      P0A78-266, 267, 586 Drive Motor "A" Inverter Performance
      P0A94-442 DC / DC Converter Performance
      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
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-800, 801 High Voltage Power Resource

      HINT: 

      • P3004-131 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.
    5. Turn the power switch off.

    B → See step   14 

    A: Go to next step 

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

      Result

      Result Proceed to
      P3004-131 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1F-123 Battery Energy Control Module
      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
      P0B3D-123 Hybrid Battery Voltage Sensor "A" Circuit Low
      P0B42-123 Hybrid Battery Voltage Sensor "B" Circuit Low
      P0B47-123 Hybrid Battery Voltage Sensor "C" Circuit Low
      P0B4C-123 Hybrid Battery Voltage Sensor "D" Circuit Low
      P0B51-123 Hybrid Battery Voltage Sensor "E" Circuit Low
      P0B56-123 Hybrid Battery Voltage Sensor "F" Circuit Low
      P0B5B-123 Hybrid Battery Voltage Sensor "G" Circuit Low
      P0B60-123 Hybrid Battery Voltage Sensor "H" Circuit Low
      P0B65-123 Hybrid Battery Voltage Sensor "I" Circuit Low
      P0B6A-123 Hybrid Battery Voltage Sensor "J" Circuit Low
      P0B6F-123 Hybrid Battery Voltage Sensor "K" Circuit Low
      P0B74-123 Hybrid Battery Voltage Sensor "L" Circuit Low
      P0B79-123 Hybrid Battery Voltage Sensor "M" Circuit Low
      P0B7E-123 Hybrid Battery Voltage Sensor "N" Circuit Low
      P0B83-123 Hybrid Battery Voltage Sensor "O" Circuit Low
      P0B88-123 Hybrid Battery Voltage Sensor "P" Circuit Low
      P0B8D-123 Hybrid Battery Voltage Sensor "Q" Circuit Low
      P0B92-123 Hybrid Battery Voltage Sensor "R" Circuit Low
      P308A-123 Hybrid Battery Voltage Detection Circuit Open
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor

      HINT: 

      P3004-131 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

    5. Turn the power switch off.

    B → See step   19 

    A: Go to next step 

  3. CHECK FREEZE FRAME DATA 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Read the freeze frame data of DTC P3004-131.

      Result

      Result Proceed to
      Both of the following conditions are met:
      • Post-boost voltage (VH-Voltage after Boosting) is below 50 V.
      • Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VLVoltage before Boosting) is 50 V or less.
      		 A
      Other than above B
    5. Turn the power switch off.

    B → See step   4 

    A → See step   18 

  4. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR). Refer to PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  5. CHECK FRAME WIRE (INVERTER WITH CONVERTER ASSEMBLY SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      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.
      Fig 1: Identifying Inverter With Converter Assembly, Connector Cover Assembly & Bolts
      GTY281217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the connection between frame wire N1 and the inverter with converter assembly.
      Fig 2: Identifying Connection Between Frame Wire N1 & The Inverter With Converter Assembly
      GTY272896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

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

    4. Install the connector cover assembly to the inverter with converter assembly.

    NG → CONNECT SECURELY 

    OK: Go to next step 

  6. CHECK FRAME WIRE (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      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. Check the connection between the frame wire and the hybrid battery junction block assembly.
      Fig 3: Identifying Frame Wire N3 And N4 & Hybrid Battery Junction Block Assembly
      GTY279829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque

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

      NOTE:

      Make sure that the tightening torque of the bolts is between 7.2 and 10.8 N*m (73 and 110 kgf*cm, 64 and 96 in.*lbf).

    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 → REPLACE MALFUNCTIONING PARTS 

    A: Go to next step 

  7. CHECK FRAME WIRE (INVERTER WITH CONVERTER - HYBRID BATTERY JUNCTION BLOCK) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      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.
      Fig 4: Identifying Inverter With Converter Assembly, Connector Cover Assembly & Bolts
      GTY281217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect frame wire N1 from the inverter with converter assembly.
      Fig 5: Identifying Connection Between Frame Wire N1 & The Inverter With Converter Assembly
      GTY272896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect frame wire N3 and N4 from the hybrid battery junction block assembly.
      Fig 6: Identifying Frame Wire N3 And N4 & Hybrid Battery Junction Block Assembly
      GTY279829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the resistance according to the value(s) in the table below.
      Fig 7: Identifying N3 & N4 Frame Wire Terminals & N1 Connector Terminals
      GTY258618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      N4-1 (CBI) - N1-1 (CBI) Power switch off Below 1 Ω
      N3-1 (CEI) - N1-2 (CEI) Power switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Component without frame wire
      (Frame Wire (Inverter with Converter Assembly Side))
      *2 Component without frame wire
      (Frame Wire (Hybrid Battery Junction Block Assembly Side))
      *3 Red Mark
    6. Connect the frame wire from the hybrid battery junction block assembly.
    7. Connect the frame wire from the inverter with converter assembly.
    8. Install the inverter terminal cover to the inverter with converter assembly.

    NG → See step   17 

    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.
      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. Check the connections between the main battery cables and the hybrid battery junction block assembly.

      OK

      The connectors are connected securely and not damaged.

      Fig 8: Identifying z13 & z11 HV Battery Assembly Connectors
      GTY272641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 → REPLACE MALFUNCTIONING PARTS 

    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.
      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. Measure the voltage according to the value(s) in the table below.
      Fig 9: Identifying z13 & z11 Connector Terminals
      GTY260757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      z11-1 (+) - Terminal A Power switch off 114 to 183 V
      Z13-1 (-) - Terminal B Power switch off 90 to 144 V
      WARNING:

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

    NG → See step   16 

    OK: Go to next step 

  10. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK) See step   3 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  11. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      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. Check the connections between the main battery cables and the hybrid battery junction block assembly.

      OK

      The connectors are connected securely and not damaged.

      Fig 10: Identifying z26, z27 & z28 Hybrid Battery Junction Block Assembly Connectors
      GTY265173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG → CONNECT SECURELY 

    OK: Go to next step 

  12. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB). Refer to PROCEDURE - Step 16 

    NG → See step   15 

    OK: Go to next step 

  13. CHECK FOR INTERMITTENT PROBLEMS 
    1. Check for intermittent problems. Refer toCHECK FOR INTERMITTENT PROBLEMS .

      Result

      Result Proceed to
      P3004-131 is not output. A
      P3004-131 is output again. B

      HINT: 

      • Since 2 trip detection logic is used, the DTC detection condition must be met twice.
      • If DTC P3004-131 is output again after performing the inspection, replace the hybrid vehicle converter. If DTC P3004-131 is not output again, replace the hybrid battery junction block assembly.

    B → See step   20 

    A → See step   15 

  14. GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART 
  15. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to COMPONENTS 
  16. REPLACE HV BATTERY ASSEMBLY. Refer to COMPONENTS 
  17. REPLACE FRAME WIRE. Refer to COMPONENTS 
  18. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to COMPONENTS 
  19. GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART 
  20. REPLACE HYBRID VEHICLE CONVERTER. Refer to COMPONENTS 
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