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

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

      HINT: 

      P3004-800 or P3004-801 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   12 

    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
      P3004-800or P3004-801 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1F-123 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
      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: 

      P3004-800 or P3004-801 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   18 

    A: Go to next step 

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  4. CHECK COMPRESSOR WITH MOTOR 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. 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. Disconnect No. 2 engine wire (air conditioning harness) D2 from the inverter with converter assembly.
      Fig 2: Identifying D2 No. 2 Engine Wire (Air Conditioning Harness) From The Inverter With Converter Assembly
      GTY287598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      Fig 3: Identifying D2 Inverter With Converter Assembly & Shielded Wire Ground
      GTY280750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection
      (Tester Probe Polarity)      		 Switch Condition Specified Condition
      D2-1 (ACPE) (Negative probe) -
      D2-2 (ACPB) (Positive probe)      		 Power switch off 100 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Front view of No. 2 engine wire (air conditioning harness) connector
      (to Inverter with Converter Assembly)
      *2 Shield Wire Ground
      NOTE:
      • Do not use a megohmmeter.
      • Read the resistance after the value has stabilized.
      • 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.
    5. Connect the No. 2 engine wire (air conditioning harness) from the inverter with converter assembly.
    6. Install the connector cover assembly to the inverter with converter assembly.

    NG → See step   10 

    OK: Go to next step 

  5. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR). Refer to PROCEDURE - Step 4 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  6. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR). Refer to PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  7. CHECK HYBRID VEHICLE CONTROL ECU. Refer to PROCEDURE - Step 9 

    NG → See step   9 

    OK: Go to next step 

  8. CHECK FRAME WIRE (HYBRID VEHICLE CONTROL ECU - HYBRID VEHICLE CONVERTER) 
    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 (high voltage DC connector) 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. Measure the resistance according to the value(s) in the table below.
      Fig 6: Identifying N3 & N4 Frame Wire and Red Mark
      GTY258917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      N4-1 (CBI) - N3-1 (CEI) Power switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Frame Wire
      *2 Red Mark
    5. Connect the hybrid battery junction block assembly connector.
    6. Connect the frame wire (high voltage DC connector) to inverter with converter assembly.
    7. Install the connector cover assembly to the inverter with converter assembly.

    NG → See step   11 

    OK → See step   13 

  9. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID VEHICLE CONVERTER). Refer to PROCEDURE - Step 13 

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   14 

  10. CHECK NO. 2 ENGINE WIRE 
    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 7: Identifying Inverter With Converter Assembly, Connector Cover Assembly & Bolts
      GTY281217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect No. 2 engine wire (air conditioning harness) D2 from the inverter with converter assembly.
      Fig 8: Identifying D2 No. 2 Engine Wire (Air Conditioning Harness) From The Inverter With Converter Assembly
      GTY287598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect No. 2 engine wire (air conditioning harness) D1 from the compressor with motor assembly.
      Fig 9: Identifying D1 No. 2 Engine Wire From The Compressor With Motor Assembly & Green Lock
      GTY259495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Green Lock
    5. Measure the resistance according to the value(s) in the table below.
      Fig 10: Identifying D2 Inverter With Converter Assembly & Shielded Wire Ground
      GTY280750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      D2-1 (ACPE) (Negative probe) - D2-2 (ACPB) (Positive probe) Power switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Front view of No. 2 engine wire (air conditioning harness) connector
      (to Inverter with Converter Assembly)
      *2 Shielded Wire Ground
    6. Connect the No. 2 engine wire (air conditioning harness) to the compressor with motor assembly.
    7. Connect the No. 2 engine wire (air conditioning harness) from the inverter with converter assembly.
    8. Install the connector cover assembly to the inverter with converter assembly.

    NG → REPLACE NO. 2 ENGINE WIRE 

    OK → See step   15 

  11. CHECK HYBRID BATTERY JUNCTION BLOCK 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. Disconnect connector z11 and z13 from the hybrid battery junction block assembly.
      Fig 11: Identifying z13 & z11 HV Battery Assembly Connectors
      GTY272641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect frame wire N3 and N4 from the hybrid battery junction block assembly.
      Fig 12: Identifying Frame Wire N3 And N4 & Hybrid Battery Junction Block Assembly
      GTY279829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      Fig 13: Identifying N3, N4 HV Battery J/B Assembly & z13, z13 Inverter With Converter Assembly
      GTY269414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      N3-1 (CEI) - N4-1 (CBI) Power switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Component with harness connected
      (Hybrid Battery Junction Block Assembly)
      *2 Inverter with Converter Assembly
      *3 HV Battery Assembly
    5. Connect the frame wire to the hybrid battery junction block assembly.
    6. Connect the hybrid battery junction block assembly connector.

    NG → See step   17 

    OK → See step   16 

  12. GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART 
  13. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to COMPONENTS 
  14. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to COMPONENTS 
  15. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY. Refer to COMPONENTS 
  16. REPLACE FRAME WIRE. Refer to COMPONENTS 
  17. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to COMPONENTS 
  18. GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART 
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