DTC P3004-803: Power Cable Malfunction: Procedure

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
   P3004-803 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
   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
   P0ADF-229	Hybrid Battery Negative Contactor Control Circuit Low
   P0AE0-228	Hybrid Battery Negative Contactor Control Circuit High
   P0C76-523	Hybrid Battery System Discharge Time Too Long

   HINT: 

   P3004-803 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   7 

A: Go to next step 

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
   P3004-803 only is output.	A
   Any of the following DTCs are also output.	B

   DTC No.	Relevant Diagnosis
   P0A95-123	High Voltage Fuse
   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

   HINT: 

   P3004-803 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.

B → See step   10 

A: Go to next step 

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 and record the DTCs and freeze frame data.
5. Clear DTCs and freeze frame data.
6. Turn the power switch off.

NEXT: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (READY).
3. Ensure the safety of the areas in front and at the back of the vehicle.
4. Move the shift lever to D and depress both the accelerator pedal and brake pedal at the same time.

   HINT: 

   • Depressing both the accelerator pedal and brake pedal at the same time causes the HV battery current to flow and makes it possible to confirm that there is no problem with the high-voltage wiring.
   • Depressing both the accelerator pedal and brake pedal at the same time causes accelerator and brake depressing in the inappropriate operation and history data to be counted.
5. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
6. Check if DTCs are output.

   Result

   Result	Proceed to
   P3004-803 is output, or no DTCs are output.	A
   Power switch is not turned on (READY) and P3004-131 is output.	B

7. Turn the power switch off.

B → See step   8 

A: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

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 A58 from the hybrid vehicle control ECU.
3. Disconnect connector z16 from the hybrid battery junction block assembly.

   HINT: 

   Before disconnecting the connector, check whether it is connected securely to the hybrid battery junction block assembly.

4. Measure the resistance according to the value(s) in the table below.
   Fig 1: Identifying A58 Hybrid Vehicle Control ECU & z16 Hybrid Battery Junction Block Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A58-60 (SMRB) - z16-3 (SMRB)	Power switch off	Below 1 Ω
   A58-96 (SMRG) - z16-1 (SMRG)	Power switch off	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Front view of wire harness connector (Hybrid vehicle control ECU)
   *2	Rear view of wire harness connector (Hybrid Battery Junction Block Assembly)

5. Connect the hybrid battery junction block assembly connector.
6. Connect the hybrid vehicle control ECU connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   9