DTC P3004-131: 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
   P3004-131 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 (all INF codes) *1	Battery Energy Control Module
   P0A78-266, 267, 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
   P0C76-523	Hybrid Battery System Discharge Time Too Long
   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.
   • P3004-131 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   16 

A: Go to next step 

1. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
2. Read the freeze frame data of DTC P3004-131.

   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 (VL-Voltage before Boosting) is 50 V or less.	A
   Other than above	B

B → See step   3 

A → See step   21 

1. Check the connections of the hybrid vehicle control ECU connectors.

   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 1: 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 2: Locating DC Connector Of Inverter

   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. Check that the service plug grip is not installed.
2. Check the connection between the frame wire and the HV battery junction block.
   Fig 3: Identifying Frame Wire Connectors

   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 frame wire connection. Refer to COMPONENTS .

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 

1. Check that the service plug grip is not installed.
2. Disconnect the frame wire from the inverter with converter assembly.
   Fig 4: Locating DC Connector Of Inverter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the frame wire from the HV battery junction block.
   Fig 5: Identifying Frame Wire Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Measure the resistance according to the value(s) in the table below.
   Fig 6: Identifying Frame Wire HV Battery Junction Block And Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	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   20 

OK: Go to next step 

1. Disconnect connectors A74 and E55 from the hybrid vehicle control ECU.
2. Disconnect the No. 1 battery pack wire connector.

   HINT: 

   • Before disconnecting the No. 1 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 No. 1 battery pack wire connector resistance check should be performed before these connectors are disconnected.
   Fig 7: Locating No. 1 Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 8: Identifying E55 And ZR3 Terminal Connectors

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

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   E55-5 (SMRB) - zR3-5 (SMRB)	Power switch off	Below 1 Ω

4. Disconnect the No. 2 battery pack wire connector.

   HINT: 

   • Before disconnecting the No. 2 battery pack wire connector, make sure that the connectors are securely engaged.
   • Due to the time required to disconnect the HV battery junction block and hybrid vehicle converter connectors, the No. 2 battery pack wire connector resistance check should be performed before these connectors are disconnected.
   Fig 9: Locating No. 2 Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 10: Identifying A74 And NS1 Terminal Connectors

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

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   A74-25 (SMRP) - nS1-11 (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.

   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 COMPONENTS .

   Fig 11: Locating High-Voltage HV Battery Connectors

   Courtesy 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 

1. Check that the service plug grip is not installed.
2. Measure the voltage according to the value(s) in the table below.
   Fig 12: Locating Battery Cable Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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   19 

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.
   Fig 13: Locating HV Battery Junction Block Low Voltage Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.

3. Measure the resistance according to the value(s) in the table below.
   Fig 14: Identifying ZR3 And Z38 Terminal Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   zR3-5 (SMRB) - z38-3 (SMRB)	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.
   Fig 15: Identifying NS1 And Z82 Terminal Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the low voltage connector from the hybrid vehicle converter.

   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.

   Standard resistance

   Tester Connection	Switch Condition	Specified Condition
   nS1-11 (SMRP) - z82-10 (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 Battery Connections

   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 COMPONENTS .

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 → REPLACE MALFUNCTIONING PARTS 

A: Go to next step 

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

   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 Battery Terminal Block

   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   22 

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 COMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 19: HV Battery Junction Block G2, Z30 And Z38 Terminal Connectors

   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 (SMRB) 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 (SMRB) - z38-2 (GND)	-31 to 176°F (-35 to 80°C)	18.8 to 32.1 Ω

NG → See step   18 

OK: Go to next step 

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

   HINT: 

   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 HV battery junction block.

NG → See step   17 

OK → See step   18