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Home >> Lexus >> 2010 >> LS 600hL >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Vehicle Control (Diagnostic Codes (P2120-152 - U0424-537) & Circuit Tests) >> Hybrid Control System >> DTC P3004-803: Power Cable Malfunction >> Procedure

DTC P3004-803: Power Cable Malfunction: Procedure

  1. CHECK DTC OUTPUT (HV) 
    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
      P3004-803 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Part
      P0A1A-151, 155, 156, 658, 659 Generator Control Module
      P0A1B-163, 164, 193, 511, 512, 786, 788, 661 Drive Motor "A" Control Module
      P0A78-266, 267, 586 Drive Motor "A" Inverter Performance
      P0A94-442 DC / DC Converter Performance
      P0A95-123 High Voltage Fuse
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0AFA-123 Hybrid Battery System Voltage Low
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P3004-131 Power Cable Malfunction
      P3240-443 DC / DC Converter Control Circuit

    B → See step   7 

    A: Go to next step 

  2. CLEAR DTC (HV) 
    1. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    2. Read and record the DTCs and freeze frame data.
    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    4. Clear DTCs and freeze frame data.

    NEXT: Go to next step 

  3. CHECK DTC OUTPUT (HV) 
    1. Turn the power switch on (READY).
    2. Move the shift lever to the D position and depress both the accelerator pedal and brake pedal at the same time.
      NOTE:

      Make sure the areas in front and at the back of the vehicle are safe.

      HINT: 

      • Depressing both the accelerator pedal and brake pedal at the same time causes the HV battery current to flow and ensures 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 operation counter in the inappropriate operation and history data to be incremented.
    3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    4. 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

    B → See step   8 

    A: Go to next step 

  4. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) 
    1. Check the connections of the hybrid vehicle control ECU connectors.

      Result

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 BATTERY PACK WIRE CONNECTOR) 
    1. Disconnect connector E55 from the hybrid vehicle control ECU.
    2. Disconnect the No. 1 battery pack wire connector.
      Fig 1: Locating No. 1 Battery Pack Wire Connector
      GTY259841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      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.

    3. Measure the resistance according to the value(s) in the table below.
      Fig 2: Identifying E55 And ZR3 Terminal Connectors
      GTY266183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Switch Condition Specified Condition
      E55-5 (SMRB) - zR3-5 (SMRB) Power switch off Below 1 Ω
      E55-4 (SMRG) - zR3-4 (SMRG) Power switch off Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (NO. 2 BATTERY PACK WIRE CONNECTOR - HV BATTERY JUNCTION BLOCK) 
    WARNING:

    Be sure to wear insulated gloves.

    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. Disconnect the low voltage connector that drives the relay of the HV battery junction block.
      Fig 3: Locating HV Battery Junction Block Low Voltage Connector
      GTY257509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      For the removal and installation procedures related to the HV battery junction block connector. Refer to COMPONENTS .

    4. Measure the resistance according to the value(s) in the table below.
      Fig 4: Identifying ZR3 And Z38 Terminal Connectors
      GTY272640Courtesy 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
      zR3-4 (SNRG) - z38-1 (SNRG) Power switch off Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   9 

  7. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  8. GO TO DTC CHART (P3004-131). Refer to  DTC P3004-131: Power Cable Malfunction  
  9. REPLACE HV BATTERY JUNCTION BLOCK. Refer to  COMPONENTS 
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