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Home >> Toyota >> 2006 >> Prius >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> P112 Hybrid Vehicle Control - DTC P0A94 - P3226, U0100 - U0146 >> DTC P3004-132 Power Cable Malfunction >> Inspection Procedure

Inspection Procedure

CAUTION:
  • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system.
  • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:

At least 5 minutes are required to discharge the high-voltage condenser inside the inverter.

  1. READ OUTPUT DTC (HV ECU) 
    1. Connect the intelligent tester to the DLC3.
    2. Turn the power switch ON (IG).
    3. Turn the intelligent tester ON.
    4. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
    5. Read DTCs.

      Result: DTC P3004 (INF 132) and other DTCs are output 

      HINT:

      If any other codes besides P3004 (INF 132) are output, perform troubleshooting for those DTCs first.

    YES : GO TO RELEVANT  DIAGNOSTIC TROUBLE CODE CHART 

    NO : GO TO NEXT STEP 

  2. INSPECT SYSTEM MAIN RESISTOR 
    CAUTION: Wear insulated gloves and goggles before performing the following operation.
    1. Remove the system main resistor (See REMOVAL ).
    2. Measure the resistance between the terminals.

      Standard resistance: 18 to 22 Ω 

    3. Reinstall the system main resistor (See INSTALLATION ).

    NG : REPLACE SYSTEM MAIN RESISTOR 

    Fig 1: Identifying System Main Resistor
    G04473662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  3. INSPECT NO. 1 SYSTEM MAIN RELAY 
    1. Inspect the No. 1 system main relay (See INSPECTION ).

    NG : REPLACE NO. 1 SYSTEM MAIN RELAY 

    OK : GO TO NEXT STEP 

  4. INSPECT NO. 3 SYSTEM MAIN RELAY 
    1. Inspect the No. 3 system main relay (See INSPECTION ).

    NG : REPLACE NO. 3 SYSTEM MAIN RELAY 

    OK : GO TO NEXT STEP 

  5. INSPECT MAIN BATTERY CABLE 
    CAUTION: Wear insulated gloves and goggles before performing the following operation.
    1. Remove the HV battery assembly (see REMOVAL ).
    2. Remove the main battery cable (See REMOVAL ).
    3. Measure the resistance between the terminals of the main battery cable.

      Standard resistance: Below 1 Ω 

    NG : REPLACE MAIN BATTERY CABLE 

    Fig 2: Identifying Main Battery Cable
    G04473663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  6. INSPECT MAIN BATTERY CABLE 
    CAUTION: Wear insulated gloves and goggles before performing the following operation.
    1. Check the cover and terminals of the main battery cable for any abnormality.

      OK : No abnormality is found on the cover and terminals. 

    2. Check the terminals of the HV battery and the system main relay, which are to be connected to the main cable, for any abnormality.

      OK : No abnormality is found on the terminals of the HV battery and system main relay. 

    NG : REPLACE MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY 

    OK : GO TO NEXT STEP 

  7. INSPECT NO. 2 MAIN BATTERY CABLE 
    CAUTION: Wear insulated gloves and goggles before performing the following operation.
    1. Remove the No. 2 main battery cable with the HV battery assembly removed (See REMOVAL ).
    2. Measure the resistance between the terminals of the No. 2 main battery cable.

      Standard resistance: Below 1 Ω 

    NG : REPLACE NO. 2 MAIN BATTERY CABLE 

    Fig 3: Identifying Main Battery Cable
    G04473664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : GO TO NEXT STEP 

  8. INSPECT NO. 2 MAIN BATTERY CABLE 
    CAUTION: Wear insulated gloves and goggles before performing the following operation.
    1. Check the cover and terminals of the No. 2 main battery cable for any abnormality.

      OK : No abnormality is found on the cover and terminals. 

    2. Check the terminals of the HV battery and the system main relay, which are to be connected to the No. 2 main battery cable, for any abnormality.

      OK : No abnormality is found on the terminals of the HV battery and system main relay. 

    NG : REPLACE NO. 2 MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY 

    OK : GO TO NEXT STEP 

  9. INSPECT FRAME WIRE 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Disconnect the frame wire from the inverter with converter.
      Fig 4: Identifying Frame Wire Terminals
      G04473665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the frame wire has been disconnected from the system main relay.
    3. Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and body ground.

      Standard resistance 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      A - Body ground 10 MΩ or higher
      B - Body ground 10 MΩ or higher
      Fig 5: Identifying High-Voltage Terminals Of The Frame Wire
      G04473666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance between the terminals of the frame wire.

      Standard resistance 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      A - C Below 1 Ω
      B - D Below 1 Ω
    5. Reinstall the HV battery assembly (See REASSEMBLY ).
    6. Reconnect the frame wire.

    NG : REPLACE FRAME WIRE 

    OK : GO TO NEXT STEP 

  10. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) 
    CAUTION: Wear insulated gloves before performing the following operation.
    1. Turn the power switch OFF.
    2. Remove the service plug grip (See REMOVAL ).
      NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
    3. Remove the inverter cover (see REMOVAL ).
    4. Disconnect the H15 HV control ECU connector.
      Fig 6: Disconnecting H15 HV Control ECU Connector
      G04473667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the I10 inverter connector.
    6. Turn the power switch ON (IG).

      HINT:

      DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.

    7. Measure the voltage between the terminals of the HV control ECU connector and body ground.

      Standard voltage (Check for open) 

      TERMINALS VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      VH (H15-26) - Body ground Below 1 V
      GINV (H15-23) - Body ground Below 1 V
    8. Turn the power switch OFF.
    9. Measure the resistance between the wire harness side connectors.
      Fig 7: Disconnecting I10 Inverter Connector
      G04473668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance (Check for short) 

      TERMINALS RESISTANCE SPECIFICATION

      Tester Connection Specified Condition
      VH (H15-26) or VH (I10-12) - Body ground 10 kΩ or higher
      GINV (H15-23) or GINV (I10-16) - Body ground 10 kΩ or higher
    10. Reconnect the inverter connector.
    11. Reconnect the HV control ECU connector.
    12. Reinstall the inverter cover (see INSTALLATION ).
    13. Reinstall the service plug grip (See INSTALLATION ).

    NG : REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK : GO TO NEXT STEP 

  11. CHECK HYBRID VEHICLE CONTROL ECU (VH VOLTAGE) 
    1. Turn the power switch ON (READY).

      HINT:

      DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.

    2. Measure the voltage between the terminals of the H15 HV control ECU connector.

      Standard voltage 

      TERMINALS VOLTAGE SPECIFICATION

      Tester Connection Specified Condition
      VH (H15-26) - GINV (H15-23) 1.6 to 3.8 V

    NG : REPLACE INVERTER WITH CONVERTER ASSEMBLY 

    Fig 8: Identifying HV Control ECU Connector
    G04473669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : REPLACE HYBRID VEHICLE CONTROL ECU 

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