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

   DTC No.	Related Part
   P0A95	Electric vehicle fuse circuit
   P0AE7-224, P0AE6-225	SMRP control line circuit
   P0ADC-226, P0ADB-227	SMRB control line circuit
   P0A1F, P3105, P0AFA	Battery smart unit, VB sensor circuit
   P0ABF, P0AC0, P0AC1, P0AC2	IB sensor circuit
   P3004-800, 801	High-voltage power source line circuit
   P0A1A-156, 658, 151, 155, 659 P0A1B-511, 164, 163, 512, 193, 786, 788, 661 P0A78-266, 267, 523, 586, P0A94-442	VH sensor circuit

   HINT: 

   • Turning the power switch on (IG) with the service plug grip and inverter cover removed causes interlock switch system DTC P0A0D-350 to be output.
   • P3004-131 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.

YES → See step   17 

NO: Go to next step 

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. Read output DTCs.
5. Read the freeze frame data for DTC P3004-131.

   Result

   Result	Proceed to
   Inverter voltage (VH-Voltage after Boosting) is below 50 V and difference between HV battery voltage (Power Resource VB) and boost converter voltage (VL-Voltage before Boosting) is 50 V or less.	A
   Other than above	B

A → See step   21 

B: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

1. Turn the power switch off and 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.

2. Check the connections between the frame wire and the inverter with converter assembly.
   Fig 1: Identifying Inverter With Converter Assembly Bolts Location

   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 connections between the frame wire and the HV relay assembly.
   Fig 2: Identifying Frame Wire Connections Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   For the removal and installation procedures related to inspection of the frame wire connection. Refer to REMOVAL .

   Torque: 9.0 N*m (92 kgf*cm, 81 in.*lbf) 

NG → CONNECT SECURELY 

OK: 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. Refer to REMOVAL .
   Fig 3: Identifying Inverter With Converter Assembly Bolts Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the frame wire from the HV relay assembly. Refer to REMOVAL .
4. Measure the resistance according to the value(s) in the table below.
   Fig 4: Identifying Frame Wire Connector And Frame Wire Terminal Identification

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Specified Condition
   h1-1 (High voltage +) - h4-1 (High voltage +)	Below 1 Ω
   h1-2 (High voltage -) - h3-1 (High voltage -)	Below 1 Ω

NG → REPLACE FRAME WIRE 

OK: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the A61 hybrid vehicle control ECU connector.
3. Disconnect the On1 battery pack wire connector. Refer to REMOVAL .
   Fig 5: Identifying On1 Battery Pack Wire Connector Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Due to the time required to disconnect the HV relay assembly and hybrid vehicle converter (DC/DC converter) connectors, the battery pack wire resistance check should be performed before these connectors are disconnected.

4. Measure the resistance according to the value(s) in the table below.
   Fig 6: Identifying Hybrid Control ECU And Battery Pack Wire Connector Terminal Identification

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   SMRB (A61-60) - CON2 (On1-3)	Below 1 Ω
   SMRP (A61-72) - SMRP (On1-8)	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 7: Identifying High-Voltage Connectors Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the connections between the main battery cable and the HV relay assembly.

   Result

   Result	Proceed to
   The connectors are connected securely and there are no contact problems.	A
   The connectors are not connected securely.	B
   The HV relay assembly connector is damaged.	C
   The main battery cable is damaged.	D

   HINT: 

   The main battery cable and HV battery are supplied as one unit.

B → CONNECT SECURELY 

C → See step   19 

D → See step   20 

A: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 8: Identifying Main Battery Cable Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the main battery cable from the HV relay assembly. Refer to REMOVAL
3. Measure the voltage according to the value(s) in the table below.

   Standard voltage

   Tester Connection	Specified Condition
   s1-1 - Service plug grip terminal 1	114 to 190 V
   t1-1 - Service plug grip terminal 2	90 to 150 V

   WARNING:

   Do not allow the probes of the electrical tester to contact each other during this inspection.

NG → See step   20 

OK: Go to next step 

1. Turn the power switch off and remove the service plug grip. Refer to PRECAUTION .
   Fig 9: Identifying n3 HV Relay Assembly Connector Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

2. Check the connections of the HV relay assembly connectors.

   Result

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

   HINT: 

   For the removal procedure of the HV relay assembly connector. Refer to REMOVAL .

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the n3 HV relay assembly connector.
   Fig 10: Identifying n3 HV Relay Assembly Connector Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Measure the resistance according to the value(s) in the table below.
   Fig 11: Identifying Battery Pack Wire And HV Relay Assembly Connector Terminal identification

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   CON2 (On1-3) - CON2 (n3-3)	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the n4 hybrid vehicle converter (DC/DC converter) connector. Refer to REMOVAL .
3. Measure the resistance according to the value(s) in the table below.
   Fig 12: Identifying Hybrid Vehicle Converter (DC/DC Converter) And Battery Pack Connector Terminal Identification

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   SMRP (On1-8) - SMRP (n4-4)	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. Remove the HV relay assembly from the vehicle. Refer to REMOVAL .
3. Measure the resistance according to the value(s) in the table below.
   Fig 13: Identifying s1 HV Relay Assembly Connector Terminal Identification

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   h4-1 - s1-1	Below 1 Ω (When battery voltage (12 V) applied to terminals n3-2 and n3-3)

4. Measure the resistance according to the value(s) in the table below.

   Standard resistance

   Tester Connection	Specified Condition
   CON2 (n3-3) - GND (n3-2)	18.8 to 32.1 Ω at -35 to 80°C (-31 to 176°F)

NG → See step   19 

OK: Go to next step 

HINT: 

If DTC P3004-131 is output again after performing the inspection, replace the hybrid vehicle converter (DC/DC converter). If DTC P3004-131 is not output, replace the HV relay assembly.

YES → See step   18 

NO → See step   19