DTC P3004-132: Power Cable Malfunction: Procedure

WARNING: This page is about a different variant/trim than selected.

CHECK DTC OUTPUT

Connect the Techstream to the DLC3.
Turn the power switch on (IG).
Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

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 circuit, VB sensor circuit
P0ABF, P0AC0, P0AC1, P0AC2	IB sensor circuit
P3004-131, 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.
P3004-132 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 18

NO: Go to next step

CHECK FREEZE FRAME DATA

Connect the Techstream to the DLC3.
Turn the power switch on (IG).
Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
Read output DTCs.

Read the freeze frame data for DTC P3004-132.

Result

Result	Proceed to
Difference between HV battery voltage (Power Resource VB) and boost converter voltage (VL-Voltage before Boosting) is 50 V or less, difference between HV battery voltage (Power Resource VB) and inverter voltage (VH-Voltage after Boosting) is more than 70 V, and difference between boost converter voltage (VL-Voltage before Boosting) and inverter voltage (VH-Voltage after Boosting) is more than 90 V.	A
HV battery current (IB) is 3 A or more.	B
Other than above	C

A → See step 19

B → See step 20

C: Go to next step

CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR). Refer to PROCEDURE - Step 3
NG → CONNECT SECURELY

OK: Go to next step
CHECK CONDITION OF FRAME WIRE CONNECTION(S) (INVERTER WITH CONVERTER ASSEMBLY SIDE)
WARNING:
Be sure to wear insulated gloves.
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
CHECK CONDITION OF FRAME WIRE CONNECTION(S) (HV RELAY ASSEMBLY SIDE)
WARNING:
Be sure to wear insulated gloves.
1. Check that the service plug grip is not installed.
  
  Fig 2: Identifying Frame Wire Connections Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the connections between the frame wire and the HV relay assembly.
  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
CHECK FRAME WIRE See step 6
NG → REPLACE FRAME WIRE

OK: Go to next step
CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTOR). Refer to PROCEDURE - Step 3
NG → CONNECT SECURELY

OK: Go to next step
CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR) See step 8
NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step
CHECK CONDITION OF MAIN BATTERY CABLE CONNECTION(S) See step   9
B → CONNECT SECURELY

C → See step   22

D → See step   21

A: Go to next step
CHECK HV BATTERY ASSEMBLY See step 10
NG → See step 21

OK: Go to next step
CHECK CONNECTOR CONNECTION CONDITION (HV RELAY ASSEMBLY CONNECTOR) See step 11
NG → CONNECT SECURELY

OK: Go to next step
CHECK HARNESS AND CONNECTOR (HV RELAY ASSEMBLY - BATTERY PACK WIRE CONNECTOR) See step 12
NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step
CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR). Refer to PROCEDURE - Step 6
NG → CONNECT SECURELY

OK: Go to next step
CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR) See step 14
NG → REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: Go to next step
INSPECT HV RELAY ASSEMBLY (SMRB) See step 15
NG → See step 22

OK: Go to next step
CLEAR DTC
1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Read and record the DTCs and freeze frame data.
4. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
5. Clear DTCs and freeze frame data.
NEXT: Go to next step

CHECK FOR INTERMITTENT PROBLEMS

Connect the Techstream to the DLC3.
Check for intermittent problems. Refer to CHECK FOR INTERMITTENT PROBLEMS .
Turn the power switch on (READY).
Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.

Check if DTCs are output.

Result

Result	Proceed to
DTC P3004-131 is output (SMRP may remain off).	A
DTC P3004-132 is output.	B
No DTC is output.	C

A → GO TO INSPECTION PROCEDURE INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P3004-131)

B → See step 23

C → See step 23

GO TO DTC CHART. Refer to DIAGNOSTIC TROUBLE CODE CHART
REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to REMOVAL
GO TO INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P3004-800). Refer to DTC P3004-800: Power Cable Malfunction; DTC P3004-801: Power Cable Malfunction
REPLACE HV BATTERY ASSEMBLY. Refer to REMOVAL
REPLACE HV RELAY ASSEMBLY. Refer to REMOVAL
REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to REMOVAL