LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2011 >> Camry Base, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 101 (Hybrid Vehicle Control System (P311) (Hybrid) (Diagnostic Codes (P0AA1-233 - U0424-537)) >> Hybrid Control System >> DTC P3004-800: Power Cable Malfunction; DTC P3004-801: Power Cable Malfunction >> Procedure

DTC P3004-800: Power Cable Malfunction; DTC P3004-801: Power Cable Malfunction: Procedure

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

      DTC No. Related Part
      P0A09-265, P0A10-263 Hybrid vehicle converter circuit
      P0AFA, P0A1F, P3105 VB sensor circuit, battery smart unit circuit
      P0ABF, P0AC0, P0AC1, P0AC2 IB 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.
      • P3004-800 or P3004-801 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   13 

    NO: Go to next step 

  2. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR). Refer to  PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  3. CHECK COMPRESSOR WITH MOTOR ASSEMBLY 
    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. Disconnect the air conditioning harness from the inverter with converter assembly. Refer to REMOVAL
      Fig 1: Identifying Air Conditioning Harness Assembly Connector Location
      GTY186401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance according to the value(s) in the table below.
      Fig 2: Identifying Air Conditioning Harness Assembly Connector Terminal Identification
      GTY192733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      j2-1 - j2-2 100 kΩ or more
      NOTE:
      • Do not use a megohmmeter.
      • Make sure that the tester probes are connected to the correct terminals.

    OK → See step   5 

    NG: Go to next step 

  4. CHECK AIR CONDITIONING HARNESS ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      Fig 3: Identifying Air Conditioning Harness Assembly And Compressor Connector Location
      GTY207150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the air conditioning harness from the compressor with motor assembly.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 4: Identifying Air Conditioning Harness Assembly Connector Terminal Identification
      GTY192733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      j2-1 - j2-2 10 MΩ or more

    NG → REPLACE AIR CONDITIONING HARNESS ASSEMBLY 

    OK → REPLACE COMPRESSOR WITH MOTOR ASSEMBLY 

  5. CHECK FRAME WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Remove the A/C fuse cover from the inverter with converter assembly.
    3. Disconnect the frame wire from the inverter with converter assembly. Refer to REMOVAL .
      Fig 5: Locating Inverter With Converter Assembly Bolts Location
      GTY192887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the frame wire from the HV relay assembly. Refer to REMOVAL .
    5. Measure the resistance according to the value(s) in the table below.
      Fig 6: Identifying Frame Wire Point Location
      GTY172897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      h4-1 (High voltage +) - h3-1 (High voltage -) 10 kΩ or more

    NG → REPLACE FRAME WIRE 

    OK: Go to next step 

  6. CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTOR). Refer to  PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR 
    1. Turn the power switch off.
    2. Disconnect the On1 battery pack wire connector. Refer to REMOVAL .
      Fig 7: Identifying ON1 Battery Pack Wire Connector Location
      GTY168866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance according to the value(s) in the table below.
      Fig 8: Identifying On1 Battery Pack Wire Connector Terminal Identification
      GTY172579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      NODD (On1-6) - Body ground 120 to 140 kΩ

    NG → See step   12 

    OK: Go to next step 

  8. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR). Refer to  PROCEDURE - Step 6 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  9. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR) 
    WARNING:

    Be sure to wear insulated gloves.

    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 9: Identifying n4 Hybrid Vehicle Converter (DC/DC Converter) Connector Terminal Identification
      GTY170932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance (Check for open)

      Tester Connection Specified Condition
      NODD (On1-6) - NODD (n4-2) Below 1 Ω

      Standard resistance (Check for short)

      Tester Connection Specified Condition
      NODD (On1-6) or NODD (n4-2) - Body ground 10 kΩ or more

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  10. CHECK HYBRID VEHICLE CONVERTER 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Disconnect the hybrid vehicle converter (DC/DC converter) connectors from the HV relay assembly. Refer to REMOVAL
    3. Measure the resistance according to the value(s) in the table below.
      Fig 10: Identifying W1, V1 And V3 Hybrid Vehicle Converter (DC/DC Converter) Connector Location
      GTY186747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      v1-1 (High voltage -) - v3-1 (High voltage +) 100 kΩ or more
      v3-1 (High voltage +) - w1-1 (High voltage precharge) 1 MΩ or more
      NOTE:
      • Do not use a megohmmeter.
      • Make sure that the tester probes are connected to the correct terminals.

    NG → See step   15 

    OK: Go to next step 

  11. CHECK HV RELAY ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
    2. Disconnect the high voltage connectors from the HV relay assembly. Refer to REMOVAL .
      Fig 11: Identifying h3,h4,t1 And s1 In HV Relay Assembly Component
      GTY178294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance according to the value(s) in the table below.
      Fig 12: Identifying HV Relay Assembly Circuit Diagram
      GTY192990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      h4-1 - h3-1 10 kΩ or more

    NG → See step   14 

    OK → See step   16 

  12. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR) 
    1. Disconnect the A61 hybrid vehicle control ECU connector.
      Fig 13: Identifying A61 Hybrid Vehicle Control System ECU And On1 Battery Pack Wire Connector Terminal Identification
      GTY192864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the power switch off.
    3. Measure the resistance according to the value(s) in the table below.

      Standard resistance (Check for open)

      Tester Connection Specified Condition
      NODD (A61-75) - NODD (On1-6) Below 1 Ω

      Standard resistance (Check for short)

      Tester Connection Specified Condition
      NODD (A61-75) or NODD (On1-6) - Body ground 10 kΩ or more

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   17 

  13. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  14. REPLACE HV RELAY ASSEMBLY. Refer to  REMOVAL 
  15. REPLACE HYBRID VEHICLE CONVERTER. Refer to  REMOVAL 
  16. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL 
  17. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
scientia non olet · About LEMON Manuals