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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 P3004-803: Power Cable Malfunction >> Procedure

DTC P3004-803: 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. Relevant Part
      P0A95, P0AFA Open in electric vehicle fuse
      P0ADF-229, P0AE0-228 SMRG control line
      P0ADC-226, P0ADB-227 SMRB control line
      P0A1A-156, 658, 659, 151, 155, 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.
      • P3004-803 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   10 

    NO: Go to next step 

  2. 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 

  3. RECONFIRM DTC OUTPUT 
    1. Turn the power switch on (READY), move the shift lever to the D position, and depress both the accelerator pedal and brake pedal.

      HINT: 

      • Depressing both the accelerator pedal and brake pedal causes the HV battery current to flow and can be used to check that there is no problem with the high-voltage wiring.
      • Depressing both the accelerator pedal and brake pedal causes ACCEL AND BRK in the inappropriate operation and history data to be counted.
    2. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
    3. 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 → GO TO  INSPECTION PROCEDURE   INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P3004-131) 

    A: Go to next step 

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR) 
    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 A61 hybrid vehicle control ECU connector.
    3. Disconnect the On1 battery pack wire connector. Refer to REMOVAL .
      Fig 1: Identifying On1 Battery Pack Wire Connector Location
      GTY180714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      It takes time to disconnect the HV relay assembly and hybrid vehicle converter (DC/DC converter) connectors. 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 2: Identifying Battery Pack Wire Connector Terminal Identification
      GTY167812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      SMRB (A61-60) - CON2 (On1-3) Below 1 Ω
      SMRG (A61-96) - CON3 (On1-2) Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  7. CHECK CONNECTOR CONNECTION CONDITION (HV RELAY ASSEMBLY CONNECTOR) See step   11 

    NG → CONNECT SECURELY 

    OK: Go to next step 

  8. CHECK HARNESS AND CONNECTOR (HV RELAY ASSEMBLY - BATTERY PACK WIRE CONNECTOR) 
    1. Check that the service plug grip is not installed.
    2. Disconnect the n3 HV relay assembly connector.
      Fig 3: Identifying n3 HV Relay Assembly Connector Location
      GTY192883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      For the removal and installation procedures related to the HV relay assembly connector. Refer to REMOVAL .

    3. Measure the resistance according to the value(s) in the table below.
      Fig 4: Identifying Battery Pack Wire Connector Terminal Identification
      GTY172228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance

      Tester Connection Specified Condition
      CON2 (On1-3) - CON2 (n3-3) Below 1 Ω
      CON3 (On1-2) - CON3 (n3-1) Below 1 Ω

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   9 

  9. REPLACE HV RELAY ASSEMBLY. Refer to  REMOVAL 
  10. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
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