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Home >> Toyota >> 2012 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 115 (Hybrid Vehicle Control System (Diagnostic Codes (P0ADB-227 - U0424-537) & Circuit Tests)) (Hybrid)) >> Hybrid Control System >> DTC P3004-131: Power Cable Malfunction >> Procedure

DTC P3004-131: 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 ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      P3004-131 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A1A-151, 155, 156, 658, 659 Generator Control Module
      P0A1B-164, 193, 512, 661, 786 Drive Motor "A" Control Module
      P0A1D-148 Hybrid Powertrain Control Module
      P0A78-266, 267, 586 Drive Motor "A" Inverter Performance
      P0A94-442 DC / DC Converter Performance
      P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low
      P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High
      P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low
      P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High
      P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low
      P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High
      P0C76-523 Hybrid Battery System Discharge Time Too Long
      P2511-149 HV CPU Power Relay Sense Circuit Intermittent No Continuity
      P3004-800, 801 High Voltage Power Resource
      P324E-788 MG-ECU Power Relay Intermittent Circuit
      U0110 (all INF codes)*1 Lost Communication with Drive Motor Control Module "A"

      HINT: 

      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
      • 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.
    5. Turn the ignition switch off.

    B → See step   14 

    A: Go to next step 

  2. CHECK DTC OUTPUT (HV) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      P3004-131 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0ABF-123 Hybrid Battery Pack Current Sensor Circuit
      P0AC0-123 Hybrid Battery Pack Current Sensor Circuit Range / Performance
      P0AC1-123 Hybrid Battery Pack Current Sensor Circuit Low
      P0AC2-123 Hybrid Battery Pack Current Sensor Circuit High
      P0AFC-123 Hybrid Battery Pack Sensor Module
      P0B3D-123 Hybrid Battery Voltage Sensor "A" Circuit Low
      P0B42-123 Hybrid Battery Voltage Sensor "B" Circuit Low
      P0B47-123 Hybrid Battery Voltage Sensor "C" Circuit Low
      P0B4C-123 Hybrid Battery Voltage Sensor "D" Circuit Low
      P0B51-123 Hybrid Battery Voltage Sensor "E" Circuit Low
      P0B56-123 Hybrid Battery Voltage Sensor "F" Circuit Low
      P0B5B-123 Hybrid Battery Voltage Sensor "G" Circuit Low
      P0B60-123 Hybrid Battery Voltage Sensor "H" Circuit Low
      P0B65-123 Hybrid Battery Voltage Sensor "I" Circuit Low
      P0B6A-123 Hybrid Battery Voltage Sensor "J" Circuit Low
      P0B6F-123 Hybrid Battery Voltage Sensor "K" Circuit Low
      P0B74-123 Hybrid Battery Voltage Sensor "L" Circuit Low
      P0B79-123 Hybrid Battery Voltage Sensor "M" Circuit Low
      P0B7E-123 Hybrid Battery Voltage Sensor "N" Circuit Low
      P0B83-123 Hybrid Battery Voltage Sensor "O" Circuit Low
      P0B88-123 Hybrid Battery Voltage Sensor "P" Circuit Low
      P0A95-123 High Voltage Fuse
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module

      HINT: 

      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.

    5. Turn the ignition switch off.

    B → See step   19 

    A: Go to next step 

  3. CHECK FREEZE FRAME DATA 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Read the freeze frame data of DTC P3004-131.

      Result

      Result Proceed to
      Both of the following conditions are met:
      • Post-boost voltage (VH-Voltage after Boosting) is below 50 V.
      • Difference between HV battery voltage (Power Resource VB) and pre-boost voltage (VL-Voltage before Boosting) is 40 V or less.
      		 A
      Other than above B
    5. Turn the ignition switch off.

    B → See step   4 

    A → See step   18 

  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 NO. 3 WIRE FRAME (INVERTER WITH CONVERTER ASSEMBLY SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter terminal cover from the inverter with converter assembly.
      Fig 1: Identifying Inverter Terminal Cover, Inverter With Converter Assembly & Fasteners
      GTY278201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the connection between the No. 3 wire frame j8 connector and the inverter with converter assembly.
      Fig 2: Identifying Connection Between The No. 3 Wire Frame J8 Connector And The Inverter With Converter Assembly
      GTY303635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

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

    4. Install the inverter terminal cover to the inverter with converter assembly.

    NG → CONNECT SECURELY 

    OK: Go to next step 

  6. CHECK NO. 3 WIRE FRAME (HV BATTERY JUNCTION BLOCK SIDE) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the battery cover sub-assembly. Refer to REMOVAL .
    3. Check the connection between the No. 3 wire frame j2 and j3 connectors, and the hybrid battery junction block assembly.
      Fig 3: Checking No. 3 Wire Frame (HV Battery Junction Block Side)
      GTY298859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    4. Check for arc marks on the terminals of the No. 3 wire frame.

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    5. Install the battery cover sub-assembly. Refer to INSTALLATION .

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  7. CHECK NO. 3 WIRE FRAME (INVERTER WITH CONVERTER - HYBRID BATTERY JUNCTION BLOCK) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the inverter terminal cover from the inverter with converter assembly.
      Fig 4: Identifying Inverter Terminal Cover, Inverter With Converter Assembly & Fasteners
      GTY278201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the battery cover sub-assembly. Refer to REMOVAL .
    4. Disconnect the No. 3 wire frame j8 connector from the inverter with converter assembly.
      Fig 5: Identifying No. 3 Wire Frame J8 Connector From The Inverter With Converter Assembly
      GTY307353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the resistance according to the value(s) in the table below.
      Fig 6: Identifying J2, J3, & J8 Wire Connectors
      GTY302313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      j2-1 - j8-2 (CBI) Ignition switch off Below 1 Ω
      j3-1 - j8-1 (CEI) Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 No. 3 Wire Frame (Inverter with Converter Assembly Side)
      *2 No. 3 Wire Frame (Hybrid Battery Junction Block Assembly Side)
      *a Red Mark
    6. Connect the No. 3 wire frame to the inverter with converter assembly.
    7. Install the battery cover sub-assembly. Refer to INSTALLATION .
    8. Install the inverter terminal cover to the inverter with converter assembly.

    NG → See step   17 

    OK: Go to next step 

  8. CHECK CONDITION OF MAIN BATTERY CABLE CONNECTION(S) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the battery cover sub-assembly. Refer to REMOVAL .
    3. Check the connections between the main battery cable connectors z30 and z31, and the hybrid battery junction block assembly.

      OK

      The connectors are connected securely and not damaged.

      Fig 7: Checking Condition Of Main Battery Cable Connection(s)
      GTY302383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check for arc marks on the terminals of the main battery cable connectors.

      Result

      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B
    5. Install the battery cover sub-assembly. Refer to INSTALLATION .

    B → REPLACE MALFUNCTIONING PARTS 

    C → CONNECT SECURELY 

    A: Go to next step 

  9. CHECK HV BATTERY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the battery cover sub-assembly. Refer to REMOVAL .
    3. Measure the voltage according to the value(s) in the table below.
      Fig 8: Identifying Z30 & Z31 Wire Connectors
      GTY306098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Switch Condition Specified Condition
      z30-1 - 2 Ignition switch off 160 to 266 V
      z20-1 - 1 Ignition switch off 80 to 133 V
      WARNING:

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

    4. Install the battery cover sub-assembly. Refer to INSTALLATION .

    NG → See step   16 

    OK: Go to next step 

  10. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Disconnect connector D72 from the hybrid vehicle control ECU.
    3. Remove the battery cover sub-assembly. Refer to REMOVAL .
    4. Disconnect the connector z20 that drives the relay of the hybrid battery junction block assembly.

      HINT: 

      Before disconnecting the connector z20 that drives the relay of the hybrid battery junction block assembly, make sure that the connector is securely engaged.

    5. Measure the resistance according to the value(s) in the table below.
      Fig 9: Checking Harness And Connector (Hybrid Vehicle Control ECU - Hybrid Battery Junction Block)
      GTY307243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      D72-4 (SMRB) - z20-4 (SMRB) Ignition switch off Below 1 Ω
      D72-3 (SMRP) - z20-3 (SMRP) Ignition switch off Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Hybrid Battery Junction Block Assembly
      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
    6. Connect the hybrid battery junction block assembly connector.
    7. Install the battery cover sub-assembly. Refer to INSTALLATION .
    8. Connect the hybrid vehicle control ECU connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  11. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the hybrid battery junction block assembly. Refer to REMOVAL .
    3. Measure the resistance according to the value(s) in the table below.
      Fig 10: Checking Hybrid Battery Junction Block Assembly (SMRB)
      GTY301111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      z30-1 - j2-1 Auxiliary battery voltage is applied between terminals 4 (SMRB) and 2 (GND). Below 1 Ω
      TEXT IN ILLUSTRATION

      *1 Hybrid Battery Junction Block Assembly
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      z20-4 (SMRB) - z20-2 (GND) -40 to 176°F (-40 to 80°C) 19.0 to 35.5 Ω
    5. Install the hybrid battery junction block assembly. Refer to INSTALLATION .

    NG → See step   15 

    OK: Go to next step 

  12. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Remove the hybrid battery junction block assembly. Refer to REMOVAL .
    3. Measure the resistance according to the value(s) in the table below.
      Fig 11: Checking Hybrid Battery Junction Block Assembly (SMRP)
      GTY304620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Condition Specified Condition
      z31-1 - j3-1 Auxiliary battery voltage is applied between terminals 3 (SMRP) and 2 (GND). 28.5 to 31.5 Ω
      TEXT IN ILLUSTRATION

      *1 Hybrid Battery Junction Block Assembly
    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      z20-3 (SMRP) - z20-2 (GND) -40 to 176°F (-40 to 80°C) 111 to 275 Ω
    5. Install the hybrid battery junction block assembly. Refer to INSTALLATION .

    NG → See step   15 

    OK: Go to next step 

  13. CHECK FOR INTERMITTENT PROBLEMS 
    1. Check for intermittent problems. Refer to CHECK FOR INTERMITTENT PROBLEMS .

      HINT: 

      • Since 2 trip detection logic is used, the DTC detection condition must be met twice.
      • If DTC P3004-131 is output again after performing the inspection, replace the hybrid vehicle converter. If DTC P3004-131 is not output again, replace the hybrid battery junction block assembly.

    NG → See step   18 

    OK → See step   15 

  14. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  15. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  REMOVAL 
  16. REPLACE HV BATTERY. Refer to  REMOVAL 
  17. REPLACE NO. 3 WIRE FRAME. Refer to  REMOVAL 
  18. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL 
  19. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
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