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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 P3004-800: 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 ignition switch to ON.
    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
    4. Check if DTCs are output.

      Result

      Result Proceed to
      P3004-800 or P3004-801 only is output. A
      Any of the following DTCs are also output. B
      DTC No. Relevant Diagnosis
      P0A09-265 DC/DC Converter Status Circuit Low Input
      P0A10-263 DC/DC Converter Status Circuit High Input

      HINT: 

      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.

    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
      P3004-800 or P3004-801 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
      P308A-123 Hybrid Battery Voltage Sensor All Circuits Low
      U029A-123 Lost Communication with Hybrid Battery Pack Sensor Module

      HINT: 

      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.

    5. Turn the ignition switch off.

    B → See step   15 

    A: Go to next step 

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

    NG → CONNECT SECURELY 

    OK: Go to next step 

  4. CHECK COMPRESSOR WITH MOTOR ASSEMBLY 
    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. Disconnect the No. 4 engine wire (air conditioning harness) i3 connector from the inverter with converter assembly.
      Fig 2: Identifying I3 Connector And Converter Assembly
      GTY295585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      Fig 3: Identifying I3 Air Conditioning Harness
      GTY297331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      i3-1 (ACPB) - i3-2 (ACPE) Ignition switch off 100 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 No. 4 Engine Wire
      (Air Conditioning Harness)
      *a Shielded Wire Ground
      NOTE:
      • Do not use a megohmmeter.
      • Read the resistance after the value has stabilized.

      HINT: 

      The polarities of the tester probes may differ depending on the tester. Use the current output probe of the tester as the positive probe for this measurement. To determine the polarity, use another voltmeter to confirm the current output probe of the tester. When measuring the output of the tester, the voltmeter positive probe indicates the tester current output probe.

    5. Connect the No. 4 engine wire (air conditioning harness) from the inverter with converter assembly.
    6. Install the inverter terminal cover to the inverter with converter assembly.

    NG → See step   10 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE HYBRID VEHICLE CONTROL ECU) 
    1. Disconnect connector A64 from the inverter with converter assembly.
    2. Measure the resistance according to the value(s) in the table below.
      Fig 4: Checking Harness And Connector (Resistance Value Of NODD Inside Hybrid Vehicle Control ECU)
      GTY296652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      A64-24 (NODD) - Body ground Ignition switch off 120 to 140 kΩ
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Inverter with Converter Assembly)
    3. Connect the inverter with converter assembly connector.

    NG → See step   8 

    OK: Go to next step 

  6. CHECK NO. 3 WIRE FRAME 
    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 5: Identifying Inverter Terminal Cover, Inverter With Converter Assembly & Fasteners
      GTY278201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 3 wire frame j8 connector (high-voltage DC connector) from the inverter with converter assembly.
      Fig 6: Identifying Battery Cover Sub Assembly & Fasteners
      GTY301406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the battery cover sub-assembly. Refer to REMOVAL .
    5. Measure the resistance according to the value(s) in the table below.
      Fig 7: Identifying J2, J3 Wires & Battery Cover Sub Assembly
      GTY301480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      j3-1 - j2-1 Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 No. 3 Wire Frame
      *a Red Mark
    6. Connect the hybrid battery junction block assembly connector.
    7. Install the battery cover sub-assembly. Refer to INSTALLATION .
    8. Connect the No. 3 wire frame (high-voltage DC connector) to the inverter with converter assembly.
    9. Install the inverter terminal cover to the inverter with converter assembly.

    NG → See step   12 

    OK → See step   7 

  7. REPLACE INVERTER WITH CONVERTER ASSEMBLY. Refer to  REMOVAL 
  8. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER) 
    1. Disconnect connector A64 from the inverter with converter assembly.
    2. Disconnect connector A65 from hybrid vehicle control ECU.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 8: Checking Harness And Connector (Hybrid Vehicle Control ECU - Inverter With Converter)
      GTY300197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance (Check for Open)

      Tester Connection Switch Condition Specified Condition
      A65-21 (NODD) - A64-24 (NODD) Ignition switch off Below 1 Ω

      Standard Resistance (Check for Short)

      Tester Connection Switch Condition Specified Condition
      A65-21 (NODD) or A64-24 (NODD) - Body ground and other terminals Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Rear view of wire harness connector
      (to Hybrid Vehicle Control ECU)
      *b Front view of wire harness connector
      (to Inverter with Converter Assembly)
    4. Connect the hybrid vehicle control ECU connector.
    5. Connect the inverter with converter assembly connector.

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → See step   9 

  9. REPLACE HYBRID VEHICLE CONTROL ECU. Refer to  REMOVAL 
  10. CHECK NO. 4 ENGINE WIRE 
    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 9: Identifying Inverter Terminal Cover, Inverter With Converter Assembly & Fasteners
      GTY278201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 4 engine wire (air conditioning harness) i3 connector from the inverter with converter assembly.
      Fig 10: Identifying I3 Connector And Converter Assembly
      GTY295585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the No. 4 engine wire (air conditioning harness) i1 connector from the compressor with motor assembly.
      Fig 11: Identifying I1 Connector & Compressor Motor Assembly
      GTY305720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Green Lock
    5. Measure the resistance according to the value(s) in the table below.
      Fig 12: Identifying I3 Air Conditioning Harness
      GTY297331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      i3-1 (ACPB) - i3-2 (ACPE) Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 No. 4 Engine Wire
      (Air Conditioning Harness)
      *a Shielded Wire Ground
    6. Connect the No. 4 engine wire (air conditioning harness) to the compressor with motor assembly.
    7. Connect the No. 4 engine wire (air conditioning harness) to the inverter with converter assembly.
    8. Install the inverter terminal cover to the inverter with converter assembly.

    NG → REPLACE NO. 4 ENGINE WIRE 

    OK → See step   11 

  11. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY. Refer to  REMOVAL 
  12. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 
    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. Disconnect the No. 3 wire frame j2 and j3 connectors from the hybrid battery junction block assembly.
      Fig 13: Checking No. 3 Wire Frame (HV Battery Junction Block Side)
      GTY298859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      Fig 14: Identifying J3, J2 Connectors & The Hybrid Battery Junction Block Assembly
      GTY295909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance

      Tester Connection Switch Condition Specified Condition
      j2-1 - j3-1 Ignition switch off 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *1 Hybrid Battery Junction Block Assembly
    5. Connect the No. 3 wire frame to the hybrid battery junction block assembly.
    6. Connect the hybrid battery junction block assembly connector.
    7. Install the battery cover sub-assembly. Refer to INSTALLATION .

    NG → See step   16 

    OK → See step   13 

  13. REPLACE NO. 3 WIRE FRAME. Refer to  REMOVAL 
  14. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  15. GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART 
  16. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  REMOVAL 
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