DTC P3004-803: Power Cable Malfunction: Procedure

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
   P3004-803 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
   P0C76-523	Hybrid Battery System Discharge Time Too Long
   P2511-149	HV CPU Power Relay Sense Circuit Intermittent No Continuity
   P3004-131, 132	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.
   • P3004-803 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.
5. Turn the ignition switch off.

B → See step   7 

A: Go to next step 

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
   P3004-803 only is output.	A
   P0A95-123 is also output.	B

5. Turn the ignition switch off.

B → See step   10 

A: Go to next step 

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 and record the DTCs and freeze frame data.
5. Clear DTCs and freeze frame data.
6. Turn the ignition switch off.

NEXT: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the ignition switch to ON (READY).
3. Ensure the safety of the areas in front and at the back of the vehicle.
4. Move the shift lever to D and depress both the accelerator pedal and brake pedal at the same time.

   HINT: 

   • Depressing both the accelerator pedal and brake pedal at the same time causes the HV battery current to flow and ensures that there is no problem with the high-voltage wiring.
   • Depressing both the accelerator pedal and brake pedal at the same time causes "Accelerator & Brake Depress" in the inappropriate operation history data to be incremented.
5. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
6. Check if DTCs are output.

   Result

   Result	Proceed to
   P3004-803 is output, or no DTCs are output.	A
   Ignition switch is not turned to ON (READY) and P3004-131 is output.	B

7. Turn the ignition switch off.

B → See step   8 

A: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

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 connector z20 from the hybrid battery junction block assembly.

   HINT: 

   Before disconnecting the connector, check whether it is connected securely to the hybrid battery junction block assembly.

5. Measure the resistance according to the value(s) in the table below.
   Fig 1: Checking Harness And Connector (Hybrid Vehicle Control ECU - Hybrid Battery Junction Block)

   Courtesy 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
   D72-2 (SMRG) - z20-1 (SMRG)	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 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 → See step   9