DTC P3004-131: Power Cable Malfunction: Procedure

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
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
   DTCs shown in Table 1 are output simultaneously.	B
   DTCs shown in Table 2 are output simultaneously.	C

   TABLE 1
   
   

   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	ECM/PCM Power Relay Sensor Circuit Intermittent
   P3004-800, 801	Power Cable Malfunction
   P324E-788	MG-ECU Power Relay Intermittent Circuit
   U0110 (all INF codes)*1	Lost Communication with Drive Motor Control Module "A"

   TABLE 2
   
   

   DTC No.	Relevant Diagnosis
   P0A95-123	High Voltage Fuse
   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 "A" Circuit Low
   P0AC2-123	Hybrid Battery Pack Current Sensor "A" 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
   P308A-123	Hybrid Battery Voltage Sensor All Circuits Low
   U029A-123	Lost Communication with Hybrid Battery Pack Sensor Module

   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 power switch off.

B → See step   13 

C → See step   18 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
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: "VH-Voltage after Boosting" is below 50 V. Difference between "Power Resource VB" and "VL-Voltage before Boosting" is 50 V or less.	A
   Other than above	B

5. Turn the power switch off.

B → See step   3 

A → See step   17 

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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the inverter cover from the inverter with converter assembly.
   Fig 1: Identifying Inverter Cover & Fasteners

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the connection between the frame wire T1 and the inverter with converter assembly.
   Fig 2: Identifying Frame Wire T1 & Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specified Condition

   Bolt A 

   8.0 N*m (82 kgf*cm, 71 in.*lbf)

   Bolt B 

   9.2 N*m (94 kgf*cm, 81 ft.*lbf)

   Check for arc marks on the terminals of the frame wire.

   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

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

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL - Step 19 .
3. Check the connection between the frame wire T4, T3 and the hybrid battery junction block assembly.
   Fig 3: Checking Frame Wires (Hybrid Battery Junction Block Assembly Side)

   Courtesy 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 frame wire.

   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 upper hybrid battery cover sub-assembly.

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the inverter cover from the inverter with converter assembly.
   Fig 4: Identifying Inverter Cover & Fasteners

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the frame wire T1 from the inverter with converter assembly.
   Fig 5: Identifying Frame Wire T1 & Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL - Step 19 .
5. Measure the resistance according to the value(s) in the table below.
   Fig 6: Checking Resistance Of Frame Wire T1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   T4-1 (CBI) - T1-2 (CBI)	Power switch off	Below 1 Ω
   T3-1 (CEI) - T1-1 (CEI)	Power switch off	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Frame Wire (Hybrid Battery Junction Block Assembly Side)
   *a	Front view of Frame Wire connector (to Inverter with Converter Assembly)

6. Install the upper hybrid battery cover sub-assembly.
7. Connect the frame wire from the inverter with converter assembly.
8. Install the inverter cover to the inverter with converter assembly.

NG → See step   16 

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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL - Step 19 .
3. Check the connections between the HV battery high voltage connectors (h2, k2) and the hybrid battery junction block assembly.

   OK

   The connectors are connected securely and not damaged.

   Fig 7: Identifying Hybrid Battery Junction Block Assembly & High Voltage Cables H2 & K2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check for arc marks on the terminals of the HV battery high voltage 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 upper hybrid battery cover sub-assembly.

B → REPLACE MALFUNCTIONING PARTS 

C → CONNECT SECURELY 

A: 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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL - Step 19 .
3. Measure the voltage according to the value(s) in the table below.
   Fig 8: Checking HV Battery Voltage

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   h2-1 (+) - 2	Power switch off	114 to 190 V
   k2-1 (-) - 1	Power switch off	54 to 90 V

   WARNING:

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

4. Install the upper hybrid battery cover sub-assembly.

NG → See step   15 

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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Disconnect connector L5 from the power management control ECU.
3. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL - Step 19 .
4. Disconnect the connector c3 that drives the system main relay of the hybrid battery junction block assembly.

   HINT: 

   Before disconnecting the connector c3 that drives the system main 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 (Power Management Control ECU - Hybrid Battery Junction Block)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   L5-4 (SMRB) - c3-4 (SMRB)	Power switch off	Below 1 Ω
   L5-3 (SMRP) - c3-3 (SMRP)	Power switch off	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Rear view of wire harness connector (to Power Management Control ECU)
   *b	Rear view of wire harness connector (to Hybrid Battery Junction Block Assembly)

6. Connect the hybrid battery junction block assembly connector.
7. Install the upper hybrid battery cover sub-assembly.
8. Connect the power management control ECU connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the hybrid battery junction block assembly. Refer to COMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 10: Checking Hybrid Battery Junction Block Assembly (SMRB)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   h2-1 (+) - T4-1 (CBI)	Auxiliary battery voltage is applied between terminals c3-4 (SMRB) and c3-2 (GND)	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Component without harness connected (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
   c3-4 (SMRB) - c3-2 (GND)	-40 to 80 °C (-40 to 176°F)	19.0 to 35.5 Ω

5. Install the hybrid battery junction block assembly.

NG → See step   14 

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 power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Remove the hybrid battery junction block assembly. Refer to COMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 11: Checking Hybrid Battery Junction Block Assembly (SMRP)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   k2-1 (-) - T3-1 (CEI)	Auxiliary battery voltage is applied between terminals c3-3 (SMRP) and c3-2 (GND)	28.5 to 31.5 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Component without harness connected (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
   c3-3 (SMRP) - c3-2 (GND)	-40 to 80 °C (-40 to 176°F)	112 to 274 Ω

5. Install the hybrid battery junction block assembly.

NG → See step   14 

OK: Go to next step 

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   17 

OK → See step   14