DTC P3004-800: Power Cable Malfunction; DTC P3004-801: 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
   P3004-800 or P3004-801 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
   P0A09-265	DC/DC Converter Status Circuit Low Input
   P0A10-263	DC/DC Converter Status Circuit High Input

   TABLE 2
   
   

   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
   P308A-123	Hybrid Battery Voltage Detection Circuit Open
   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 power switch off.

B → See step   9 

C → See step   15 

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 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. Disconnect the No. 2 engine wire (air conditioning harness) E2 from the inverter with converter assembly.
   Fig 2: Identifying No. 2 Engine Wire (Air Conditioning Harness) E2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Measure the resistance according to the value(s) in the table below.
   Fig 3: Measuring Resistance Of No. 2 Engine Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection (Tester Probe Polarity)	Switch Condition	Specified Condition
   E2-1 (ACPB) - E2-2 (ACPE)	Power switch off	100 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shielded Wire Ground
   *a	Front view of No. 2 Engine Wire (Air Conditioning Harness) connector (to Inverter with Converter Assembly)

   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. 2 engine wire (air conditioning harness) from the inverter with converter assembly.
6. Install the inverter cover to the inverter with converter assembly.

NG → See step   7 

OK: Go to next step 

1. Disconnect connector A59 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 Power Management Control ECU)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   A59-12 (NODD) - Body ground	Power 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   6 

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 5: Identifying Inverter Cover & Fasteners

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the frame wire (high voltage DC connector) T1 from the inverter with converter assembly.
   Fig 6: 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 7: Identifying Frame Wires T3 & T4

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   T3-1 (CEI) - T4-1 (CBI)	Power switch off	10 kΩ or higher

6. Connect the frame wire (high voltage DC connector) to inverter with converter assembly.
7. Install the inverter cover to the inverter with converter assembly.

NG → See step   8 

OK → See step   10 

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 A59 from the inverter with converter assembly.
3. Disconnect connector A21 from power management control ECU.
4. Measure the resistance according to the value(s) in the table below.
   Fig 8: Checking Harness And Connector (Power Management Control ECU - Inverter With Converter)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance (Check for Open)

   Tester Connection	Switch Condition	Specified Condition
   A21-21 (NODD) - A59-12 (NODD)	Power switch off	Below 1 Ω

   Standard Resistance (Check for Short)

   Tester Connection	Switch Condition	Specified Condition
   A21-21 (NODD) or A59-12 (NODD) - Body ground and other terminals	Power switch off	10 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *a	Rear view of wire harness connector (to Power Management Control ECU)
   *b	Front view of wire harness connector (to Inverter with Converter Assembly)

5. Connect the power management control ECU connector.
6. Connect the inverter with converter assembly connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   11 

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 9: Identifying Inverter Cover & Fasteners

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the No. 2 engine wire (air conditioning harness) E2 from the inverter with converter assembly.
   Fig 10: Identifying No. 2 Engine Wire (Air Conditioning Harness) E2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disconnect the No. 2 engine wire (air conditioning harness) E1 from the compressor with motor assembly.
   Fig 11: Checking No. 2 Engine Wire E1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Green Lock

5. Measure the resistance according to the value(s) in the table below.
   Fig 12: Measuring Resistance Of No. 2 Engine Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   E2-1 (ACPB) - E2-2 (ACPE)	Power switch off	10 kΩ or higher

   TEXT IN ILLUSTRATION
   
   

   *1	Shielded Wire Ground
   *a	Front view of No. 2 Engine Wire (Air Conditioning Harness) connector (to Inverter with Converter Assembly)

6. Connect the No. 2 engine wire (air conditioning harness) to the compressor with motor assembly.
7. Connect the No. 2 engine wire (air conditioning harness) to the inverter with converter assembly.
8. Install the inverter cover to the inverter with converter assembly.

NG → REPLACE NO. 2 ENGINE WIRE 

OK → See step   12 

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. Disconnect the frame wire T3 and T4 from the hybrid battery junction block assembly.
   Fig 13: Identifying Frame Wires T3 & T4

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Measure the resistance according to the value(s) in the table below.
   Fig 14: Measuring Resistance Of Frame Wire Terminals On The Hybrid Battery Junction Block Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   T3-1 (CEI) - T4-1 (CBI)	Power switch off	10 kΩ or higher

5. Connect the frame wire to the hybrid battery junction block assembly.
6. Install the upper hybrid battery cover sub-assembly.

NG → See step   14 

OK → See step   13