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Home >> Toyota >> 2017 >> Prius V Three >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Control System - (Diagnostic Codes (P0E32-585 - U0424-537) & Circuit Tests) >> Hybrid Control System >> DTC P3004-800: Power Cable Malfunction; DTC P3004-801: Power Cable Malfunction [08/2015 - ] >> Procedure

DTC P3004-800: Power Cable Malfunction; DTC P3004-801: Power Cable Malfunction [08/2015 - ]: Procedure

  1. CHECK DTC OUTPUT (HYBRID CONTROL) 
    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 → Refer to   13 

    C → Refer to   15 

    A: Go to next step 

  2. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR). Refer to  PROCEDURE - Step 3 

    NG → CONNECT SECURELY 

    OK: Go to next step 

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

    2. Remove the inverter cover from the inverter with converter assembly.
      GTY231954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 2 engine wire (air conditioning harness) E2 from the inverter with converter assembly.
      GTY328547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      GTY225739Courtesy 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 → Refer to   7 

    OK: Go to next step 

  4. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE POWER MANAGEMENT CONTROL ECU) 
    1. Disconnect connector A59 from the inverter with converter assembly.
    2. Measure the resistance according to the value(s) in the table below.
      GTY337747Courtesy 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 → Refer to   6 

    OK: Go to next step 

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

    2. Remove the inverter cover from the inverter with converter assembly.
      GTY231954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the frame wire (high voltage DC connector) T1 from the inverter with converter assembly.
      GTY339794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL [08/2015 - ] - Step 19 .
    5. Measure the resistance according to the value(s) in the table below.
      GTY329060Courtesy 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 → Refer to   8 

    OK → Refer to   11 

  6. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER 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 power switch on (READY), unless instructed by the repair service 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.
      GTY327526Courtesy 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 → Refer to   14 

  7. CHECK NO. 2 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 power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.

    2. Remove the inverter cover from the inverter with converter assembly.
      GTY231954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 2 engine wire (air conditioning harness) E2 from the inverter with converter assembly.
      GTY328547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the No. 2 engine wire (air conditioning harness) E1 from the compressor with motor assembly.
      GTY340321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Green Lock
    5. Measure the resistance according to the value(s) in the table below.
      GTY225739Courtesy 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 → Refer to   10 

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

    2. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL [08/2015 - ] - Step 19 .
    3. Disconnect the frame wire T3 and T4 from the hybrid battery junction block assembly.
      GTY329060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the resistance according to the value(s) in the table below.
      GTY336809Courtesy 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 → Refer to   12 

    OK → Refer to   9 

  9. REPLACE FRAME WIRE. Refer to  COMPONENTS [08/2015 - ] 
  10. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY. Refer to  COMPONENTS [08/2015 - ] 
  11. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS. Refer to  DTC CHECK / CLEAR [08/2015 - ] 
  12. REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY. Refer to  COMPONENTS [08/2015 - ] 
  13. GO TO DTC CHART (HYBRID CONTROL SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2015 - ] 
  14. REPLACE POWER MANAGEMENT CONTROL ECU. Refer to  COMPONENTS [08/2015 - ] 
  15. GO TO DTC CHART (HYBRID BATTERY SYSTEM). Refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2015 - ] 
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