P3004-132

P310 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P3004-131: Power Cable Malfunction

DTC P3004-131 - Power Cable Malfunction

DTC P3004-132 - Power Cable Malfunction

DESCRIPTION

The hybrid vehicle control ECU monitors the high-voltage wiring between the HV battery and inverter with converter assembly and detects the following malfunction.

WIRING DIAGRAM

INSPECTION PROCEDURE
CAUTION:
- Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
- After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. After waiting for 5 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.
HINT: Waiting for at least 5 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CHECK DTC OUTPUT (HV)
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
(d) Check if DTCs are output.
Result:

B -- GO TO DTC CHART Diagnostic Trouble Code Descriptions
A -- Continue to next step.
2. INSPECT HV RELAY ASSEMBLY (SMR1 AND SYSTEM MAIN RESISTOR)
CAUTION: Be sure to wear insulated gloves.
(a) Turn the power switch off.

(b) Remove the service plug grip Removal.
NOTE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
(c) Remove the HV relay assembly from the vehicle Removal.
(d) Measure the resistance according to the value(s) in the table below.
Standard resistance:

(e) Measure the resistance according to the value(s) in the table below.
Standard resistance:

NG -- REPLACE HV RELAY ASSEMBLY
OK -- Continue to next step.
3. INSPECT HV RELAY ASSEMBLY (SMR3)
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.
(b) Remove the HV relay assembly from the vehicle Removal.

(d) Measure the resistance according to the value(s) in the table below.
Standard resistance:

NG -- REPLACE HV RELAY ASSEMBLY
OK -- Continue to next step.
4. INSPECT NO. 2 MAIN BATTERY CABLE (NEGATIVE SIDE)
CAUTION: Be sure to wear insulated gloves and protective goggles.
(a) Measure the resistance according to the value(s) in the table below.

Standard resistance:

NG -- REPLACE NO. 2 MAIN BATTERY CABLE
OK -- Continue to next step.
5. INSPECT NO. 2 MAIN BATTERY CABLE (NEGATIVE SIDE), HV RELAY ASSEMBLY AND HV BATTERY
CAUTION: Be sure to wear insulated gloves and protective goggles.
HINT: Check the connections with the No. 2 main battery cable (negative side) connected.
(a) Check that the nut that tightens the No. 2 main battery cable (negative side) is properly engaged with the connector on the HV battery terminal (RH side).

OK:
The nut is securely tightened and there are no contact problems.
NOTICE:
- The nut that tightens the No. 2 main battery cable is not reusable.
- Do not overtighten this nut.
(b) Check if the No. 2 main battery cable (negative side) is properly engaged with the connector on the HV relay assembly side.
OK:
The connector is connected securely and there are no contact problems.
NG -- REPLACE NO. 2 MAIN BATTERY CABLE, HV RELAY ASSEMBLY OR HV BATTERY
OK -- Continue to next step.
6. INSPECT HV BATTERY
CAUTION: Be sure to wear insulated gloves and protective goggles.
(a) Measure the voltage according to the value(s) in the table below.

Standard voltage:

NOTE: Connect the tester correctly.

NG -- REPLACE HV BATTERY
OK -- Continue to next step.
7. INSPECT HV BATTERY AND HV RELAY ASSEMBLY
CAUTION: Be sure to wear insulated gloves and protective goggles.
HINT: Check the connections with the HV battery CTR cable.
(a) Check if the cable on the HV relay assembly side connector in the HV battery CTR is properly engaged.

OK:
The connector is connected securely and there are no contact problems.
(b) Check that the nut that tightens the HV battery CTR cable on the HV battery LH side is not loose.
OK:
The nut is securely tightened and there are no contact problems.
NOTICE:
- The nut that tightens the No. 2 main battery cable is not reusable.
- Do not overtighten this nut.

NG -- REPLACE HV BATTERY OR HV RELAY ASSEMBLY
OK -- Continue to next step.
8. INSPECT NO. 3 FRAME WIRE
CAUTION: Be sure to wear insulated gloves and protective goggles.
(a) Check that the service plug grip is not installed.
(b) Remove the inverter cover Removal.
NOTICE:
- Wrap the round interlock terminal for the inverter cover with insulating tape to prevent it from shorting to ground.
- Be sure to prevent coolant in the inverter reserve tank from entering the inverter.
- Removing the inverter cover causes the MG ECU board to be exposed. Therefore, temporarily install the inverter cover for each area to be inspected.

(d) Disconnect the No. 3 frame wire (DC cable for the inverter with converter assembly) from the HV relay assembly.

(e) Measure the resistance according to the value(s) in the table below.
Standard resistance:

NG -- REPLACE NO. 3 FRAME WIRE
OK -- Continue to next step.
9. INSPECT INVERTER WITH CONVERTER ASSEMBLY (VH VOLTAGE)
CAUTION: Be sure to wear insulated gloves.
(a) Turn the power switch on (IG).
HINT: Turning the power switch on (IG) with the service grip and inverter cover removed causes interlock switch system DTC (P0A0D-350) to be set.

(b) Measure the voltage according to the value(s) in the table below.
Standard voltage:

NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
OK -- Continue to next step.
10. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

(a) Check the connections of all hybrid vehicle control ECU connectors.
OK:
The connectors are connected securely and there are no contact problems.
NG -- CONNECT SECURELY
OK -- Continue to next step.
11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HV RELAY ASSEMBLY)
CAUTION: Be sure to wear insulated gloves and protective goggles.
(a) Check that the service plug grip is not installed.
(b) Disconnect the D36 connector from the hybrid vehicle control ECU.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
12. CHECK FOR INTERMITTENT PROBLEMS
(a) Check for intermittent problems Check For Intermittent Problems.
NEXT -- Continue to next step.
13. CHECK DTC OUTPUT (HV)
(a) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
(b) Check if DTCs are output.
Result:

HINT: After the check, if DTCs P3004-131 and 132 are output again, replace the hybrid vehicle control ECU. If they are not output, replace the HV relay assembly.

B -- REPLACE HYBRID VEHICLE CONTROL ECU
A -- REPLACE HV RELAY ASSEMBLY