P3004-801

L110F HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P3004-800: Power Cable Malfunction

DTC P3004-800 - Power Cable Malfunction

DTC P3004-801 - Power Cable Malfunction

DESCRIPTION

The SMRs (System Main Relays) are the relays that connect or disconnect the high voltage power system in accordance with commands from the hybrid vehicle control ECU.
The SMR system is composed of three SMRs and one system main resistor. SMRB and SMRG are located on the HV battery junction block in the HV battery pack. SMRP and the system main resistor are located in the hybrid vehicle converter (DC/DC converter) assembly in the HV battery pack.
To connect to the high voltage power system, the vehicle will first turn on SMRP and SMRB to charge the vehicle through the system main resistor. Then, SMRP will be turned off after SMRG is turned on. To shut off the high voltage power system, SMRB and SMRG are turned off.
When there is an open in the AMD line or IGCT line, the following DTCs are output:

P0AE6-225 is output first because the time required for diagnosis is the shortest.

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 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 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 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CHECK DTC OUTPUT (HV)
(a) Connect the intelligent tester or Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Select the following menu items:
(1) Intelligent tester - Select: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES.
(2) Techstream - Select: Powertrain / Hybrid Control / Trouble Codes.
(d) Check if DTCs are output.
Result:

HINT:
- *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic flowchart.
- P0343-747 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output.

B -- GO TO DTC CHART
A -- Continue to next step.
2. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

(a) Check the connections of the 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.
3. CHECK WITH MOTOR COMPRESSOR ASSEMBLY
CAUTION: Be sure to wear insulated gloves.
(a) Turn the power switch off.
(b) Remove the service plug grip. L110F Hybrid Vehicle Control System

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.

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

- 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.

NG -- CHECK AIR CONDITIONING HARNESS ASSEMBLY
OK -- Continue to next step.
4. CHECK FRAME WIRE
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.

(b) Remove the connector cover from the inverter with converter assembly.

(d) Disconnect the frame wire from the HV battery junction block.

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

NG -- REPLACE FRAME WIRE
OK -- Continue to next step.
5. CHECK HARNESS AND CONNECTOR (RESISTANCE VALUE OF NODD INSIDE HYBRID VEHICLE CONTROL ECU)
(a) Turn the power switch off.

(b) Disconnect the battery pack wire connector. Components

NG -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)
OK -- Continue to next step.
6. CHECK HARNESS AND CONNECTOR (BATTERY PACK WIRE CONNECTOR - HYBRID VEHICLE CONVERTER)
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.

(b) Disconnect the low voltage connector from the hybrid vehicle converter.
HINT: For the removal and installation procedures related to the low voltage connector of the hybrid vehicle converter, Components.

Standard resistance (Check for short):

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
7. CHECK HYBRID VEHICLE CONVERTER
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.

(b) Disconnect the 3 high voltage connectors of the hybrid vehicle converter from the HV battery junction block.

- 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.

NG -- REPLACE HYBRID VEHICLE CONVERTER
OK -- Continue to next step.
8. CHECK HV BATTERY TERMINAL BLOCK
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.

(b) Disconnect the high voltage connectors from the HV battery junction block.

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

NG -- CHECK HV BATTERY JUNCTION BLOCK
OK -- Continue to next step.
9. CHECK POWER STEERING CONVERTER WIRE (HV BATTERY JUNCTION BLOCK - POWER STEERING CONVERTER)
CAUTION: Be sure to wear insulated gloves.

(a) Disconnect the frame wire No. 3 (connector for the HV battery) from the power steering converter.

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

NG -- REPLACE POWER STEERING CONVERTER WIRE
OK -- Continue to next step.
10. CHECK POWER STEERING CONVERTER
CAUTION: Be sure to wear insulated gloves.

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

- 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.

NG -- REPLACE POWER STEERING CONVERTER
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)

(a) Disconnect connector A74 from the hybrid vehicle control ECU.
(b) Turn the power switch off.
(c) Measure the resistance according to the value(s) in the table below.
Standard resistance (Check for open):

Standard resistance (Check for short):

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE HYBRID VEHICLE CONTROL ECU
12. CHECK AIR CONDITIONING HARNESS ASSEMBLY
CAUTION: Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.
(b) Disconnect the air conditioning harness assembly from the with motor compressor assembly.

NG -- REPLACE AIR CONDITIONING HARNESS ASSEMBLY
OK -- REPLACE WITH MOTOR COMPRESSOR ASSEMBLY
13. CHECK HV BATTERY JUNCTION BLOCK
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.

(b) Remove the HV battery terminal block.
(c) Disconnect the connector for the power steering converter from the HV battery junction block.

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

NG -- REPLACE HV BATTERY JUNCTION BLOCK
OK -- REPLACE HV BATTERY TERMINAL BLOCK