P3004-803

L110 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P3004-803: Power Cable Malfunction

DTC P3004-803 - Power Cable Malfunction

DESCRIPTION

The SMRs (System Main Relay) 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 relay assembly in the battery carrier under the HV battery. SMRP and the system main resistor are located in the hybrid vehicle converter (DC/DC converter) assembly in the battery carrier.
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:

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, check the voltage at 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 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:

YES -- GO TO DTC CHART
NO -- Continue to next step.
2. CLEAR DTC (HV)
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Read and record the DTCs and freeze frame data.
(d) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
(e) Clear the DTCs.
NEXT -- Continue to next step.
3. RECONFIRM DTC OUTPUT (HV)
(a) Turn the power switch on (READY), move the shift lever to the D position, and depress both the accelerator pedal and brake pedal.
HINT:
- Depressing both the accelerator pedal and brake pedal causes the HV battery current to flow and can be used to check that there is no problem with the high-voltage wiring.
- Depressing both the Accelerator pedal and brake pedal causes accelerator and brake depressing in the inappropriate operation and history data to be counted.
(b) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
(c) Check if DTCs are output.
Result:

B -- GO TO INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC (P3004-131)
A -- Continue to next step.
4. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)

(a) Check the connections of the hybrid vehicle control ECU connectors.
Result:
The connectors are connected securely and there are no contact problems.
NG -- CONNECT SECURELY
OK -- Continue to next step.
5. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)
CAUTION:
Be sure to wear insulated gloves.
(a) Turn the power switch off and remove the service plug grip. L110 Hybrid Vehicle Control System
NOTICE:
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.
(b) Disconnect connector A54 from the hybrid vehicle control ECU.

(c) Disconnect the battery pack wire connector Components.
HINT: Due to the time required to disconnect the HV relay assembly and hybrid vehicle converter connectors, the battery pack wire resistance check should be performed before these connectors are disconnected.

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

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
6. CHECK HARNESS AND CONNECTOR (HV RELAY ASSEMBLY - BATTERY PACK WIRE CONNECTOR)
CAUTION:
Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.

(b) Disconnect connector N6 from the HV relay assembly Components.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE HV RELAY ASSEMBLY