P3004-803: Power Cable Malfunction

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P3004-803: Power Cable Malfunction
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 hybrid battery junction block 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 the 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 Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Check if DTCs are output.

Result:

HINT
P3004-803 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.

B -- GO TO DTC CHART Hybrid Battery System
A -- Continue to next step.

3. CLEAR DTC (HV)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(d) Read and record the DTCs and freeze frame data.

(e) Clear DTCs and freeze frame data.

(f) Turn the power switch off.

NEXT -- Continue to next step.

4. CHECK DTC OUTPUT (HV)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (READY).

(c) Ensure the safety of the areas in front and at the back of the vehicle.

(d) Move the shift lever to D and depress both the accelerator pedal and brake pedal at the same time.

HINT
- Depressing both the accelerator pedal and brake pedal at the same time causes the HV battery current to flow and makes it possible to confirm that there is no problem with the high-voltage wiring.
- Depressing both the accelerator pedal and brake pedal at the same time causes accelerator and brake depressing in the inappropriate operation and history data to be counted.
(e) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

(f) Check if DTCs are output.

Result:

(g) Turn the power switch off.

B -- GO TO DTC CHART (P3004-131) P3004
A -- Continue to next step.

5. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR) P0343

NG -- CONNECT SECURELY
OK -- Continue to next step.

6. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK)

CAUTION:
Be sure to wear insulated gloves.

(a) Check that the service plug grip is not installed.

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 A58 from the hybrid vehicle control ECU.

(c) Disconnect connector z16 from the hybrid battery junction block assembly.

HINT
Before disconnecting the connector, check whether it is connected securely to the hybrid battery junction block assembly.

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

Standard Resistance:

Text in Illustration

(e) Connect the hybrid battery junction block assembly connector.

(f) Connect the hybrid vehicle control ECU connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Components