P3004-131

P112 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P3004-131: Power Cable Malfunction

DTC P3004-131 - Power Cable Malfunction

DESCRIPTION





WIRING DIAGRAM





INSPECTION PROCEDURE

CAUTION:
- Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing 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.

HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter.

PROCEDURE

1. READ OUTPUT DTC (HV BATTERY)
(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:
DTC P0A95 is output
YES -- GO TO DTC P0A95
NO -- Continue to next step.
2. INSPECT SYSTEM MAIN RESISTOR

CAUTION: Wear insulated gloves before performing the following operation.





(a) Remove the system main resistor (Removal).
(b) Measure the resistance between the terminals.
Standard resistance:
18 to 22 Ohms
(c) Reinstall the system main resistor (Installation).
NG -- REPLACE SYSTEM MAIN RESISTOR
OK -- Continue to next step.
3. INSPECT NO. 1 SYSTEM MAIN RELAY
(a) Inspect the No. 1 system main relay (System Main Relay).
NG -- REPLACE NO. 1 SYSTEM MAIN RELAY
OK -- Continue to next step.
4. INSPECT NO. 2 SYSTEM MAIN RELAY
(a) Inspect the No. 2 system main relay (System Main Relay).
NG -- REPLACE NO. 2 SYSTEM MAIN RELAY
OK -- Continue to next step.
5. INSPECT NO. 3 SYSTEM MAIN RELAY
(a) Inspect the No. 3 system main relay (System Main Relay).
NG -- REPLACE NO. 3 SYSTEM MAIN RELAY
OK -- Continue to next step.
6. INSPECT MAIN BATTERY CABLE

CAUTION: Wear insulated gloves and goggles before performing the following operation.





(a) Remove the HV battery assembly (Removal).
(b) Remove the main battery cable (Removal).
(c) Measure the resistance between the terminals of the main battery cable.
Standard resistance:
Below 1 Ohms
NG -- REPLACE MAIN BATTERY CABLE
OK -- Continue to next step.
7. INSPECT MAIN BATTERY CABLE

CAUTION: Wear insulated gloves and goggles before performing the following operation.

(a) Check the cover and terminals of the main battery cable for any abnormality.
OK:
No abnormality is found on the cover and terminals.
(b) Check the terminals of the HV battery and the system main relay, which are to be connected to the main cable, for any abnormality.
OK:
No abnormality is found on the terminals of the HV battery and system main relay.
NG -- REPLACE MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY
OK -- Continue to next step.
8. INSPECT NO. 2 MAIN BATTERY CABLE

CAUTION: Wear insulated gloves and goggles before performing the following operation.





(a) Remove the No. 2 main battery cable with the HV battery assembly removed (Removal).
(b) Measure the resistance between the terminals of the No. 2 main battery cable.
Standard resistance:
Below 1 Ohms
NG -- REPLACE NO. 2 MAIN BATTERY CABLE
OK -- Continue to next step.
9. INSPECT NO. 2 MAIN BATTERY CABLE

CAUTION: Wear insulated gloves and goggles before performing the following operation.

(a) Check the cover and terminals of the No. 2 main battery cable for any abnormality.
OK:
No abnormality is found on the cover and terminals.
(b) Check the terminals of the HV battery and the system main relay, which are to be connected to the No. 2 main battery cable, for any abnormality.
OK:
No abnormality is found on the terminals of the HV battery and system main relay.
NG -- REPLACE NO. 2 MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY
OK -- Continue to next step.
10. INSPECT FRAME WIRE

CAUTION: Wear insulated gloves before performing the following operation.





(a) Disconnect the frame wire from the inverter with converter.





(b) Check that the frame wire has been disconnected from the system main relay.
(c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and body ground.
Standard resistance:





(d) Measure the resistance between the terminals of the frame wire.
Standard resistance:





(e) Reinstall the HV battery assembly (Installation).
(f) Reconnect the frame wire.
NG -- REPLACE FRAME WIRE
OK -- Continue to next step.
11. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER)

CAUTION: Wear insulated gloves before performing the following operation.

(a) Turn the power switch OFF.
(b) Remove the service plug grip (Removal).

NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.

(c) Remove the inverter cover (Removal).





(d) Disconnect the H15 HV control ECU connector.





(e) Disconnect the I10 inverter connector.
Standard resistance (Check for open):





(f) Turn the power switch OFF.
(g) Measure the resistance between the wire harness side connectors.
Standard resistance (Check for short):





(h) Reconnect the inverter connector.
(i) Reconnect the HV control ECU connector.
(j) Reinstall the inverter cover (Installation).
(k) Reinstall the service plug grip (Installation).
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
12. INSPECT HYBRID VEHICLE CONTROL ECU (HV VOLTAGE)
(a) Turn the power switch ON (READY).

HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.





(b) Measure the voltage between the terminals of the H15 HV control ECU connector.
Standard voltage:





NG -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
OK -- REPLACE HYBRID VEHICLE CONTROL ECU