P3004-801

P311 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 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 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:

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

NG -- CONNECT SECURELY
OK -- Continue to next step.
3. CHECK COMPRESSOR WITH MOTOR ASSEMBLY
CAUTION: Be sure to wear insulated gloves.
(a) Turn the power switch off and remove the service plug grip. Hybrid 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.

(b) Disconnect the air conditioning harness from the inverter with converter assembly Components.

- Do not use a megohmmeter.
- Make sure that the tester probes are connected to the correct terminals.

OK -- CHECK FRAME WIRE
NG -- Continue to next step.
4. 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 from the compressor with motor assembly.

NG -- REPLACE AIR CONDITIONING HARNESS ASSEMBLY
OK -- REPLACE COMPRESSOR WITH MOTOR ASSEMBLY
5. CHECK FRAME WIRE
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.
(b) Remove the A/C fuse cover from the inverter with converter assembly.

(c) Disconnect the frame wire from the inverter with converter assembly Components.
(d) Disconnect the frame wire from the HV relay assembly Components.

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

NG -- REPLACE FRAME WIRE
OK -- Continue to next step.
6. CHECK CONNECTOR CONNECTION CONDITION (BATTERY PACK WIRE CONNECTOR) P0A09-591

NG -- CONNECT SECURELY
OK -- Continue to next step.
7. CHECK HARNESS AND CONNECTOR
(a) Turn the power switch off.

(b) Disconnect the On1 battery pack wire connector Components.

NG -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)
OK -- Continue to next step.
8. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONVERTER CONNECTOR) P0A09-591

NG -- CONNECT SECURELY
OK -- Continue to next step.
9. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONVERTER - BATTERY PACK WIRE CONNECTOR)
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.
(b) Disconnect the n4 hybrid vehicle converter (DC/DC converter) connector Components.
(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 -- Continue to next step.
10. CHECK HYBRID VEHICLE CONVERTER
CAUTION: Be sure to wear insulated gloves.
(a) Check that the service plug grip is not installed.
(b) Disconnect the hybrid vehicle converter (DC/DC converter) connectors from the HV relay assembly Components.

- Do not use a megohmmeter.
- Make sure that the tester probes are connected to the correct terminals.

NG -- REPLACE HYBRID VEHICLE CONVERTER
OK -- Continue to next step.
11. CHECK HV RELAY ASSEMBLY
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 relay assembly Components.

NG -- REPLACE HV RELAY ASSEMBLY
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
12. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - BATTERY PACK WIRE CONNECTOR)
(a) Disconnect the A61 hybrid vehicle control ECU connector.

(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