2001 battery/computer problem with error codes

[sunrise]

I was hoping to run this one by you folk for feedback.

After spending about a week of checking, the dealer has told me that my 2001 Prius (as per the thread 2001 Prius major eeeek! symptoms ) needs to have battery, computer and battery cables replaced:

HV Recycle Battery (G9520-47050)
Battery Computer ASSY (89890-47050)
Main Battery Cable NO.2 (G92420-47040)
Main Battery Cable (G92420-47040)

The person translating for me (I'm in Japan) said they found that the connector/cable was burned as 'it seems to have overheated'.
I then asked if the issue is with the cable/connector, how would they know if the battery and computer need replacing as well without first replacing the cable. They told the translator that: this cable connects the computer and the battery, and it is tied with both as one so everything needs to be replaced this time.

Do those of you in the know agree with that?

Here are the error codes (translated from Japanese so maybe not what you're used to in English):
- Battery P3030 Disconnection between battery ECU
P3006 △SOC Large
- (HV) Hybrid P3000 HV battery Error
- ABS VSC C1259 HV related regeneration error


Still need to decide if it's worthwhile going thru with the repair. The labor fee is quite cheap, around the equivalent of US$200, so if I can get used parts that are in usable/trustworthy condition it would be worth it. This dealers' quote for the battery is about 135,000 yen (I guess that's around US$1500?), plus the same again for the computer, so the total is high. If I can cut those costs that would be great, I wonder how much a reconditioned computer would cost (assuming it's possible to get something reliable). I guess I'd have to get a Japanese one, not sure if it's possible for me to buy one from overseas if it's in English (though personally I'd prefer English, just not sure if it's possible to install one in a Japanese domestic model).

I might also consider getting a new battery, (with a used computer) since it's a lot 'cheaper' than originally quoted from the first dealer and might be more reliable than something reconditioned.

Any suggestions/advice here?

Anyone know how the cable could have burned out? Could it have been from attaching the new 12V battery? That's when things started to go crazy, though perhaps it had been related somehow to the older low 12v battery and the error I had gotten from that before I changed it.

I'm assuming that if the main battery is caput one usually doesn't have to change the computer as well, but this case is different.

Thanks!

Julianne

[Patrick Wong]

Hi Julianne,

The two cables in question connect the traction battery modules to the system main relays (SMR). The purpose of the SMRs is to switch the positive and negative sides of the battery. The relays are located within the battery case along with the 38 modules and the battery ECU.

Usually the battery ECU does not have to be replaced when the traction battery is replaced. For example, when the battery on my 2001 was replaced, the Toyota dealer tech moved the battery ECU and the system main relays from the old battery's enclosure to the new battery's enclosure.

However, the fact that the cables were apparently damaged implies some sort of short within the battery case. If you had a chance to view the old cables maybe you could see what was happening and why they were damaged. This has no relationship to your replacing the 12V battery which is located elsewhere.

If the cables were damaged then it is possible that the battery ECU might have also been damaged, due to its physical proximity. Again, your visual inspection would be the best way to determine the situation.

In any event I suppose the question is whether you want to spend > US$3K to get your car fixed. Also, it would be interesting and potentially entertaining for you to request to see the car and the opened battery case; and let us know the response to your request. (I am wondering how many Japanese women would make a similar request.) If this visit should happen please bring a good digital camera and take some photos.

If you can buy used parts in Japan, I would expect the battery ECU to come with the traction battery since both are in the same metal case. That is frequently how used batteries are sold in the US.

I note that the battery offered to you is explicitly a "recycle" battery. What warranty is associated with that? $1,500 seems pretty high for a recycled battery since the US$ list price is $2,299 for a new battery (not incl labor.) You can buy it for a discounted price of $1,747 plus shipping. Warranty would be one year, same as for any Toyota part sold in the US. Look up G9510-47020 on the following website of a Houston Toyota dealer.
http://www.trademotion.com/partlocat...&siteid=213747

According to my data sources, the part number for a US NHW11 battery ECU is either 89890-47030 or 89890-47060. Since you listed a different part number it could be that the Japanese battery ECU is different so that it can interface with the Japanese engine ECU and hybrid vehicle ECU. The engine ECU is different between NA and Japan due to the presence of the fuel tank bladder in NA and the associated sensors that report incorrect operation or leakage.

[sunrise]

Thanks so much, Patrick for such a detailed reply!

I showed it to a friend more versed in Japanese and cars than I. He's wondering if one of the cells that make up the main battery died/corroded and perhaps short circuited the whole battery pack which then caused the damage to the main battery connector cable. His advice was to try and replace the battery and see if it works with the old computer, just in case it's not damaged, and try and get a used one i that doesn't work. (as long as such a thing doesn't risk damaging the battery of course).

We both think that 'recycle battery' might be an error in translation from the person who translated the quote, but I will check that.

I'm also going to try and get more info about whether the dealer knows for sure that the computer is damaged, or if it's just a safety thing that they automatically do - however the error codes point to damage of course.

Yes, definitely got to keep considering all the costs too.

I'm still travelling for another few weeks, so no photos likely at this point.

Anyway, many thanks again, Patrick. Your responses have been really helpful and appreciated. I'll keep you posted, even if there's nothing new to tell until after I get back.

Julianne