1. Attachments are working again! Check out this thread for more details and to report any other bugs.

FIRE! no start P3006 - P3016 - P3030 - parts & install ECU + Wire Harness to Traction Batt

Discussion in 'Generation 1 Prius Discussion' started by lovemy02prius, Sep 1, 2014.

  1. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Hello,
    I'm Michy
    Here's my Vehicle: 2002 prius 4 door

    Here's my back story,, I bought my 2002 Prius nov 2013, it was throwing codes, I had Toyota run a test and here's the codes:
    P3006 battery levels are unusually different
    P3016 battery block 6 becomes weak
    P3030 Batter Voltage Detective Line Snapped

    3.) We removed the HV hybrid battery and opened it up for a look. There were notes on the HV Battery that it was rebuilt in 2008 so maybe they installed a faulty ECU or the wrong ECU??)

    ALL of the Cells test good for resistance and voltage. But both the ECU (89890-47060) inside my hybrid battery AND its Wire Harness show signs of fire damage. Its a 89890-47060 comp assembly battery (ECU) installed (weird but true.. it ran great from the time i got it through the entire winter at cold temperatures but anything over 58f it will not start...summer came and it stopped running (I think I also drained the 12v starting battery trying to get it to start - i need some advice on that as well. )

    My questions begin here….
    1.) Can i replace the wire harness and ECU with good ones to solve the problem?

    2.) What model #'s can i use exactly?

    3.) is the 89890-47060 the right model for my car? how can i verify?

    4.) anyone know where i can find both items????
    I'm having a hard time finding the exact 89890-47060 AND the harness.

    5.) can i use a different model, which models are ok to use?? are their problems or drawbacks to using a different model? i found an alternative model.. #: 89980-47060 on ebay….

    6.) does the Harness have a specific name, descriptions and/or model number?? please let me know! Is this the harness see harness to traction battery illustration here:
    Prius PHEV TechInfo - EAA-PHEV

    (Again Im referring to the ECU computer box inside the hv hybrid battery in case there are a couple ECU's)
    Here's my ECU #

    DOES ANYONE HAVE EXPERIENCE WITH THIS PROBLEM? CAN ANYONE HELP ME OUT HERE??

    This is my ONLY transpo so I'm literally stranded! (i can taking the bus) I really can't afford to pay $1500 (plus a core battery) for a new doremus battery, i was interested because they offer a 3 yr warranty and they claim they have fixed all problems, improved the design for no leaks and better seals and little to no corrosion and that you don't have to program it for your individual car. Anyone know about these or have experience for future refference?

    if you leave a contact ill be happy to call you if its too much to write out the info.
    THANKS!!!!
    MICHY


    PS i orig posted in the wrong section so please respond here in GEN 1 forums and thanks for your help!!!

    Read more: http://priuschat.com/conversations/wire-harness-plugs-into-ecu-inside-the-hv-hybrid-battery-02-prius.126759/#ixzz3C5nWjdTu
    Follow us: @PriusChat on Twitter | PriusChat on Facebook
     
    #1 lovemy02prius, Sep 1, 2014
    Last edited by a moderator: Dec 6, 2018
  2. Britprius

    Britprius Senior Member

    Joined:
    Jun 14, 2010
    5,194
    1,910
    0
    Location:
    Herefordshire England
    Vehicle:
    2008 Prius
    Hi Michy welcome to PC.
    It sounds as though the only problem with your battery is a broken sense wire most probably to battery block 6. The wire used is subject to braking just where it is crimped in the eye terminals. These terminals are fastened on the bus bars of the battery.

    The wire can usually be soldered back onto the terminal eye without changing the complete harness. There are 19 of these wires going from each pair of modules back to a connector on the battery ECU. Check each wire from the connector "after removing it from the ECU" back to it's eye terminal with an ohm meter. When you find the one that is open circuit that's the one to repair.

    John (Britprius)
     
    Robert Holt likes this.
  3. Britprius

    Britprius Senior Member

    Joined:
    Jun 14, 2010
    5,194
    1,910
    0
    Location:
    Herefordshire England
    Vehicle:
    2008 Prius
    I should have added the reason for the codes:-
    P3030 broken sense wire.
    P3016 ECU sees a low voltage on block 6 (because the wire is broken to this block).
    P3006 voltages are unusually different (because the voltages are not being reported correctly again broken wire)
    I could be wrong but the obvious place to start is with the broken wire.

    John (Britprius)
     
    Robert Holt likes this.
  4. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Hi John, thanks but we opened the Hybrid battery up and the ECU and The Wire Harness are both burnt up and need to be replaced. I will pay special attention to the "sense wire" to battery block 6 (and the other 18 wires!) when installing the new wire harness. This one is TOAST at the plug in end. Do you know where I can find some diagrams and installation instructions for for installing a new ECU and Wire Harness? And where I can find the parts at an affordable rate? i hear toyota sells the wire harness for $100 bucks i can do that but the ECU they sell is TOO EXPENSIVE for me. Thanks!
    Michy
     
  5. bwilson4web

    bwilson4web BMW i3 and Model 3

    Joined:
    Nov 25, 2005
    27,065
    15,372
    0
    Location:
    Huntsville AL
    Vehicle:
    2017 Prius Prime
    Model:
    Prime Plus
    Ok,

    Sharing this on the forum gives a chance for others to offer insights and clues. But I'm a little confused about the time-line:

    Bought - November 2013
    Toyota codes read - when?
    Has the car run at all since November 2013?
    When did it fail?

    Now looking at your resources:

    So where is the car now?
    Do you have a workbench or place to work on the traction battery?
    Do you have a helper or hand cart to move the battery to the work area?
    Do you have a VOM to measure the 12V battery?
    Do you have a charger for the 12V battery?

    Do you have a soldering iron or pencil?
    What sort of things have you done with power electronics in the past?

    The reason for these questions is to understand what you have and how best to suggest what to do next.

    BTW, are you anywhere near San Francisco or Berkley? The reason is there are some very good Prius shops in that area who could help a lot.

    Bob Wilson
     
  6. Britprius

    Britprius Senior Member

    Joined:
    Jun 14, 2010
    5,194
    1,910
    0
    Location:
    Herefordshire England
    Vehicle:
    2008 Prius
    I am sorry I cannot help with the battery harness supply as I am in the UK . Hopefully member "Usnavystgc" will chime in when he comes on line, he is very knowledgeable on the gen1 Prius and is in the US.

    John (Britprius)
     
  7. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Thanks you so much for the input John! I very much appreciate it!

    Is it probably that if one of the wires broke,, it caused the fire? or maybe the ECU was bad and caused the fire and the broken wire code began with the fire severed the wires from the ECU? Just trying to understand what happened. In your opinion do you think I can install a good ECU and Wire harness and be done or will i have to go through a month long charging session and other hoops?
    Thanks! Michy
     
  8. Britprius

    Britprius Senior Member

    Joined:
    Jun 14, 2010
    5,194
    1,910
    0
    Location:
    Herefordshire England
    Vehicle:
    2008 Prius
    We have one instance of a battery fire caused probably by moisture in the connector of the sense wires at the ECU. This was on a gen2 version, but the system is much the same. There is a voltage of around "depending on state of charge of the battery"
    275 volts on this connector. Once a conducting path is formed it can speedily cause a lot of damage.
    If your modules are not melted and can be cleaned you may be lucky with replacing the harness without balancing the modules, but do check all the voltages first.
    See the post (5) from Bob Wilson a well respected, and knowledgeable member here on PC.

    John (Britprius)
     
  9. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Hi Bob,
    Details:
    I Bought it Nov 10 2013
    Toyota codes read was Nov 15 2013
    Opened up the hv traction battery and noted the BURNT ECU & WIRE HARNESS NOV 16 2013 (we did this ourselves)
    like i said the weird thing is that he car ran great from Nov 10th all the way until the temperature got above 60 degrees
    in mid May…

    Car fail May 24th, 2014 (hard start, started ran and stopped after a couple miles for about 4 days)
    May 29th - Car would no longer turn over and run (you could still hear it try and start though)
    June 1 12v battery was completely drained, no lights no power nothing..


    resources:
    the cars at a guy friends Brian's fabricating machine shop and warehouse waiting for parts (we think we can repair it ourselves, can't find anyone here thats reasonable) Its a professional facility and my friend is a machinist and mechanic whose willing to do the work with my help. Theres a workbench, a hoist, all normal mechanics tools, VOM present and soldering iron so plenty of resources to work on the traction battery.

    12V Battery
    There is a normal 12V battery charger (not sure if its better to remove the 12v and fully charge it and check to see if its still good after all this starting attempts and jumps? or charge while on car, ill need specifics (if its different from a normal 12v battery in a non hybrid gas car)


    Brian has done extensive electrical work on various cars but never on a hybrid. I've learned a lot about VW's as I had a 4 1990 Cabriolet Karman's and a vintage 73 VW Karman in the past that I help to restore w Brian. Now I'm researching a lot on the Prius and learning. Thats how i found you guys and this cool forum and found out I could possible rebuild the battery instead of buying a new one for $1500 (doremus 3 year warranty - who claim they have resolved most of the leak & pinch issues with these batteries plus you don't have to reprogram theirs)

    I'm in Saint Clair Shores MI but would love the contacts for the San Francisco or Berkley Prius shops for a couple friends w the same car who live in those cities. Thanks


    Thank you! Michelle



    Read more: FIRE! no start P3006 - P3016 - P3030 - parts & install ECU + Wire Harness to Traction Batt | PriusChat
    Follow us: @PriusChat on Twitter | PriusChat on Facebook
     
  10. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Hi Bob,
    Your probably out bbq'ing for Labor day! I have an alert to my phone for the post so I'm here when you get a chance to respond or if anyone else gives vital input. Brian said he's VERY confident that with the proper parts and instructions from seasoned pros like yourself, we can easily do the repair at the warehouse himself. He has all the tools just need the correct parts and instructions..
    Thanks Michelle
     
  11. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    OMG...This thread about FKZ's car throwing the same 3 codes gave me the shakes…lol wow i hope mine does not require the same especially the 30 day charging time…i have to get back on the road asap
    main battery rebuild | PriusChat
     
  12. Patrick Wong

    Patrick Wong DIY Enthusiast

    Joined:
    Mar 8, 2008
    18,198
    6,461
    0
    Location:
    Green Valley, AZ
    Vehicle:
    2015 Prius
    Model:
    Two
    1. Regarding your need for part number information, look at toyodiy.com
    2. Regarding where to obtain used parts, try eBay. If you need a used traction battery ECU, any working unit from model years 2001 - 2003 should work. For example,
    2001 03 Toyota Prius Hybrid Battery Control Computer ECU ECM 89890 47030 | eBay
    or
    01 03 Toyota Prius Hybrid HV 89890 47060 Battery Control Computer ECU ECM | eBay

    3. Regarding repair manual info, subscribe to techinfo.toyota.com to obtain factory repair manual info including how to access the traction battery, safety precautions, tightening torques required, etc.
    4. If your 12V battery has been discharged since mid-May, it is certainly totally dead now, so plan to buy a replacement.
     
    #12 Patrick Wong, Sep 1, 2014
    Last edited: Sep 1, 2014
  13. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,064
    14,970
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV


    As some other posters have suggested, you can probably solve the problem by replacing whatever was damaged in the, er, adverse thermal event. The trick will be figuring out just what was and wasn't damaged.

    Can you describe more precisely where the signs of toastage were? There are a few wire harnesses inside the battery. Are you referring to just the one with the many skinny wires going into the 26-pin orange connector as described in this old post? Is there some spot along those wires' length where it looks like the trouble was most intense? Is it right at the orange connector itself where it plugs into the ECU? Is the plastic connector itself deformed?

    How about other wires in the battery? There are thicker wires from the two ends of the module stack (on the front), and from the two middles of the stack (on the rear) ... and also skinny wires to the five or so temperature sensors arranged on the top. Do any of the NiMH modules themselves look scorched or deformed? Do some just look sprayed with soot that can be wiped off?

    How about the ECU itself? If you unplug it and take it out, does it show any signs of damage beyond a soot coat you can wipe off? How about inside, if you open the cover? It seems like it's been giving you some codes, so it's at least not completely dead. The codes are consistent with trouble in the sense wire harness (where you already know there's trouble), so just maybe the ECU's ok.

    If you check over at Village Toyota Parts (I try to plug these guys because their online part lookup gives the part numbers, which a lot of the other online dealers don't ... even if the price is a trifle higher, I'll support them for that), both 89890-47030 and 89890-47060 are listed as usable. The -47030 is listed for 2001 and 2002 but not 2003, where the later one covers all three years (and is a bit cheaper too). If you find you need the ECU, whichever one you find should work for your 2002.

    If the only wire harness you need is the 82165-47030, that's about $110 there. But there's (or at least used to be) an option that might be better for you. Years ago there was a service campaign for leaks in these batteries, and they put together a replacement parts kit for that job, part number 04003-35147. For some reason I get nothing for this number at Village, but over at, say, Metro Toyota Parts it still shows up, at about $116. This includes pretty much all the wiring you'd ever replace in a leaky corroded battery, the various busbar covers and insulators and such, and even some insulating sheets to add at the ends of your module stack if that wasn't already done in the rebuild.

    Hope this helps,
    -Chap
     
  14. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,064
    14,970
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    +1 especially on getting familiar with the safety precautions.

    There was also a set of instructions for doing the battery sealing service, which you can find pretty easily if you google for "technical instructions" "special service campaign 40G" and that gives you a lot of the important information in one place. (It's also where you find the part number for the special rebuild parts kit I mentioned above).

    There used to be an outfit called ReInVolt that made rebuilt batteries; they were bought by Dorman which now sells their batteries in the wider auto parts distribution world. One of the improvements in their rebuild is they nickel-plate the busbar elements, making them resistant to leaked electrolyte, so those are even better than what comes new in the Toyota kit. But I don't know if they'll sell just their nickel-plated busbar kits. Back when it was just ReInVolt in a small shop, I'd have guessed it might be worth asking, but I'm guessing Dorman wouldn't be interested.

    -Chap
     
  15. bwilson4web

    bwilson4web BMW i3 and Model 3

    Joined:
    Nov 25, 2005
    27,065
    15,372
    0
    Location:
    Huntsville AL
    Vehicle:
    2017 Prius Prime
    Model:
    Prime Plus
    No BBQ today, work so I can bank the holiday and take the wife for a long weekend later this year. No problem as you've gotten excellent advice.

    I think we need to see photos of the traction battery on a bench with the cover off.

    Bob Wilson
     
  16. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Hi Guys,
    wow your terrific, I'm trying to take it all in and becoming hopeful for the first time (and waiting for Bob to come back online : )


    Good Evening ChapmanF
    (took me a long time to read and write this but I figure communication key here! and I really appreciate all the time, resources and input date you and the other guys like Bob and Patrick are giving me, really makes me feel like we can make this happen with out buying an expensive HV Battery that i can't afford at the moment! So here's my responses, Im on line til about midnight so I'll respond a lot quicker for the rest of the night if that helps!!! - Michy


    Wheres the damage
    The Blackened burned looking area is directly right at the part of the plastic connector (male) where it plugs into the HV ECU brain box (female) You can't just wipe away the black soot. Its burnt to a crisp. It severed the wires and the plastic connector itself is deformed. However the ECU doesn't look so bad..(never thought to check to see if it was still good, just assumed it would be damaged…is there some test i can run on it somehow to check?

    Pictures of burnt parts and the hv battery insides in general.

    I took some pic but have no way of posting them (if someone wants to cc me their email I send them maybe you can post them and copy the link here! Or tell me how to do it. I think the pics will help a lot.

    Test to see whats damaged

    Any way to test the ECU to see if its fully functional? what would you do to make sure? how bout for testing the other parts in the HV battery? example NIMH Modules and other parts you haven't mentioned yet…anyway to test for leaks??

    Grounds
    what about grounds is it necessary to test the grounds ...could they have caused it? I don't want to blow a new harness or /ecu if i need to replace this one. (or am i lets just say…newbie-ing up the wrong tree?)

    NIMH MODULES & Diagrams of the prius hybrid battery inside and out
    I don't know what the NIMH Modules are (i really could use a diagram! ill read through the message again as i just skimmed to answer your question and see if you or anyone send me link to a diagram of all these parts.

    No other burned parts no signs of other damage or leaky cells (just some mild corrosion and i have pics)
    I don't remember seeing any other parts burned just lightly sprayed with soot. the rest of the harness seemed in tack unless once you unplug it and pull it out theres parts that aren't visible to the birds eye view we had when we open it and inspected it.

    2002 Prius - 3 compatible units Brain Box - ECU/ECM Module
    WOW my cars a 2002 so ALL THREE of these model numbers are compatible with my car!!!? I'm very happy to find that out, one guy on ebay found out i was looking for the 89890-47060 and nearly tripled his price in 24 hours from 100 to 287..
    So I am VERY HAPPY to discover that all three of these are compatible with my 2002 Prius:
    89890-47030 and 89890-47060 are listed as usable. The 89890-47030 is listed for 2001 and 2002 but not 2003,
    PS What is the correct ref name for this part? grr

    "technical instructions" "special service campaign 40G" a set of instructions for doing the battery sealing service
    I found & downloaded the pdf "notice" from Toyota to dealer.here it is cached:
    40G Prius HV Battery

    but where do i obtain the actual kit contents (see list below) is there a link I'm seeking or do i need to contact the dealer? The training video is NOT on youtube where can i find it?

    • Training video outlining the repair
    • Special 48 in·lb T-Handle Torque wrench
    • Vinyl Mat rated for 1,000 volts
    • Litmus paper
    • Special tool label for tool cabinet
    ReinVolt rebuild w/ nickel-plate the busbar elements (any other elements that make this kit special or desirable besides the nickel plate busbar element? Can i buy the the nickel plate busbar separately?

    Replacement parts kit for that job (part number 04003-35147)
    can be purchased @Metro Toyota Parts $116
    Would this be the kit that I would get if i can't find the ReinVolt kit??? they about the same except for the way awesome nickel plate busbars?

    Battery Cells (Swap Gen 1 for Gen 3?)
    Lastly (for this message that is) Since were pulling the HV battery and working on it, is it wise to swap out the Gen 1 cells for Gen 3 cells at this time? Do you think this is wise for long haul? Does it make sense financially? Do you think its possible to tell the Gen 1 cells to recoup the cost? How many Gen 3 cells would I need exactly? and any other parts or stuff id have to do to swap out the Gen 1 cells for the Gen 3 cells???


    gee i can't thank you all enough for being here for me!

    Sincerely,
    Michelle


    Read more: FIRE! no start P3006 - P3016 - P3030 - parts & install ECU + Wire Harness to Traction Batt | PriusChat
    Follow us: @PriusChat on Twitter | PriusChat on Facebook
     
  17. Patrick Wong

    Patrick Wong DIY Enthusiast

    Joined:
    Mar 8, 2008
    18,198
    6,461
    0
    Location:
    Green Valley, AZ
    Vehicle:
    2015 Prius
    Model:
    Two
    1. Since the traction battery ECU is exposed to high voltage, if there is any damage due to scorching, corrosion, etc. that part should be replaced.
    2. The Classic traction battery is composed of 38 modules plus the traction battery ECU.
    3. You have no practical way to test the traction battery ECU other than by installing it in the car and seeing what happens.
    4. Yes, it would be great to replace the modules with G3 battery modules and you will need 38 modules total. That is likely to be costly and you will face the question of how to balance the modules since 2G and 3G traction batteries only contain 28 modules. There are many posts about how to balance module voltage so that the traction battery ECU won't have a fit.
    5. I doubt you will be able to sell the Classic battery modules for very much, but you can try on eBay - since one man's trash is another man's treasure.
     
    #17 Patrick Wong, Sep 1, 2014
    Last edited: Sep 1, 2014
  18. SageBrush

    SageBrush Senior Member

    Joined:
    Jun 4, 2008
    11,627
    2,530
    8
    Location:
    Southwest Colorado
    Vehicle:
    2012 Prius v wagon
    Model:
    Two
    This DIY repair sounds like a bad idea, for a number of reasons:
    1. OP+boyfriend are not proficient
    2. The root cause of the fire is not known
    A remanufactured battery with G3 modules seems like a *much* safer and smarter long term investment
    Or alternatively a new battery installed by BF
     
    #18 SageBrush, Sep 1, 2014
    Last edited: Sep 1, 2014
    robert mencl likes this.
  19. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,064
    14,970
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV


    Patrick makes a good point - the battery ECU is a sort of part-low-voltage, part-high-voltage item. Most of it runs at 12 volts like other computers in the car, but the end of it where that toasted orange connector plugs in does have to safely withstand 300 volts or so (the highest voltage difference being between pins 14 and 24 of the orange plug). Scorching/tracks of carbon/sprays of soot can be conductive paths that high voltage can follow.

    We know that front busbar/sensor wiring/plug assembly is shot. A new one is definitely needed, whether $110 for it alone, or $116 for it in a kit with other shiny new stuff. I would recommend the kit; that way you can replace the included plastic insulators/covers that might have been damaged/scorched/soot-covered too, and not spend time trying to clean or check them.

    That leaves the 38 NiMH modules themselves, and the battery ECU. Ideally, you'll find you can clean these up - meaning really clean, with no trace of any soot paths and no residue from cleaning substances. (Someone will chime in, I'm sure, with a good non-residue-leaving solvent for cleaning up sooty paths; I might try isopropyl alcohol.)

    The ECU is where this is most critical. The battery modules can present 300 V between the two farthest apart, but each one is really only 8 volts away from the ones next to it. Inside the ECU you've got 300-volt differences at very close spacing.

    So I would look very closely at the ECU. You said the orange plug on the harness itself was deformed. How about the one on the ECU that it mates with? Not deformed? Cleanable? To no-traces-of-carbon with a swab and cleaner?

    Also inside the ECU, with the lid off ... any signs of deformation, overheating, or carbon tracks near the end of the circuit board where that connector is attached? I think you'll find the circuit board on that end actually features saw cuts between different traces to provide better voltage isolation. There should certainly be no carbon anywhere around that area and no gunk of any sort bridging across the saw cuts.

    If the ECU can be cleaned up to the point that visually you see no doubtful points, then you're probably ok replacing the damaged wiring, reassembling the well-cleaned battery, and seeing what happens. If after visually inspecting and trying to clean it you are left with any doubt of its condition, replacing it is probably smart. (Just remember that if you're not replacing it with a new one from Toyota, you might check the condition of the replacement just as carefully!)

    I only count two different Battery ECU part numbers for you to choose from: (1) 89890-47030 or (2) 89890-47060. You mention three - did you find a third someplace else?

    The parts kit I mentioned includes only replacement parts to be used in the battery. It doesn't include supplies like high voltage protective gear, boric acid, litmus paper, torque wrench, etc. Any low-range (inch-pound) torque wrench Brian might already have should be ok if 48 in-lb is within its accurate range. Boric acid shouldn't be too hard to find at the hardware (insect pest control). Chemical resistant gloves, face shields, also hardware store. Litmus paper ... hmm ... Teacher's Delight? Or other pH testing options at a swimming pool store. You can get 'cher gloves here. If you're feeling lucky, the voltages in a Prius battery are in the class 00 range, but you'll notice Toyota doesn't mess around, and recommends class 0 (only $8 more, anyway). Measure glove size carefully - if you're between sizes the larger will be waay easier to put on than the smaller.

    I don't know of any place to freeload off Toyota's training videos, but there is a lot of good safety information in the 40G document you downloaded. It helps if you and/or Brian already have some basic electrical knowledge ... then just read the 40G info carefully and make sure you understand why every step is the way it is. If it's not clear, ask. At 300 volts, mistakes don't always come with do-overs.

    -Chap
     
  20. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    I'm posting pics on photo bucket.com now and will cc a link here shortly..

    I don't know if the burnt part of the harness is the orange plug in you keep mentioning…its just dark black now..is there only 1 plug in point on the ECU? If so then that IS IT. grrr I need a diagram..tried searching and only got a lame incomplete wikipedia one..

    I'm listening to you ALL…hmm now I'm stressing.
    . maybe I need to go for a rebuilt with Gen 3 cells or a Doremus (not sure which gen cells they use) hopefully Gen 3 at $1500 for their rebuilt + a core or add another 1k! which would you buy if you were in my shoes and planned on keeping the car for a long time to come??

    I can show brian all the necessary steps and equipment we need to do the job and if he still thinks he can do it….we go forward in restoring mine...Im all for getting a replacement ECU especially since they are about $120 I mentioned the three as…but like you said a used one or even a new aftermarket rom toyota (which i would not buy at $1000 when i can buy the enter rebuilt battery for $1500)poses the same issues…needs cleaning with a fine tooth comb.. Also when you buy a rebuilt i believe they may be using old worn parts that still are in working order for the time being…makes me shutter to think what I'd fine if i opened it up and looked…lol

    We already pulled out the hybrid battery and know the safety protocols

    as Patrick kindly pointed out regardless of how i proceed i probably need a new 12V battery since it has been discharged since mid-May.. it is certainly totally dead now, so I should plan to buy a replacement. Anyone want to chime in on testing it or a good replacement brand..oem standard or an improved design??

    Super many Thanks
    Michelle
    Read more: FIRE! no start P3006 - P3016 - P3030 - parts & install ECU + Wire Harness to Traction Batt | PriusChat
    Follow us: @PriusChat on Twitter | PriusChat on Facebook