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Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Pablo1914, May 27, 2015.

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  1. Pablo1914

    Pablo1914 Junior Member

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    Hi guys,
    My name is Pablo. I own a 2005 Prius and I love it.
    Recently one of the cells went bad in my prius so I replaced it. I also balanced the charges after replacing the bad module. After 1200 miles, the battery died again. I checked and on one side of the relay I have 220 volts and on the other side of the relays 0 volts. I took a closer look and this time one of the relays (the one towards the rear of the car) had melted in the area where the bolt is, on the side that goes to the car.
    I went ahead and I replaced both relays. On the other side is showing 220, but is still showing 0 voltage on the car side..
    Now I'm lost guys.. Any idea?

    I replaced a cell in my 05 prius battery.
    It run for 1200 miles and then the battery died again.
    When I opened it, I realized that I'm not having voltage on the orange wires that go to the car. I do have voltage on the battery side. (from the relays standpoint) I replaced both relays (the one next to the trunk had melted a little bit), but still not voltage on the other side of the relays. I do have voltage on the battery side..( 200+ )
    Any tips?
     
    #1 Pablo1914, May 27, 2015
  2. ChapmanF

    ChapmanF Senior Member

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    Under what conditions are you testing on the car side of the relays? There would only ever be voltage there when the car is in READY mode. You know the whole reason the relays are there is to cut off the voltage to the car side under all other conditions, right?

    -Chap
     
    #2 ChapmanF, Jun 1, 2015
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  3. Pablo1914

    Pablo1914 Junior Member

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    Chap,
    Honestly..
    I didn't know.
    I'm very new..
    This is what I have done.
    I replaced one cell. I balanced the charges. I drove it for 1200 miles. the triangle appeared again. I opened it and I saw that one relay had overheated.. I though that relay was the issue. I replaced both of them. Connected everything again, and red triangle shows up again..
    The multimeter shows 206 volts coming from the battery..
    Maybe another cell went bad?
    But why would the relay melt? Maybe I didn't tighten the bolt enough?
    I'm soo new man..
    IMG_1599.JPG
     
    #3 Pablo1914, Jun 1, 2015
  4. ChapmanF

    ChapmanF Senior Member

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    What codes do you have? They can tell you a lot about what's ok and not ok with the battery. What codes are there now, and what were the original ones that led you to changing a module?

    When you replaced a module the first time, did you disconnect the cable at the relay? If so, what was your torque wrench set to when you reattached and tightened it again? Where did you get the torque specs? Have you got the manuals, or a techinfo.toyota.com subscription so you can look them up?

    One of the manuals you'll find there is called the "New Car Features Manual" - it is sort of the intro that explains what everything's for. (The main ones come out the first year of a model, so you want to look at the 2004.) You'll get a good sense of what the relays do and how and when by looking at page TH-49.

    Being new and enthusiastic is great! :) But this is a powerful 200 volt battery you're working on, so I'll worry about you less if you also take some time to be informed.

    Cheers,
    -Chap
     
    #4 ChapmanF, Jun 1, 2015
  5. strawbrad

    strawbrad http://minnesotahybridbatteries.com

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    Did you remember to push the orange handle down? It is a three step process to reinstall the orange safety plug. Push the plug in, flip the level up, and push the lever straight down.

    Brad
     
    #5 strawbrad, Jun 2, 2015
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  6. Avi's Advanced Automotive

    Avi's Advanced Automotive Independent hybrid repair shop

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    Loose and/or poor connections cause things to get really hot. Considering the other post doesn't look like it got as hot, my money is on the nut not being tight enough. Keep in mind that swapping modules is a short term solution. You might get luck and have a battery last a while, but that is not always the case. At this point, you need some data. Are there any codes? Do any of the module connections look like they've gotten toasty as well?

    Avi
     
    #6 Avi's Advanced Automotive, Jun 2, 2015
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  7. Pablo1914

    Pablo1914 Junior Member

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    Hi guys!
    I'm pretty new here. I still don't know where to post too well.

    I was having issues with my old battery. It gave me the famous P0A80 code..
    I bought a used one on ebay (used but guaranteed to work) and after installing it, the triangle came back and the code P0A80 too...

    Any thoughts? Could it be that something else is bad?
     
    #7 Pablo1914, Jun 15, 2015
  8. bisco

    bisco cookie crumbler

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    it's probably just another bad battery. do they have another to swap you?

    does the car start and run?

    did you reconnect the hybrid locking switch properly, according to the video?

    any troubleshooting offered by the seller?
     
    #8 bisco, Jun 15, 2015
  9. Pablo1914

    Pablo1914 Junior Member

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    The car doesn't start. It does if I disconnect the 12 volt battery and the hybrid battery. Then after one minute the triangle comes back. Once I turn off the car, it doesn't start up.

    Yes

    I haven't asked. Since I'm new with this I kind of wanted to know what the issue could be. The seller is just a guy parting out his prius, so I bet he doesn't know much.. I may be wrong..
     
    #9 Pablo1914, Jun 15, 2015
  10. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Was the safety plug properly installed after you installed the battery? That's the most common cause of zero volts on the other side.
     
    #10 usnavystgc, Jun 15, 2015
  11. bisco

    bisco cookie crumbler

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    good thought.

    you're new at this, but you managed to remove and install a hybrid battery?
     
    #11 bisco, Jun 15, 2015
  12. Pablo1914

    Pablo1914 Junior Member

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    I have been reading about this and watching videos about this for two years.
    I rebuilt my old battery, and then after 1300 miles it broke down again. I thought buying one with 65,000 would give me some time to fix the other one.. You know how it is.. I wanna fix the other one, but I can't wait to have the car running.
    I still consider myself new, because I don't know too much about electronic stuff if you know what I mean
     
    #12 Pablo1914, Jun 15, 2015
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  13. bisco

    bisco cookie crumbler

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    i do, but you know a lot more than me!:)
     
    #13 bisco, Jun 15, 2015
  14. JC91006

    JC91006 Senior Member

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    buying a battery from a guy that's parting out his car, does not mean he was selling a good battery.
     
    #14 JC91006, Jun 15, 2015
  15. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Here's the procedure. Page 3 for install
     

    Attached Files:

    #15 usnavystgc, Jun 15, 2015
  16. JC91006

    JC91006 Senior Member

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    It's not the service plug, he was able to start it......he gets the red triangle after 1 minute of running....then it doesn't restart.
     
    #16 JC91006, Jun 15, 2015
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  17. Pablo1914

    Pablo1914 Junior Member

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    Lol.. well If I can help with anything I'll be glad to do it..
     
    #17 Pablo1914, Jun 15, 2015
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  18. Pablo1914

    Pablo1914 Junior Member

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    That is correct
     
    #18 Pablo1914, Jun 15, 2015
  19. Pablo1914

    Pablo1914 Junior Member

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    I'm thinking that if it would be something else, the car wouldn't run at all..
     
    #19 Pablo1914, Jun 15, 2015
  20. JC91006

    JC91006 Senior Member

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    You would need a mini VCI or something similar to tell you what's wrong with the car. The logged codes will point to the right direction.

    A guess would be you got a bad battery on ebay.....but that's just guessing.
     
    #20 JC91006, Jun 15, 2015
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