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How do you restart after replacing service plug

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by justjeff, Nov 27, 2011.

  1. justjeff

    justjeff Junior Member

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    I am putting back together a 2004 Gen 2 that I bought wrecked. I want to see if it runs before I go any further. So I plugged in the mechanical plugs, other than the coolant fan plugs and headlights. Then I connected the DC 12V negative, and before even putting the service plug back in I had all the lights on the dash light up and think I could hear the inverter. then I installed the service plug and the vehicle didnt start. I just showed a warning emblem in the upper left side of the consumption screen and all the lights stayed lit up on the dash. Is there a sequence I need to reinstall the battery and service plug? Is there a certain amount of time I need to leave everything plugged in until the vehicle may start? Please if available, send me a link to the technical stuff for this, or explain it as best as possible. I would rather not buy a bunch of stuff at this point just to see if it runs.

    Prior to taking apart the parts of the vehicle to repair structural stuff, the car did try to start when I put it in neutral so I could push it out of the guys yard, but motor mount was broken, so I turned power off immediately before I knew if it ran or not. Now all I see is a bunch of christmas lights lighting up the whole dash, and when I push power button (which is orange when I put power to the 12 v battery) I get nothing but it stays orange.

    Any words of wisdom???
     
  2. uart

    uart Senior Member

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    There's a trick to that plug. After rotating the lever to re-connect the service plug you also have to slide it (the lever) into the lock position or it wont work.

    After you successfully reconnect the HV battery I'd suggest disconnecting the 12V battery for 5 min and re-connecting to let it clear any errors.
     
  3. justjeff

    justjeff Junior Member

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    So after inserting the plug, then flipping the switch up, I need to also "lock" into position? How do you do that?

    Thanks! Keep 'em coming. I plan on working on it tomorrow am. It would be awesome to make the car run, briefly, just to set my mind at ease. This car was hit a bit harder than I initially anticipated.
     
  4. justjeff

    justjeff Junior Member

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    So I got the service plug locked in. That seemed to make the power warning light go off on the consumption screen on the dash. But once I hook up the 12V battery, the dash lights automatically light up, and power button doesnt turn green. When I push the power button it does nothing. It does sound like the inverter or something under the hood is making a hum. Any ideas?
     
  5. seilerts

    seilerts Battery Curmudgeon

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    Humming noise is probably the inverter cooling pump trying to run.

    The symptom that you describe, everything comes on as soon as you connect 12V power, sounds like what happens after power is restored following an incomplete shutdown due to a failed cell in a 12V battery. So, connect a known good 12V battery (not the one in the car, probably it is bad), press and hold the power button for a few seconds until the car shuts off, then, foot on the brake, Press the power button.
     
  6. justjeff

    justjeff Junior Member

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    Vehicle:
    2004 Prius
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    Great tips. I will try this as soon as I am back near the car. I have a friend that is going to finish painting the car today. He will throw it on a small trickle charger at 2A to see if we can save the battery. I actually checked that before I left and the battery was only showing 11.5V. So I assumed that is also a problem after reading the threads. Also I decided I am going to pick up as many of the parts as I can find locally and try putting the cooling system back together before trying to start. Will the car start if I dont have all the lights hooked up? Is there a list of things that absolutely need to be hooked up in order to get a successful start?

    Thanks again for all the help!
    Jeff