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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.

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  1. ChapmanF

    ChapmanF Senior Member

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    Whoa there, you're throwin' out new random part numbers faster'n an old Corvair could throw fan belts.

    You should already have been given in this thread the part numbers of anything you'll need, including two ECU choices.

    If your Toyota parts counter person is rattling off a bunch of other numbers, I'd urge you to check them yourself, which is easy to do at the Village Toyota site (mentioned above).

    If you just want the front bus bar assembly with the wires you toasted, use the part number Eric gave you. My recommendation would be the rebuild kit, which totally includes that, with the part number I gave you. That's one part number. One kit. All this stuff is in it. You won't beat the kit by ordering all those parts a la carte.

    kit.jpg
    Regarding the 12 V battery ... hey, I thought this wasn't going to be regarding the 12 V battery yet, so you could give it a chance to charge and desulfate while attending to more pressing things, and then see how it turned out. Then you can look at the left-over-after-house money and see how important a 12 V battery upgrade is to you. :) (There's even a pretty good upgrade you can get straight from Toyota: 28800-31290 is a 51 amp-hour capacity, which nothing else I've ever seen mentioned on PriusChat can beat ... at least not while fitting in the space.)

    Your mentioning buying a house cash and your profile location in Ferndale reminds me of Susan Calloway's story about her family being all skeptical about her music career, until she got hired for vocals on one Lincoln-Mercury ad (if I'm getting the story right) and turned the cash into a house, also in Ferndale, I think it was.

    My time in town was back when she still sang with Red C and you could catch them playing for free outside Gayle's Chocolates. I should have got an autograph....

    -Chap
     
    #41 ChapmanF, Sep 2, 2014
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  2. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Also don't mention tires, cleaning products, lubricants, or audio electronics. <GRINS>

    Bob Wilson
     
    #42 bwilson4web, Sep 2, 2014
  3. bwilson4web

    bwilson4web BMW i3 and Model 3

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    So I was cleaning out the trunk and found the old, buss bar assemblies, both back and the two front, from when I upgraded my traction battery. Rex did not want the old NHW11 modules which I kept for experiments so I stripped 'em out and sent back the housing and battery ECU. If you want them to test and try cleaning, use a 'conversation' to send a mailing address. Note, I don't see the 'safety covers' that fit on the outside to keep the terminals from touching the case.

    I noticed the sense wire lugs are bright and shiny and suspect they are nickel plated. I'll magnet check them before shipping. If one wants to nickel plate these copper buss bars, contact electro-plating companies and see what they charge. Alternatively, research nickel plating; buy the chemicals, and; voila!

    Bob Wilson
     
    #43 bwilson4web, Sep 3, 2014
  4. lovemy02prius

    lovemy02prius Member

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    im back..
     
    #44 lovemy02prius, Sep 9, 2014
    Last edited: Sep 9, 2014
  5. lovemy02prius

    lovemy02prius Member

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    we had a bad storm and it knocked out the cable lines for a few days, just getting back on line..
    UPDATE:

    1.) charged up the 12V battery and seems to be holding at 12.6 (will check again today)
    2.) The "used" ECU arrived. I just need to clean some white build up corrosion on the mettle box w some baking soda and water..

    OK take a deep breath...hold on I've done pretty good so far following your instructions..so i appologise for this detour..


    WARNING: BRAIN TEASER AHEAD...

    I KNEW ONE WAS COMING BECAUSE EVERYTHING WAS GOING TOO SMOOTHLY!! LOL

    IMPORTANT: Chap, you mentioned earlier that the kit INCLUDES the wire harness that I need IE pic of the fried harness that plugs into part: 89890-4703 ECU (Computer Assy Battery) see link to pic below..did i read that right??????


    The 40g kit: 04003-35147 Has arrived at the Toyota Dealership
    I want to make sure i'm taking a hike over there for the right parts!! Am i missing something here....The Toyota parts manager said he looked in the box (besides the bus bar & plastic pieces) the 40g KIT only contains ONE very long wire harness with only ONE plug in piece attached...(doesn't the correct harness come with a 24 pin male part (which plugs into my large ORANGE 24 pin female part on my ecu) AND a smaller 8 pin male part (which plugs into the small white plastic female part on my ecu) and he doesn't THINK the kit included wire harness is the one im seeking..(does the one in the kit need to be assembled further? that would explain)


    ALSO:
    If i have to order the Wire Harness ALA CARTE, which is it? Have you or anyone ordered the kit or the harness ala cart?? Can anyone confirm because Toyota claims their diagrams are exploded and they can't be sure.. I lean toward Chap as you all seemed to agree but can anyone re confirm from first hand experience (inc ChapmanF)


    Chap thinks its Wire Harness 82165-47030
    Name Of Part: WIRE, FRAME, NO.2
    Toyota Parts - metrotoyotapartsnow.com

    Jesse from Metro Toyota Parts says it's this one g3830-47040
    Name Of Part: electric vehicle battery plug assembly
    Toyota Parts - metrotoyotapartsnow.com

    Toyota says its this one g9242-47020 (but i think he's wack)
    Name Of Part: main battery cable part / electric vehicle plug assembly / harness hooking to hybrid battery relay assembly
    Toyota Parts - metrotoyotapartsnow.com
     
    #45 lovemy02prius, Sep 9, 2014
  6. lovemy02prius

    lovemy02prius Member

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    love to have these!! how do i message you? I looked around...no luck..
     
    #46 lovemy02prius, Sep 9, 2014
  7. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Look for "Conversation" links. It will let you compose a message just to me with the mailing address. I'll reply with the tracking number and the mailing cost.

    Bob Wilson
     
    #47 bwilson4web, Sep 9, 2014
  8. ChapmanF

    ChapmanF Senior Member

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    The 04003-35147 kit that your dealer is holding for you has the right stuff in it. The orange (believe me, it is originally orange, not black and crispy like yours) 26-pole plug is hanging off the front busbar assembly.

    The ECU might also have a white or other color plug attaching to it for the five or so temperature sensors spread across the top of the row of battery modules. That wiring is not included in the kit. If yours is ok, you can reuse it - if not, you'll need to order the battery thermistor wiring (I'm expected for lunch so I'm not jumping over to Village Toyota online to look it up just now). With any luck yours is ok.

    All of the wiring needed for voltage sensing and carrying power within the battery is included in your kit.

    -Chap
     
    #48 ChapmanF, Sep 9, 2014
  9. lovemy02prius

    lovemy02prius Member

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    #49 lovemy02prius, Sep 9, 2014
  10. lovemy02prius

    lovemy02prius Member

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    Ahhhh I just seen this message~! so the kit does have the correct harness (hurray!!!) and the missing small white plug in i need to order separately, OK mystery solved!!! THANK YOU CHAP!!!
     
    #50 lovemy02prius, Sep 9, 2014
  11. lovemy02prius

    lovemy02prius Member

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    Hey Chap and anyone else...
    Metro Toyota Parts says it could be Part#: g928247030 - Hybrid battery thermistor wiring harness $38.99
    (this part number doesn't show up when i search on there website but shows in toyota dealerships part data base 1 day ship so i ordered it
    i hope this is the correct part and i hope if it is then everything i went through to verify it.

    So to be clear for anyone else who has this problem, first I put my 12v on charge and verified it was good.

    Next, here's what I purchased so far:
    1.) ECU 2001 - 2003 Only 89890-47030 and 89890-47060 are listed as usable. (if you feel you need to be on the safe side)
    $100 - $150

    2.) 40g kit Harness Kits: part number 04003-35147 Years ago there was a service campaign for leaks in these batteries, and they put together a replacement parts kit for that job. $117 - $139 (main wire harness to ecu (comp assemp battery) bus bars and other parts included for the same price as the ala cart harness. contains Protective Electrical gloves etc

    3.) Parts: g928247030 - Hybrid battery thermistor wiring harness $33 - 38.99
    if you need to replace the smaller wire harness that plugs into the small rectangle shaped 8 pin female on your ECU.

    still looking for the full length 40g doc as i only have the 3 page notice.





    Thanks for your help
     
    #51 lovemy02prius, Sep 9, 2014
  12. lovemy02prius

    lovemy02prius Member

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    Here is the "TECHNICAL INSTRUCTIONS FOR SPECIAL SERVICE CAMPAIGN 40G"
    2001 THROUGH 2003 MY PRIUS HYBRID VEHICLE (HV) BATTERY MODIFICATION

    This is the 56-page Tech Instructional (not to be confused with the 3 page Notice to the Dealers)

    http://techno-fandom.org/~hobbit/cars/TIS/ileaf/toyssc/toysspdf/sscsourc/2004/40g/40gtech.pdf

    I'm still seeking the related Training Video (or is this in the 40 g kit I ordered from Toyota)

    Thanks for all your help and especially some of your cute humor along the way...which makes me smile : )

    I
     
    #52 lovemy02prius, Sep 9, 2014
  13. lovemy02prius

    lovemy02prius Member

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    Hey guys,
    We pulled the traction battery out today and brought it to the machine shop to work on tomorrow al day. We picked up all the parts incl boric acid and litmus paper + the safety equipment (except a high voltage matt to stand on, however we have some heavy duty vinyl matts that we will double up) Were reading the 56 page doc now but still haven't found the instructional video..Anyone have a link to that?? It would really help.
    Also were just wondering besides the normal safety measures ie using the safety tools such as vinyl taped tools, goggles, vinyl matt, electric gloves rated for 1000+ then disengaging the 12v battery, pulling the main orange switch of the hybrid to disengage it, waiting the 10+ minutes for it to drain, using the voltage reader...Im assuming once the hybrid battery is opened the first thing wed remove is the bus bars...besides using one hand to remove the bus bars, does anyone else have any advice or helpful tips to avoid problems.. (namely getting electra-cated jejeje)

    ALSO

    I had a Question about the hybrid battery "cells", I had a few spares one reads at 6.34 volts. Does this mean it's bad?

    Is there some way to "charge" it up or repair it??

    what should it read to be good 7.2 minimum?? and maximum??

    Thanks!!
    M.
     
    #53 lovemy02prius, Sep 11, 2014
  14. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Minor technical point but each module consists of six cells. They share a common 'vent' space which helps keep the individual cells somewhat even. Now about the module voltages:
    • <5.8V or lower - very, very risky. Try a charge but this is getting in a bad place.
    • 6.0V - lowest operational level, ~1V per cell
    • 8.0V - highest reasonable level, ~8/6V per cell or 1.333V per cell, as much as I feel comfortable with
    • >8.0V - gosh, you really want to stress test the module?
    Bob Wilson
     
    #54 bwilson4web, Sep 11, 2014
  15. lovemy02prius

    lovemy02prius Member

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    Hey were ready to go tonight,
    Questions:
    I DO NOT SEE ANY SEALANT IN THE KIT I BOUGHT, WHAT KIND OF SEALANT IS IT EXACTLY (alternatives or where can I buy it?) AND WHAT KIND OF ABSORBENT PAPER.

    ALSO DO I HAVE TO FLASH OR PROGRAM THE REPLACEMENT ECU MODULE??? (Mime fried) We didn't cover that?? How do I do that??
     
    #55 lovemy02prius, Sep 11, 2014
  16. lovemy02prius

    lovemy02prius Member

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    HELP...jejeje
     
    #56 lovemy02prius, Sep 11, 2014
  17. ChapmanF

    ChapmanF Senior Member

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    Hi...

    By absorbent paper, do you mean the little notched-squares that are intended to be adhered under the positive terminals? You should find those in the kit you bought, if you look carefully ... look for a small plastic bag tucked in near the front of the cardboard package the kit came in.

    There is not sealant included in the kit. If you look at the 56-page procedure you downloaded, the order number for the sealant is shown on page 6 (right below the order number for the kit). I think they sell it separately because the sealant has a short shelf life, while the rest of the kit doesn't. :)

    If you flip way to the back of the same document, you can find a material safety data sheet for the sealant, which identifies it as "3M water based adhesive bond 7 JA-7632". But 3M makes so many specialty products that it's quite possible no normal 3M distributor carries this particular stuff and there'd be no source to supply it other than Toyota.

    From reading posts of other PriusChat members who have worked on the battery, I don't think that many bother to reapply sealant. It seems more like a very good thing to make sure that service was done if buying a used Gen 1, but then you just hope the battery lasts as long as possible before you have to take it apart, and then if you do, the sealant will just make the job messier and more tedious.

    -Chap
     
    #57 ChapmanF, Sep 11, 2014
  18. ChapmanF

    ChapmanF Senior Member

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    Oh, I'm not aware of any specific ECU reprogramming requirement - I haven't seen anything about it in the manuals. I think the ECU does count charge in and out of the battery as a way of tracking state of charge, and that might not match your new modules as assembled, but it also measures voltages and has a rebalance cycle it goes through from time to time, so my guess is that even if it starts out confused it won't stay that way forever.

    -Chap
     
    #58 ChapmanF, Sep 11, 2014
  19. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Can you post the module voltages from 1 to 38 where 1 is adjacent to the battery ECU?

    Bob Wilson
     
    #59 bwilson4web, Sep 11, 2014
  20. lovemy02prius

    lovemy02prius Member

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    Were freaking out, the cars been sitting since fathers day! The cells tested perfect a month prior fo fathers day...now they have low voltage. How do we charge them exactly?? and is it best to fill (top them off) them distilled water or sulfuric acid? I cant afford to buy 38 new cells..SOS Save our Sells......LOL


    1. 6.66
    2. 5.03
    3. 4.035
    4. 4.63
    5 4.73
    6. 3.66
    7. 3.8
    8. 3.655
    9. 4.64
    10. 3.654
    11. 3.849
    12. 3.353
    13. 3.334
    14. 3.373
    15. 3.424
    16. 4.94
    17 4.65
    18. 3.785
    19. 3.429
    20. 3.477
    21. 4.44
    22. 3.344
    23. 3.475
    24. 3.84
    25. 3.915
    26. 3.383
    27. 3.179
    28. 3.733
    29. 3.743
    30. 4.17
    31. 5.5
    32. 3.593
    33. 4.55
    34. 6.33
    35. 4.49
    36. 4.29
    37. 5.79
    38. 5.83
     
    #60 lovemy02prius, Sep 12, 2014
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