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.

Page 7 of 10
  1. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    ok, we put the new kit on the car (bus bar main harness wire etc) and installed the replacement (used) charged the batteries all day & night and it seemed like they were doing a decent job holding between 6 - 7 v
    we charged the 12v to 12.6
    we installed the battery on the car and popped in & flipped up the orange activation key
    and the lights and screen came on with a toyota logo and then to a screen that said problema with the main battery icon lit up.
    we turned the key and NOTHA it made a slight thump like it was trying to connect with a starter then notha
    we left the orange key activated & test for voltage @HV POWER CABLES and it was .56v ! half a volt! nothing there! (behind the drivers seat see step 8 on 40g)

    anyone have a clue?

    if the replacement ECU is no good would we still get a normal voltage reading of the cells at the HV Power Cables??

    If there is 1 bad cell or a couple would that prevent a normal voltage reading of the cells at the HV Power Cables?

    are we taking a voltage reading at the wrong spot???

    or did we miss a step assembling it back together somehow???

    Thanks!!!
     
    #121 lovemy02prius, Sep 13, 2014
  2. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,788
    15,433
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    The SMR interrupts at one end the two ends of the whole battery. The safety plug and fuse are what interrupt in the middle.

    -Chap

    Edit: late at night I only remembered "one end".
     
    #122 ChapmanF, Sep 13, 2014
    Last edited: Sep 14, 2014
  3. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,788
    15,433
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    That's totally possible too ... there's a lot of steps, some could be easy to miss.

    Get the diagnostic codes and let the computer tell you what it is and isn't seeing.

    Until then you're making guesses.

    -Chap
     
    #123 ChapmanF, Sep 14, 2014
  4. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    also when we first began we got 60 volts at module 19 & 20 (on Backside bus bar terminal)
    After we installed the new parts we got 0 volts

    i hope there is a simple or logical explain and solution! help!
     
    #124 lovemy02prius, Sep 14, 2014
  5. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,788
    15,433
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    One more thing ... you've now reached that stage of a project where (as often happens) you've done everything you thought you were supposed to, but something still doesn't work.

    In my own projects, I've noticed that this is the stage where I get as hasty and sometimes careless as I ever get. I thought I was done, I want to be done, and I'm in a real big hurry to find out why I'm not done.

    Resist that. Remember that now you have put all the bus bars back on, you have assembled a 300 volt battery. Please don't let yourself forget that for even a moment while trying to track down the last trouble spots.

    -Chap
     
    #125 ChapmanF, Sep 14, 2014
  6. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    do i need the machine to get the codes?

    can i do a home style test or pin test?
     
    #126 lovemy02prius, Sep 14, 2014
  7. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,788
    15,433
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    There is, but none of us have it yet. It will only be found by getting enough information, which will have to be collected by you acting in a simple and logical manner.

    -Chap
     
    #127 ChapmanF, Sep 14, 2014
  8. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    got cha chap thanks, we have been diligent in taking safety measures through the whole time, even installing, testing for a reading etc
     
    #128 lovemy02prius, Sep 14, 2014
  9. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,788
    15,433
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    Mini VCI, ScanGauge II, Torque app ... all workable options. Have you got any of those? I assumed before you tore into the battery you had at least some way to read codes.

    Sadly, the codes that matter most will be the ones in the Battery ECU and the HV ECU, and those are the two that don't have blinkenlight code-reading alternatives ... they only talk to a scan tool.

    -Chap
     
    #129 ChapmanF, Sep 14, 2014
  10. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    I believed we followed every step to the t except we skipped the sealant steps. I feel : (
     
    #130 lovemy02prius, Sep 14, 2014
  11. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    I can get a pro scan tool over here to test it. I wouldn't know where to hook it up though. The friend bringing it over test batteries for a living but has no experience with hybrids..ill check an see if there is a link to a vid out there
     
    #131 lovemy02prius, Sep 14, 2014
  12. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,788
    15,433
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    It's quite possible you did. Following instructions to the t is one important skill for doing a project like this. At the end there usually comes an 'integration' step where the unforeseen comes into play, and then the skill set needed shifts to staying calm while gathering the information needed to figure out what's what. Don't despair ... this is kind of a normal part of any nontrivial project....

    -Chap
     
    #132 ChapmanF, Sep 14, 2014
  13. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,788
    15,433
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    Make sure whatever tool gets brought over is able to scan all the Gen 1 Prius computers, or you'll just waste your time. Obviously if you know someone who can bring over a Techstream setup from the Toyota dealer, that definitely counts. Otherwise, there are plenty of threads on this forum where you can look up what works. I gave a few names you can search for, a couple posts ago.

    The diagnostic connector where you plug the scan tool in is facing downward in the plastic dash panel underneath the steering wheel. Look up from about where your left knee goes.

    If you haven't already, now would be a good time to sign up over at techinfo.toyota.com so you can explore the service manuals. You ask a lot of good questions, and it'll go faster if you know where the answers are.

    How about posting some pics of your reassembled battery (if you took any before putting the cover back on ... or if you have time to take the cover off again while waiting for a scan tool)? You could try to get good sharp pics of all the important connection points ... the cabling from modules 1 and 38 to the SMR on the front, from modules 19 and 20 to the safety plug/fuse assembly on the back, the reassembly of the safety plug assembly (one of the cable ends is just a blade that directly forms part of the safety assembly, right?), all the electrical connections to the ECU, etc. Tedious, but it might give you something to do if there's no scan tool right away, and maybe someone will spot something.

    Also you could get voltage readings from module 1 (where the SMR cable attaches) to 19 (where the safety cable attaches), and from 20 (where the safety attaches) to 38 (where the SMR attaches) and post those.

    -Chap
     
    #133 ChapmanF, Sep 14, 2014
  14. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    The scan tool were using is a
    MAC ET80 and its saying there are NO codes

    when you arrow to the next screen it says

    Engine
    Engine
    module #D5


    If the used replacement ECU computer is bad would it still give out codes? I'm not sure where the codes are generated.maybe the ECU we installed is no good because I thought it would at least give us some codes?
    (I never did find the list of codes on line)

    Now were charging the 12v to the correct amps

    Could it be the "starter" ? where is that located or does anyone have a diagram? its sounds like the "starter" is trying to turn over. Shouldn't I hear the fuel pump hum or something? which is exactly what it was doing before i drained the 12v on fathers day.

    Again here's what it's doing:
    you turn the key and all the lights com on the screen loads and settles on a page that says "problema" & "main battery" icon is lit up the explanation point in the triangle is not lit up on the screen but is lit on the dashboard. when you try and start the car you hear a vague thump of the starter engaging maybe or then nothing.)



    I


    THANKS!!!
     
    #134 lovemy02prius, Sep 14, 2014
    Last edited: Sep 14, 2014
  15. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Is there even an actual Starter on this car????
     
    #135 lovemy02prius, Sep 14, 2014
  16. Britprius

    Britprius Senior Member

    Joined:
    Jun 14, 2010
    5,194
    1,914
    0
    Location:
    Herefordshire England
    Vehicle:
    2008 Prius
    Not as such. The engine is started by MG1 (motor generator 1) in the transmission. So the HV battery has to be supplying voltage before the engine will turn.

    John (Britprius)
     
    #136 Britprius, Sep 14, 2014
  17. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    now trying to scan it with a mac 5500

    no codes

    the screen also giving a "breaks" lit up
     
    #137 lovemy02prius, Sep 14, 2014
  18. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    Using a 3120 LAT from oriellys auto it says no powertrain DTC or freeze frame data is presently stored in the vehicles computer
     
    #138 lovemy02prius, Sep 14, 2014
  19. lovemy02prius

    lovemy02prius Member

    Joined:
    Jul 24, 2014
    127
    5
    0
    Location:
    ferndale
    Vehicle:
    2002 Prius
    Model:
    N/A
    [QWhen I scan the abs option it gives a C1259 toyota abs current HV SYSTEM Regenerative malfunction
     
    #139 lovemy02prius, Sep 14, 2014
  20. Britprius

    Britprius Senior Member

    Joined:
    Jun 14, 2010
    5,194
    1,914
    0
    Location:
    Herefordshire England
    Vehicle:
    2008 Prius
    I believe the problem you are facing is that the code readers you are using will not read the Prius specific hybrid and transmission codes.

    The best one in my opinion "but not the only one" is the Mini VCI with Techstream.

    John (Britprius)
     
    #140 Britprius, Sep 14, 2014
(You must log in or sign up to post here.)
Page 7 of 10