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Red Triangle and P3009-526

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Sts70004, Feb 4, 2018.

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  1. Sts70004

    Sts70004 Junior Member

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    Hi all, first time posting, I’ve been lurking around the boards for a couple weeks while trying to fix my 05 Prius. It’s got 220,000 miles on it, and here’s the run-down:

    -Red triangle and hybrid warning light and car won’t start.
    -Reset the computer by unplugging the 12v battery
    -Drove home, all the while the MFD was talking about not charging the battery because of the transaxle or something or other (confession:someone else was driving it)
    -Found the aux battery halfway under water, so I drained the well
    -Fixed water leaks, car ran fine for a week
    -Red triangle comes back, take to Toyota
    -They tell me P3009-526, corrosion in the battery case, new battery ($3200 lol)
    -Find you guys, so I take the battery apart, and yes some corrosion, but no shorts to ground.
    -Remove battery, clean and grease the terminals, and reinstall
    -NOW the car won’t even start after resetting the computer...
    -Check cell voltages, first and last were 7.49 and 7.53 respectively, all other cells are 7.72-7.76

    Now I’m stuck... any ideas on what to look for next?
     
    #1 Sts70004, Feb 4, 2018
  2. hchu1

    hchu1 Active Member

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    Did you reinstall the orange hv power disconnect properly?

     
    #2 hchu1, Feb 4, 2018
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  3. Sts70004

    Sts70004 Junior Member

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    At one point, no, but did figure it out
     
    #3 Sts70004, Feb 4, 2018
  4. fotomoto

    fotomoto Senior Member

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    So it's running now?
     
    #4 fotomoto, Feb 4, 2018
  5. Sts70004

    Sts70004 Junior Member

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    No, I figured out myself that the orange plug was in wrong. Still not running
     
    #5 Sts70004, Feb 4, 2018
  6. fotomoto

    fotomoto Senior Member

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    It's best to check the HV modules voltage under load while the batt is out of the car; a popular method is connecting one module to a headlight bulb for a minute or so and check readings. For example, a 12v batt can have a "good" resting voltage but fails when trying to start an engine.

    If it's still the original HV batt in the 05, odds are it's most likely toast by now.
     
    #6 fotomoto, Feb 4, 2018
  7. TMR-JWAP

    TMR-JWAP Senior Member

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    sts,

    Do you have any current fault codes?

    A lot of 'first and only time' battery disassemblers forget to plug in the small wire harness connector to the bottom of the safety disconnect receptacle. When you install the HV battery, there are three connectors that get plugged in. A large one, a medium one and a small one. The small one plugs into a receptacle near the top of the battery. That receptacle is connected to a very short wire that also has a plug on the opposite end which plugs into the safety disconnect receptacle. When the safety dsconnect is installed, the final step of pushing the handle downward inserts a shorting wire across this plug and signals that the disconnect is installed. This end of the wire typically gets unplugged when disassembling the battery. Sometimes it gets forgotten about and doesn't get plugged back in. It will cause the battery to think the safety disconnect is not installed.
     
    #7 TMR-JWAP, Feb 4, 2018
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  8. Sts70004

    Sts70004 Junior Member

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    TMR and Fotomoto, I’ll look into these and report back, thanks for some ideas!
     
    #8 Sts70004, Feb 4, 2018
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  9. Dxta

    Dxta Senior Member

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    You're very correct. I ha e had to spend close to 5hours troubleshooting why a Neely installed HV battery I had once worked on could not immediately start. Found out it was just that small connector you explained, that wasn't connected at all. Was really silly! But atleast, got the car started afterwards.
     
    #9 Dxta, Feb 5, 2018
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  10. Sts70004

    Sts70004 Junior Member

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    Foto, haven’t done the load test yet, but will be coming up next. And yes it’s the original battery from 05. This car was driven under pretty ideal conditions for a hybrid, relatively short trips several times a day every day. Believe it or not I run an encapsulation carpet cleaning business.

    TMR, I looked and it appears I attached all the wires properly. I’ve uploaded a pic for clarification. And for this pic I’ve got the service plug out. Found a Toyota document for troubleshooting this code with a megohmeter. That being said I don’t have the codes from after I reattached the battery. I’ll have to look for a reader.
     

    Attached Files:

    #10 Sts70004, Feb 6, 2018
  11. Sts70004

    Sts70004 Junior Member

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    A curiosity led me to measure the voltage on the two sides of the HV relays. 216v (I think it’s been a couple hours since I measured) on the battery side, and 208mv on the car side with the car booted as far as I can get it. Perhaps that may mean something?
     
    #11 Sts70004, Feb 6, 2018
  12. TMR-JWAP

    TMR-JWAP Senior Member

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    sts,
    The wire I'm discussing is the purple one. It plugs into that receptacle "A" directly above the safety plug. The wire that leaves the other end of receptacle "A" is only a few inches long and plugs into another receptacle (let's call it "B") on the opposite side/bottom of the disconnect switch. This wire at "B" typically gets unplugged during battery disassembly, and sometimes gets forgotten about and doesn't get reconnected. Since this is the wire that senses the safety interlock, it will cause the battery to act as if the safety plug is not installed.

    You can see the wire immediately at the start of the video in post #2. At the bottom left corner of the disconnect.
     
    #12 TMR-JWAP, Feb 7, 2018
    Last edited: Feb 7, 2018
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  13. Sts70004

    Sts70004 Junior Member

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    So I got it running! As it turns out... that somehow, despite the fact I know you have to slide the service grip handle down, and did that once before when I had accidentally left a wire unplugged... I did not slide it down after I confirmed all the wires were plugged in.... so in essence I’m just a dummy. Thanks for all the help in this!
     
    #13 Sts70004, Feb 7, 2018
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  14. TMR-JWAP

    TMR-JWAP Senior Member

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    wooohooooooo!!! It's always nice to hear a success story.
     
    #14 TMR-JWAP, Feb 7, 2018
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