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'06 completely dead after hybrid battery cell replacement

Discussion in 'Gen 2 Prius Main Forum' started by Isaiahdrivingaprius, Jun 22, 2023.

  1. Isaiahdrivingaprius

    Isaiahdrivingaprius New Member

    Joined:
    Jun 22, 2023
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    Location:
    West Covina, CA, US
    Vehicle:
    2006 Prius
    Model:
    II
    I have a 06 prius 300k miles and she runs strong till she needs a cell replacement. I know this car is very old and very used but she still does pretty okay MPG and I cant use another car yet. Heres the issue i replaced a cell and now the car went dead. Process: I took the battery put stripped it to he cells were exposed only stripped what i needed to. Replaced the 2 bad cells I had,put them back on and then back into place on the battery. Put the bottom and side screws back on with the wire connections. Put it back in the car with the wire plugs all in and the 2 main connectors. When i clicked start for the car it showed all the error signals and wont even turn on the gas engine. What went wrong?
     
    #1 Isaiahdrivingaprius, Jun 22, 2023
  2. SFO

    SFO Senior Member

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    Feb 7, 2017
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    Location:
    Northern California
    Vehicle:
    2007 Prius
    Model:
    N/A
    Welcome to PriusChat!!

    Is the orange HV battery safety disconnect switch installed properly, and did you try to 'start' or make the vehicle ready two (2) times?
    Error signals (warning lights) are a sign that there are obd2 codes stored in the computers (ECUs), scan and post here for guidance.

    FYI : you're moderated until you've posted 5 times.
     
    #2 SFO, Jun 22, 2023
    PriusCamper likes this.
  3. mr_guy_mann

    mr_guy_mann Senior Member

    Joined:
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    Location:
    NJ-USA
    Vehicle:
    2006 Prius
    Model:
    Four
    Do you have a scantool that can retrieve codes from all systems on a Gen2 (2004-2009) Prius?
    Here's a review of several scantool options.
    https://priuschat.com/index.php?posts/3290690

    One possible problem, the orange HV fuse holder wasn't correctly installed. It's 3 steps. Insert the holder. Swing the lever in. Slide the lever straight down until it clicks. Pretty common to skip the last bit.

    Another possibilty is a bad connection at a battery "module". The busbars have to be reasonably clean and the nuts should be torqued to 48 INCH-pounds.

    Or there's corrosion at the orange connection on the HV battery ecu - this usually requires getting a new voltage sense harness and a used ecu.

    If you get it running, cross your fingers because "just" replacing modules often (most times) results in a repeat P0A80 because the "new" used modules have different effective capacity and state of charge vs the existing ones.

    Good luck. Screenshot_20230108-154956.jpeg

    Posted via the PriusChat mobile app.
     
    #3 mr_guy_mann, Jun 23, 2023
  4. donbright

    donbright Active Member

    Joined:
    Feb 17, 2018
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    Location:
    oklahoma
    Vehicle:
    2007 Prius
    Model:
    Two
    did you use a multimeter to test the total voltage after you replaced cells?

    If you can bring it up enough to get an OBDII reader working, you can also get total voltage that way, as well as reading individual cell voltages, as well as cell resistance, using the Torque App ( i had good luck with BAFX bluetooth obdii + android phone, your mileage may vary)
     
    #4 donbright, Jun 24, 2023
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