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Gen 2 isolation code issue

Discussion in 'Gen 2 Prius Main Forum' started by lalloyd, Dec 22, 2023.

  1. lalloyd

    lalloyd Junior Member

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    First off I repair hybrids for my living but I definitely don't know everything. I really appreciate this group and learn from it every time I visit. Now my new find. Gen 2 comes in with isolation code issue. Detail code shows only 526. So I am thinking traction battery most likely the culprit. Install a known good one. Within 2 minutes code sets again. Unplug the ac compressor at inverter, sets code again. Head scratcher. Swap out inverter with known good one. Code sets again. Okay, I did not get the detail code 525 but at this point I am looking at the transaxle. Pop the cover off the inverter and check the resistance of the transaxle windings, all good??? While I am in there I check the main cables coming from the traction battery. There it is. One is showing short to body ground. Disconnect cable from battery and it is still there. Cable showing signs of being overheated. The shield on the cable had shorted into the inner cable causing the isolation code. A first for me. Has anyone else ran into this. What could have caused the overheated wire condition? I am a bit concerned that it will happen again. Thank you
     
  2. ChapmanF

    ChapmanF Senior Member

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    A mistorqued or dirty connection, some piece of grit that didn't let the terminal sit flat, a bad crimp, I don't know. Have you replaced the cable with a new one and torqued it to spec?

    When you have only the 526 INF code, the thing to do is to leave that code alone (not clearing anything) and power cycle the car again; when it sees the 526 on a subsequent power-up, it runs through extra tests to set one of the 611, 612, 613, 614 codes, which then help you narrow down the search.
     
  3. Tombukt2

    Tombukt2 Senior Member

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    Have you remove the cable and tested the wire and you know that this is bad? You'll need the second subcode that comes from the next reboot without clearing codes so far and most of my cars which I think there are five generation twos It is generally been the battery itself individual modules leaking to ground so the battery is no longer isolated I just went through this in an '08 that I got for near nothing and it turned out one module was leaking the ground and I couldn't tell where from no acid no leaking just voltage escaping replace the modules on each side of it and that one and the car's been running immaculately for the last 3 weeks I have only heard of the orange wires leaving from the traction battery to the inverter going bad once or twice right here on this list but then when I ask the question what did the wire test and do when you got it out they don't have it It's already been replaced and thrown away
     
  4. lalloyd

    lalloyd Junior Member

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    Thanks for the reply. Main problem I found with trying to get a more definitive detail code is when you turn the car off you have to clear the codes to get the car to go to "ready" thus making my job harder. I replaced the cables, all fine now. I think the crimp on the cable bit into the inner cable, but why? Maybe when the last battery was installed the guy over tweeked the cable trying to remove the battery? Hope it does not happen again.
     
  5. lalloyd

    lalloyd Junior Member

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    Yes cable bad. thanks
     
  6. ChapmanF

    ChapmanF Senior Member

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    Getting it to "ready" is not what you want. What you want is for it to error out with the additional detail code that tells you the problem. Which is what happens when you try to start it that second time and it errors out.
     
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  7. Tombukt2

    Tombukt2 Senior Member

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    So then all the other stuff is moot like I say I've never been able to see that problem personally so I'm hoping that it is from people playing with the wires on battery changing battery fixing etc It just doesn't happen by itself or by sitting there hopefully I can't imagine having to jerk cables running from the back of the car all the way to the front because they just go bad sitting there but I guess anything is possible even though this voltage is not that high and so on and so forth but whatever so less than the dryer plug at my house voltage wise. We personally haven't had the bad cable issue yet although I imagine with the amount of these cars that come through here at some point I might see it same with the failing motor generator in the transmission so far never seen only read about.