My 2007 GS450H is similar to a Prius except it has 40 battery blades whereas a Prius has 28. I have just installed 40 new blades in my GS450H. Pack looks good according to diagnostic (photo) but getting error code P0A0D. Safety plug was correctly installed but there is almost no voltage at the port. I have discovered there is almost no voltage at the battery terminals the safety port is attached to (photo). When I test these terminals independently they show 150V and 165V respectively. What could be wrong? Thanks
There is nothing wrong with the hybrid battery. You are only seeing 2.4v on the meter because of where the positive and negative probes of the meter are connected to. Think about what you are measuring across those two terminals.
If your safety plug is similar to the Prius, you probably missed the last step of installation where you have to slide the lever about a half inch to engage the safety interlock contacts. If you didn't do this last step, the car thinks the interlock device is not installed. It could also be that during your rebuild, you forgot to install the interlock wire at the contact point on the interlock socket.
To answer all the fuse in the safety plug is ok and handle slide locked after insertion. The voltage on my old pack was a red herring. Probably due to shorts in old batteries. I swapped the wiring from the old pack except those connected to blade terminals. Now the vehicle runs and drives but shows battery code P0AFA, low voltage. Monitor shows both modules 8 and 9 pulsing from over 15V to 0V. Vendor is sending me new blades but I’m not sure that’s the answer. Thanks everyone for your responses.
There is a problem with the voltage sensing wires and/or the battery ECU. It sounds like you did not purchase a new OEM replacement hybrid battery. Where did you buy the new battery blades (modules) from?
Monitor shows both modules 8 and 9 pulsing from over 15V to 0V. This is actually Block 8 and 9, which is 4 modules total, right? The good news is "pulsing from over 15V to 0V" is physically impossible for a block/module to do for real, and is only an indicated value that is flip flopping. As mentioned, most likely due to failing connections in the wiring harness or ecu/ecu socket.
