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'06 Prius Cell Replacement?

Discussion in 'Gen 2 Prius Technical Discussion' started by Amonty, Dec 14, 2015.

  1. Amonty

    Amonty New Member

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    Four
    Hi All! I am a long time lurker. I do not own a Prius however I am the family mechanic and just inherited a problem where I need help! This is my sister's 2006 level 4 Prius. Backstory... my Mom actually WON this car in a Casino in Colorado in 2005 and gifted to my sister in 2013 when my mom bought a new one. It's served our family well (currently has 190K), however recently my sister had it towed to me because she says sometimes it starts sometimes it doesn't. She took it to our local Toyo dealer who diagnosed it with a code related to a HV leak "up to 100v" they recommended replacing the HV battery pack and quoted her $2500. I asked her to tow it to my house being handy to see if I could fix it.The car has been sitting for about 3 weeks since my sister's in-laws let her borrow one of their cars. When I received it I found the AUX battery was at 12.7v when it got to my house. I removed all the necessary components to test the HV battery, I found minor corrosion on the cell terminals (most on the HV output positive lead). After removing the cover of the HV pack there are no visible leaks. Here are the voltages I got from the individual cells. Starting from the computer (driver side) to the end (pass side).

    1. 7.52
    2. 7.49
    3. 7.52
    4. 7.49
    5. 7.53
    6. 7.45
    7. 7.51
    8. 7.47
    9. 7.51
    10. 7.35
    11. 7.49
    12. 7.44
    13. 7.46
    14. 7.48
    15. 7.49
    16. 7.38
    17. 7.49
    18. 7.47
    19. 7.49
    20. 7.45
    21. 7.50
    22. 7.45
    23. 7.51
    24. 7.47
    25. 7.43
    26. 7.49
    27. 7.52
    28. 7.45

    I guess I don't know where to start. I'm familiar with electrical repairs and am comfortable fixing about anything on this car just looking for some experienced advice. Thanks for your advice!
     

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    #1 Amonty, Dec 14, 2015
  2. valde3

    valde3 Senior Member

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    Have you read the actual code?

    If it’s HV-leak it’s more likely in the AC system. Has AC been recharged at some point? If they used incorrect oil (or even contaminated equipment) it will cause HV-leak. If you unplug AC compressor HV-leak caused by AC will stop.

    To diagnose this you should first read the codes. If you want to do it yourself get mini-VCI it’s cheap and can do basically everything that dealer can. Then if it’s HV-leak and it is not fixed by unplugging the AC compressor get megohmmeter to find the fault.
     
    #2 valde3, Dec 15, 2015
  3. bisco

    bisco cookie crumbler

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    welcome! $2500. maybe he lowest price ever quoted by a dealer for a new pack, installed!
     
    #3 bisco, Dec 15, 2015
  4. Amonty

    Amonty New Member

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    Four

    Here's what the RO says "CODE P0AA6, HIGH VOLTAGE INSULATION LEAK. REMOVED HV BATTERY COVER AND FOUND THE VOLTAGE LEAK OF UP TO 110 VOLTS AT RIGHT SIDE OF BATTERY. REPAIRS DECLINED"

    My guess is the dealer quoted $2500 because they are using an aftermarket part or remanufactured part. I can only assume they thought my sister wouldn't pay for a part worth the same amount of her car. LOL


    I asked my sister and she's never had any AC repairs other than replacing the blower motor herself with my instruction. The rest of the system is OEM with original oil and refrigerant.


    Okay... She just told me something I didn't know. I guess there's an AC leak and she's used a product called "A/C Pro" two times this year to recharge the system.
     
    #4 Amonty, Dec 15, 2015
  5. strawbrad

    strawbrad http://minnesotahybridbatteries.com

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    What you called and pictured the "HV output positive lead " is not, Those two cables connect to the orange safety disconnect plug. Your battery bus bars are some of the blackest I have ever seen on a Gen II. Invisible amounts of leaked electrolyte can cause a HV leak.

    Do you understand that HV is leaking out of where it should be to everywhere in your car?

    Starting points:

    Disconnect the AC compressor plug. It is a big orange plug under the inverter in the engine compartment. The AC compressor uses a high voltage electric motor. It is not belt driven. Normal AC oil is conductive. Adding such oil to a Prius establishes a path for high voltage to leak out. If pulling the plug fixes the leak you have found the problem.

    A P0AA6 codes allows a Gen II Prius just one start. Once you shut the car off it will not restart. Pulling the 12 volt battery will clear the code and you can start the car just one time again.

    Watch this You Tube video. It shows a no tool needed method of finding the source of the HV leak.


    Buy a Mini VCI cable. You are working in the dark without one.

    It is a little more complicated than that. There is a HV reference to ground through the most negative voltage sensing line and the battery ECU. A non leaking battery will show continuity to ground. The ECU reference is used to detect HV leaks.

    YES, buy a Mini VCI cable.

    Toyota thought this was serious enough to disable the car. On Gen I and again on Gen III you can keep driving with a HV leak.

    Pulling the AC compressor HV line is quick and easy. If she contaminated the AC system $2500 might not be enough. How's driving in Florida without AC?

    Watch the You Tube video. It is easy and quick to get an idea of where the leak is.

    Brad
     
    #5 strawbrad, Dec 16, 2015
    m.wynn likes this.
  6. Amonty

    Amonty New Member

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    Thanks! I'll move from here. I already started cleaning the bus bar and battery nuts last night. I'll hook it all up without reinstalling upholstery and buy a mini vci.
     
    #6 Amonty, Dec 16, 2015
  7. S Keith

    S Keith Senior Member

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    This one worked for Gen1 & Gen2 and arrived pretty quickly:



    I thought the buss bars were just in shadow. As Brad pointed out, those look very wrong. They look way worse than my Gen1 that had obvious electrolyte leaks. I suspect it may be an effect of salt laden air due to your proximity to the ocean.

    Brad,

    Thanks for setting me straight. I have some reading to do.

    Steve
     
    #7 S Keith, Dec 16, 2015
  8. strawbrad

    strawbrad http://minnesotahybridbatteries.com

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    #8 strawbrad, Dec 16, 2015
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