1. Attachments are working again! Check out this thread for more details and to report any other bugs.

Problem after module replacement

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by thebean04, Nov 21, 2015.

  1. thebean04

    thebean04 New Member

    Joined:
    Nov 21, 2015
    6
    0
    0
    Location:
    Tennessee, USA
    Vehicle:
    2007 Prius
    Model:
    II
    Hello all,

    First time posting here, so please be gentle...

    HISTORY:
    I have spent the last few weeks replacing some bad modules in my 2007 prius, following this thread:
    Gen II Prius Individual Battery Module Replacement | PriusChat

    This has been my order of steps:

    - Remove HV battery
    - Replace 3 bad modules
    - Re-assemble battery for balancing
    - Discharge/charge each module 3x using HiTec AC-Plus
    - Discharge all modules back to 7.85v
    - Wire modules in parallel to balance (24 hours)
    - Re-assemble pack and re-install into car
    - Replace 12v battery, as it was bad

    THE PROBLEM:
    I have the HV battery bolted in and the leads to the car attached, but when I plug in the safety switch, I get a good 220v on the battery side of the connectors, but I am getting nothing on the car side. Consequently, when I turn the car on, I am only getting auxiliary electrical, but nothing from the HV battery. The car is still showing a number of indicators (pictures attached) and will not switch out of park.

    I am hoping I have just missed something simple. For the amount of time I have invested in repairing this HV battery, I will be very disappointed if I am not able to get it back up and running.

    Any suggestions would be welcome. Thanks in advance!

    BG
     

    Attached Files:

    #1 thebean04, Nov 21, 2015
  2. JC91006

    JC91006 Senior Member

    Joined:
    Nov 10, 2013
    16,496
    8,406
    0
    Location:
    Los Angeles, CA
    Vehicle:
    2008 Prius
    Model:
    II
    Did you lock in the orange interlock switch properly? You have to push down the lever to lock it.

    upload_2015-11-21_9-26-34.jpeg
     
    #2 JC91006, Nov 21, 2015
    strawbrad likes this.
  3. thebean04

    thebean04 New Member

    Joined:
    Nov 21, 2015
    6
    0
    0
    Location:
    Tennessee, USA
    Vehicle:
    2007 Prius
    Model:
    II
    Thanks JC! That was the problem.

    Though, now that I have addressed that, I am now having new issues.

    I (fully) engaged the safety switch, turned the car on, and went for about a 1.5 mile test drive to see if I could get it to throw a code. I got two:
    P0301: Cylinder 1 Misfire (I am hoping this is just because the car has sat unused for almost 4 months and had a rough start the first time)
    P3021: Battery Block 11 Becomes Weak (This is not a surprise. Based on the data from my discharge/charge cycles, I new Module 11, along with a couple others, was a bit weaker than the rest. Didn't realize it was weak enough to throw a code.)

    Also, I am still seeing the following warning indicators:
    - Master Warning Light
    - Check Engine Light (presumably because of the P0301 code)
    - Hybrid System Warning Light on the display

    NEW QUESTION:
    Once I replace the remaining weak modules and clear the error codes, and those warning lights likely to go away?
     
    #3 thebean04, Nov 22, 2015
  4. strawbrad

    strawbrad http://minnesotahybridbatteries.com

    Joined:
    Aug 9, 2011
    953
    1,001
    0
    Location:
    Minnesota
    Vehicle:
    2005 Prius
    Model:
    II
    Just to be clear. Block 11 is the 21st and 22nd modules starting the count opposite the battery computer.

    Brad
     
    #4 strawbrad, Nov 22, 2015
  5. thebean04

    thebean04 New Member

    Joined:
    Nov 21, 2015
    6
    0
    0
    Location:
    Tennessee, USA
    Vehicle:
    2007 Prius
    Model:
    II
    Really? So that would be modules 7 and 8 if counting from the computer end?
     
    #5 thebean04, Nov 23, 2015
  6. greasemonkey007

    greasemonkey007 Active Member

    Joined:
    Sep 20, 2013
    286
    105
    0
    Location:
    South Central Arkansas
    Vehicle:
    2006 Prius
    Model:
    N/A
    The modules are counted from the computer end. Mods 7 & 8 are block 4. I didn't see where you load tested any of the modules. That is a critical step to weed out any weak ones. Especially important if you see a mod with a noticeably lower voltage after discharging/charging. I have even seen one that showed about the same voltage as the rest and would not hold up under a load.
     
    #6 greasemonkey007, Nov 23, 2015
  7. strawbrad

    strawbrad http://minnesotahybridbatteries.com

    Joined:
    Aug 9, 2011
    953
    1,001
    0
    Location:
    Minnesota
    Vehicle:
    2005 Prius
    Model:
    II
    No, this is wrong! For Gen II Prius, years 2004 to 2009 the count starts opposite the battery ECU.

    Brad
     
    #7 strawbrad, Nov 23, 2015
    gdanner likes this.
  8. thebean04

    thebean04 New Member

    Joined:
    Nov 21, 2015
    6
    0
    0
    Location:
    Tennessee, USA
    Vehicle:
    2007 Prius
    Model:
    II
    UPDATE (good news):

    Thanks, all, for the help! Since my last post, heres what I have done:

    - Removed the HV Battery (again)
    - Replaced four more weakening modules (Now all my modules are in great range in terms of capacity)
    - Charged/tested new modules using HiTec X4 AC Plus
    - Re-balanced pack overnight using custom wiring harness
    - Soaked terminal nuts overnight in vinegar to remove corrosion
    - Removed all 27 of the copper terminal connectors from the bus bars and cleaned with a brass bristle wire brush
    - Re-assembled and re-installed

    Pack is running great so far. I have run about 10 miles so far with no issues or trouble codes. My plan is to run it the rest of this week (50 miles or so), then if I still show now problems or trouble codes, put the back end back together this weekend.

    Thanks again for the help, everyone! This forum is great!
     
    #8 thebean04, Dec 14, 2015
  9. thebean04

    thebean04 New Member

    Joined:
    Nov 21, 2015
    6
    0
    0
    Location:
    Tennessee, USA
    Vehicle:
    2007 Prius
    Model:
    II
    Suggestion on where to get one? I am not really even sure what this equipment is that your are referring to. I am currently monitoring battery amperage and voltage using the xgauge function on the ScanGaugeII. I am assuming a Mini VCl would do something that the ScanGauge cannot?
     
    #9 thebean04, Dec 16, 2015
(You must log in or sign up to post here.)