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

Ground wire to Fusible link snapped

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Ambrosia5, May 21, 2016.

  1. Ambrosia5

    Ambrosia5 Junior Member

    Joined:
    Jan 13, 2016
    63
    6
    0
    Location:
    Colorado
    Vehicle:
    2006 Prius
    Model:
    II
    Yes i
    Had been pushin the release tab when pulling it out of the fusible link. But after hard resetting too many times the wire wore down and snapped clean. So I had to get the crimp out get the old wire out and strip the snapped wire down and recrimped it. Problem solved:)
     
    edthefox5 likes this.
  2. edthefox5

    edthefox5 Senior Member

    Joined:
    Jul 25, 2007
    10,096
    4,795
    0
    Location:
    Clearwater, Florida
    Vehicle:
    2007 Prius
    Model:
    Two
    Got it thanks. It sure beats unbolting the neg wire.
     
  3. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    23,278
    15,076
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    The wiring diagram shows where it connects, and shows it is the remote voltage sense lead for the DC/DC converter at the front of the car. Using a separate wire allows the converter to regulate to a specific voltage right at the battery, and not be thrown off by voltage drop in the main (heavier) wire when current is flowing through it. Gen 1 and Gen 2 have it.

    Moving to Gen 3, funny factoid. There isn't a remote sense wire run all the way back to the battery any more. The DC/DC converter still has a separate V sense terminal in Gen 3, but it just plugs into the engine room junction block about six inches away, somewhat defeating the purpose. They must have decided it wasn't as important as they had first thought. At the same time, Gen 3 adds a temperature sensor above the aux battery. Gen 1 didn't have that (don't know about Gen 2 and I've used up my techinfo days until I re-up....). Maybe that turned out to be a better way to control charging.

    -Chap
     
    edthefox5 likes this.
  4. edthefox5

    edthefox5 Senior Member

    Joined:
    Jul 25, 2007
    10,096
    4,795
    0
    Location:
    Clearwater, Florida
    Vehicle:
    2007 Prius
    Model:
    Two
    Oops your right Chapman good one. I thought it jumped over to the battery control power supply.
    I see it goes exactly where you say thank you.
     
  5. Ambrosia5

    Ambrosia5 Junior Member

    Joined:
    Jan 13, 2016
    63
    6
    0
    Location:
    Colorado
    Vehicle:
    2006 Prius
    Model:
    II
    I did it whoop whoop!!! Yay my car started and drives like a damn beast!
     
  6. cookprius

    cookprius Junior Member

    Joined:
    Jan 2, 2009
    20
    4
    0
    Location:
    Texas
    Vehicle:
    2007 Prius
    Model:
    N/A
    This is super helpful! However, I'm having a pretty hard time removing the crimp our of the plastic harness clip. Can't find a video for that specific thing. Do you happen to know which video it was? It seems to be bound in the plastic from both ends or something...
     
  7. cookprius

    cookprius Junior Member

    Joined:
    Jan 2, 2009
    20
    4
    0
    Location:
    Texas
    Vehicle:
    2007 Prius
    Model:
    N/A
    Got it out of the plastic housing, now having a heck of a time opening up the end to remove the busted piece of wire so I can slide the wire in from the harness to crimp. Anyone have any helpful suggestions?
     

    Attached Files:

  8. cookprius

    cookprius Junior Member

    Joined:
    Jan 2, 2009
    20
    4
    0
    Location:
    Texas
    Vehicle:
    2007 Prius
    Model:
    N/A
    Finally got it uncrimped and was able to strip the remaining wire enough to fit back in and crimped it tight. Connector back together, problem solved, red triangle/ABS lights off!