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Hv Battery or Ecu

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by pablocasaley, Nov 8, 2016.

  1. pablocasaley

    pablocasaley Junior Member

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    I had the code come up for the inverter cooler pump come up. So I replaced that. Upon restarting the car I got the code P0A80 and Bank 12 battery. So I decided to try doing the battery repair myself. When I opened the unit I had one obviously bad cell as it was reading 6.6v. So I replaced that unit and balanced all of the other modules. When I put the battery back in after a few miles of driving I got the code for bank 10. So I ordered 2 more modules and decided to replace them both. I also thought I may have had the problem because I didn't balance the voltages the last time just conditioned the modules. So this time I balanced the voltages as well. All batteries read 7.89 or 7.9v after 24 hours of balancing and conditioning. No module returned less than 6150ma on the charge most being 6500ma. So I put the unit back in and test drove and got the error code for bank10. So I went home and switched out the 12v battery with one from a different prius. Drove again and got same code. I cleared it while driving and the lights came on again and this time it was a bank 12 but not bank 10. Both of those sets of modules returned over 6500ma on the conditioning charge. Is it possibly the ecu that is bad because the banks keep changing? This battery pack was replaced or repaired before I owned the car (at least I think so because of the missing bolts and clips when I went to remove the hv battery). It is a 2006 with 250k miles, I replaced ice engine and transaxle at 225k because of burning oil. I had been getting about 35mpg before these errors came up so I suspected the battery might be going.
     
    #1 pablocasaley, Nov 8, 2016
  2. ericbecky

    ericbecky Hybrid Battery Hero

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    Check the wire looms.
    Probe it aggressively and look for breaks in the wire.
    If you have a scanner, using safety equipment, you can probe it while live and see if the vblock voltage displayed matches actual voltage at the vblocks themselves. The voltage displayed should not vary as you probe.
    It is likely that there is some kind of break or corrosion in the wires.
     
    #2 ericbecky, Nov 8, 2016
    pablocasaley and valde3 like this.
  3. pablocasaley

    pablocasaley Junior Member

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    Are you talking about the wires and connectors on the orange strips that you connect to the positive and negative terminals of the modules?

    Posted via the PriusChat mobile app.
     
    #3 pablocasaley, Nov 8, 2016
  4. ericbecky

    ericbecky Hybrid Battery Hero

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    The orange strips that hold the copper bussbars.
    It also conatins all the voltage sensing wires.
    Often they will have corrosion at the ring terminals which ultimately leads to a break in the wires/terminals.
    Sometimes the corrosion travels down the wires making them turn green and can go all the way back to the ECU as well.

    Feel free to call me if you have questions.
     
    #4 ericbecky, Nov 8, 2016
    Dino33ca and pablocasaley like this.
  5. pablocasaley

    pablocasaley Junior Member

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    Just from my memory because i have to pull it out again, i recall seeing corrosion on all of the negative connectors on that bar.

    Posted via the PriusChat mobile app.
     
    #5 pablocasaley, Nov 8, 2016
  6. pablocasaley

    pablocasaley Junior Member

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    Okay so I replaced the bus bar and I no longer get the P0A80 code, but I am still getting the P3022 code. I have moved the modules around trying to isolate the bad one and I have also put 2 new ones that in bank 12 but that code doesn't stop. Is the ecu the next step?

    Posted via the PriusChat mobile app.
     
    #6 pablocasaley, Nov 15, 2016
  7. jadziasman

    jadziasman Prius owner emeritus

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    It's likely to be either the frame wire harness or the ECU. Closely inspect the connection between the two and look for
    signs of burning or loose or broken pins in the harness. Others have fried that connector when they had bad modules
    that they continued to drive with until disaster struck.
     
    #7 jadziasman, Nov 15, 2016
  8. dolj

    dolj Senior Member

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    Out of interest, from which end of the battery are you counting the modules?
     
    #8 dolj, Nov 15, 2016
  9. pablocasaley

    pablocasaley Junior Member

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    Starting with 1 next to the ecu. I looked it up just to make sure on that.

    Posted via the PriusChat mobile app.
     
    #9 pablocasaley, Nov 15, 2016
  10. pablocasaley

    pablocasaley Junior Member

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    I didn't notice any of the wires looking bad when I disconnected then to hook up the new wires on the bus bar. I will check again when I install the new ecu.

    Posted via the PriusChat mobile app.
     
    #10 pablocasaley, Nov 15, 2016
  11. dolj

    dolj Senior Member

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    On the Gen II, the Techstream numbering references the modules starting from the end opposite the ECU. Try that.
     
    #11 dolj, Nov 15, 2016
  12. pablocasaley

    pablocasaley Junior Member

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    Okay thanks, I will try that. I must have been looking at Gen 1 info then.
     
    #12 pablocasaley, Nov 16, 2016
  13. pablocasaley

    pablocasaley Junior Member

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    That seemed to fix it. Thank you for the help.

    Posted via the PriusChat mobile app.
     
    #13 pablocasaley, Nov 16, 2016
  14. pablocasaley

    pablocasaley Junior Member

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    So after further driving that didn't solve the problem. Since then I have tried a new hybrid ecu and changed the 2 modules in bank 12 to new modules. Now the error code is jumping modules. First it said 7 then 8 and 12 together. Could it be the battery controller or should I try rebalancing all the voltages again?

    Posted via the PriusChat mobile app.
     
    #14 pablocasaley, Dec 2, 2016
  15. ericbecky

    ericbecky Hybrid Battery Hero

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    Did you aggressively probe the orange wire looms while watching the voltage readings via techstream?
    What was the result?
    I have seen plenty of bad wires. Could be the case here.
     
    #15 ericbecky, Dec 2, 2016
  16. pablocasaley

    pablocasaley Junior Member

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    I actually replaced the orange wiring harness. I don't have the tech stream software, just Bluetooth obd2 reader.

    Posted via the PriusChat mobile app.
     
    #16 pablocasaley, Dec 2, 2016
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