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HELP Cant reset codes after hybrid battery cell replacement

Discussion in 'Gen 3 Prius Main Forum' started by ericb1, Jul 19, 2019.

  1. ericb1

    ericb1 Junior Member

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    First time posting here, sorry for hurried post. I need this car running tonight if possible. My other Yota is a Landcruiser and I spend a lot of time on IH8MUD

    So I got the triangle of death in my 2010 Prius.
    "Check Hybrid System" appears on dash
    Auto-zone scan stated bad hybrid battery
    I had 4 cells test low with manual probing of each

    I ordered 4 replacement cells, all tested 7.8V+
    Installed them and mixed up the order, alternating, terminals in correct spots
    reinstalled and rewired, no loose ends found

    "Check Hybrid System" appears on dash
    My garbage OBDII reader fails
    disconnected 12V battery several times for several minutes
    Disconnected large white wire in fuse box for several minutes

    Tool Shows P0A80 & POB4C on an INNOVA 3130 Scan Tool
    I have reset each several times and the code repeats
    What am I missing?

    Thoughts:
    1. Do cells need to be "balanced" in charge before install?
    2. Is there a simple key or start sequence I need to do
    My Prius NEVER breaks so I am new to it
    THANK YOU
     

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    #1 ericb1, Jul 19, 2019
  2. ericb1

    ericb1 Junior Member

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    Anyone?....

    I have seen plenty of video where cells get charged one at a time. My thought is that perhaps after sitting about a week, Some cells discharged enough where I just keep getting the code.

    Do I need to Charge cells individually?
    Can I charge the "whole" battery?
    Am I missing a simple step to reset the PC?
     
    #2 ericb1, Jul 20, 2019
  3. cnc97

    cnc97 Senior Member

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    I’d bet that one of the small wires on the harness, the sensor wire that tells the HV ECU the voltage of the cell is broken.

    The other cells in the battery are not going to lose enough charge in a weeks time for the car to not reset. You need to recheck all of your work again. Something got missed on reassembly.
     
    #3 cnc97, Jul 20, 2019
  4. fotomoto

    fotomoto Senior Member

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    Two thoughts: 1) as mentioned check the wire harness. The sensor connections are pretty fragile and corrosion can weaken them even more. 2) Did you load test all the modules? Resting voltages don't tell the whole story.
     
    #4 fotomoto, Jul 20, 2019
  5. ericb1

    ericb1 Junior Member

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    All harness connections seem good, no loose connections or fittings and no damage to wires. As far as probes go, I had 3. I thought they were temp probes that drop into the top of the cells. I did put those 3 in random cells, are they cell specific, OR.. polarity specific? If so this could indeed be it, they appear to be temperature probes
     
    #5 ericb1, Jul 20, 2019
  6. cnc97

    cnc97 Senior Member

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    On the pic I attached, I stole it from the net, but it shows the voltage sense wire. This wire is very flimsy and is easily broken, especially if corrosion is present. I think that your issue is one of these is broken or has been left off somehow.
     

    Attached Files:

    #6 cnc97, Jul 21, 2019
  7. ericb1

    ericb1 Junior Member

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    YES INDEED
    I am at work so can not check right now. I came to post this very question this morning as I found the same pic online last night. I do not recall this wire or the assortment of wires in the harness below in the picture. Other than the bus-bar I only hooked up the 4 large gauge wires that conduct current to the batteries electronics. I will attempt to locate, as this would surely be a problem, if not the problem.
    Thank you
     
    #7 ericb1, Jul 21, 2019
  8. SparkyFirefly

    SparkyFirefly Junior Member

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    The $99 BlueDriver OBDII reader on Amazon will actually tell you which cells are bad.
     
    #8 SparkyFirefly, Jul 23, 2019
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