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Welding and red trianle of death

Discussion in 'Gen 2 Prius Main Forum' started by Georgejaunty18, Mar 2, 2020.

  1. Georgejaunty18

    Georgejaunty18 New Member

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    I currently have a 2006 prius gen 2 and ot needed some welding on the rear arches

    So as per the advice i dissabled the traction batery and the 12v battery

    After the welding was finished i reassembled everything in the correct order

    When i tried to start the car it wouldn't start pass the inital ignition

    So after this i has an rac guy plug his laptop in and it threw these error codes

    System Type: ENGINE SYSTEM TEST/VALUES
    Name: 1NZ-FXE - HYBRID VEHICLE SYSTEM (HYBRID VEHICLE SYSTEM) - 1.5L - 57 (77)
    DTC: P0A0D,High voltage system interlock circuit high
    System Type: BRAKES
    Name: ANTI-LOCK BRAKING SYSTEM - DIAGNOSE
    DTC: C1256,Accumulator low pressure malfunction
    DTC: C1259,HV system Regenerative
    DTC: C1310,HV system
    System Type: BRAKES
    Name: ABS/VSC/TRC - DIAGNOSE
    DTC: C1256,Accumulator low pressure malfunction
    DTC: C1259,HV system Regenerative
    DTC: C1310,HV system
    System Type: STEERING
    Name: POWER STEERING - POWER STEERING (EMPS)
    DTC: U0073,CAN bus off - Transmit Error
    DTC: U0121,CAN: No communication with ABS/TC
    DTC: U0073,Control module does not respond
    DTC: U0121,Communication with TC/ABS
    System Type: TEMPOMAT
    Name: CRUISE CONTROL - CRUISE CONTROL (CCS)
    DTC: P0A0D,High voltage system interlock circuit high
    System Type: AC SYSTEM
    Name: CLIMATE CONTROL - AIR CONDITIONING (AIR CONDITION)
    DTC: B1421,Sun sensor, passenger side
    DTC: B1442,Air inlet damper control servomotor

    Any ideas?
     
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  2. ydpplqbd

    ydpplqbd Active Member

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    Wow!!!

    Good question though. Sorry to hear a little welding created so many issues.
     
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  3. Prodigyplace

    Prodigyplace 2025 Camry XLE FWD

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    Would that indicate the high voltage interlock is not closed properly, triggering all the other DTCs? I know it is a common mistake.
     
  4. valde3

    valde3 Senior Member

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    Some of the codes seem a bit weird to all happen at the same time. Almost seems like 12V battery was not disconnected. Best would be to log them and clear them and then recheck which would come back.

    But first remove and reinstall the hybrid battery interlock switch. And don't forger the third step of pushing it downwards after the leaver is turned.

    Why did it need welding? Rust? Could you post a picture?
     
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  5. Georgejaunty18

    Georgejaunty18 New Member

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    The amount of replys is amazing thank you guys youve solved it

    The hybrid interlock wasnt pushed down and being a first time prius owner this is my bad oops!

    After clicking it down the car came to life with 0 faults

    It needed welding on the rear passenger (uk) sill that has a ding and rotted thru


    I think more people should be aware of this interlock it would have caused a nasty bill at the dealers

    I know its bad at the minute but its not finished .... its just the initial weld and just note i am not a welder neither is my farther in law but we try our best and allways pass an mot
     

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    #6 Georgejaunty18, Mar 4, 2020
    Last edited by a moderator: Mar 4, 2020
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  6. PriusCamper

    PriusCamper Senior Member

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    When you get that many codes a major component is not fully plugged in or has been fried...
     
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  7. PriusCamper

    PriusCamper Senior Member

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    Yea, it's one of the most common mistakes... As for your welding skills. I've never learned to weld myself, but... Um...
     
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  8. TMR-JWAP

    TMR-JWAP Senior Member

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    It is extremely difficult to cut out a rotted area and then make a replacement piece that fits exactly in the opening. Even harder to weld the seam/gap. Looks like the result of an inexpensive 120vac flux core wire feed welder being used by the average guy who is trying to learn. No shame to be had. We've all been there. This is when a good grinder comes in handy!!! Welding sheet metal is much easier when there's a lip to provide some overlap. Good technique is learned in months/years, not hours/days.
     
  9. ChapmanF

    ChapmanF Senior Member

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    I noticed in the OP, every code was listed twice, so it wasn't nearly as huge a list of codes as it appeared.

    The P0A0D was about the interlock switch, and that's a code logged in the hybrid-control ECU, which naturally means the brake ECU will log C1259 and C1310, because those mean "hey, did you hear the hybrid ECU has a code?" The B1421 is just the not-sunny-out-when-you-read-the-codes code, the U codes are all comm errors and usually come in groups (if A says "hey I can't talk to B", chances are good B will also say "hey I can't talk to A"). Along with the brake pressure and HVAC servo codes, I would guess those got logged because, with the interlock open, the car didn't go READY, and enough time was spent wondering "why won't it go READY" that the aux battery got deeply drained at one point. That's my story, anyway.
     
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  10. valde3

    valde3 Senior Member

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    That would make sense. Those were the once that I thought couldn't happens because of hybrid interlock. But I just didn't think that it was just let to drain the 12v battery. Again a good a reason to check the freeze frame every time as you would have seen the low voltage there.

    If it didn't stay in ign-on for a long time when this happened you might just need a new 12v battery soon.
     
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  11. PriusCamper

    PriusCamper Senior Member

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    Yea... If I wasn't on Reddit where people post the nicest looking welds you'll ever see in the channel known as r/oddlysatisfying
    And I bet once I start learning to weld I'll start with something like this. But I'd for sure grind it down so no one realizes I'm still learning. Lol... I guess I'm kinda vain like that...
     
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  12. PriusCamper

    PriusCamper Senior Member

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    Yep, I've seen codes flow like that when the plugs weren't fully plugged into the battery ECU... In a way, having lots of codes is actually a sign that the fix isn't' gonna be so hard once it's figure out.
     
  13. Georgejaunty18

    Georgejaunty18 New Member

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    Did my best and to me perfection is inperfect
     
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  14. Georgejaunty18

    Georgejaunty18 New Member

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    Thank you :)
     
  15. Leadfoot J. McCoalroller

    Leadfoot J. McCoalroller Senior Member

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    If the door was open during the welding repair, that could have pulled the 12v battery low to begin with. Always best to disconnect that 12v when extended doors-open work is planned.
     
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