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After HV battery repair, car won't start

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by popptj2001, Sep 11, 2013.

  1. popptj2001

    popptj2001 Member

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    After replacing one of the HV batteries defective out of the 28 in my Gen 2, I reinstalled a working battery and the car won't start. With the car turned on, I went ahead and measured current on the HV battery side and get 220, and on the car side terminals there is no power. The service switch is working correctly and engaged. For some reason the voltage is not being relayed to the car side. Any suggestions? Tks.
     
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  2. koolingit

    koolingit Member

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    Remember when you took the orange safety plug out? You had to put your finger through the ring and lift before you could swing the plug down. So --- when you're putting the plug back in, you have to press the ring down after swinging it up. Every body forgets to press down after swinging up!
     
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  3. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Here's a guide, see step 9. on pg 21-118.
     

    Attached Files:

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  4. popptj2001

    popptj2001 Member

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    Tks everybody, but did did install the service key correctly. For some reason after letting the car sit for an hour did the trick. I went back out and started. Maybe the replacement battery module I installed which was 7.4 volts has to adjust to the other 8.0 volt modules? Any thoughts?
     
  5. Graham Fitton

    Graham Fitton New Member

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    It might be your 12v battery was a bit low.
    Besides running the electronics,it is required to make a 10.8v relay to connect the HV battery when you turn the car on.
     
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  6. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Pride is a terrible thing. :)
     
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  7. Beachbummm

    Beachbummm Senior Member

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    OK OK Im also a dumbass, I forgot to put the ring down again..after taking the cover off 3 times and checking the 12 volt batt twice and 15 mins of chewing on the steering wheel before I desided to look here for help...as stated above, pride is a terrible thing...a $45 cell and 4 hours later my car is alive again, now to get the ac fixed..
     
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  8. popptj2001

    popptj2001 Member

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    I completely replaced my hybrid battery two weeks ago and wanted to follow up here. The car would not start after installing an almost new hybrid assembly. I waited 10 minutes, then the relay kicked in and the car started. For some reason there is a delay. My 12 volt battery is also new. I should mention I have 332,000 miles. Should be good for another 300,000??? haha
     
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  9. bisco

    bisco cookie crumbler

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    hope so, all the best!(y)
     
  10. cthorsman

    cthorsman Junior Member

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    I am one of the many who forgot to push the orange safety plug handle down.
    Hopefully this bump will help others find this quickly.

    Cross my fingers, hope all is well tonight when I push it down firmly.
     
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  11. Gary S

    Gary S New Member

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    I just jointed the fools club not pushing down the safety plug down and struggled mightily until I saw this tip. Great help!!!
     
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  12. Nir

    Nir Junior Member

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    So i did tried to fix my prius gen 2, found one bad cell and i shuffled all modules, i was able to get the car running for few min , but then it went back to die again, i assume that all cell are not fully balanced yet, what should i do?

    i tried to measure the pack voltage and it was 0 ( also when i pulled the battery out) is there another relay?
     
  13. Nir

    Nir Junior Member

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    So assuming the plug is connected properly , what could be the other reasons for stat issues? why the computer cannot read any problem?
     
  14. Gambitsource

    Gambitsource New Member

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    I was wondering if you had to drain and recharge the modules to get the car to work?
     
  15. Gambitsource

    Gambitsource New Member

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    Question on the Aux battery. If I test the battery with a multometer when unplugged from the car and see a 12.4 Volt vs when the car is on and it is 11.9 or sometimes 11.4 would that be a bad battery?
     
  16. mullerkp

    mullerkp Junior Member

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    This was so helpful. For 15 minutes, when the car did not want to start and only lit up warning lights on the dashboard, I was completely frustrated, bigly! I took this plug out close to 10 times and put it back in, but "push down, after swinging up", that had never come to my mind. So easy. Now it woks. Thanks so much !!!

     
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  17. dolj

    dolj Senior Member

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    Another thing to remember, if you happen to have also removed the 12 V power by disconnecting the 12 V battery, for the first start attempt you also need to press the power button with your foot pressing on the brake pedal twice. The first time it illuminates all the warning lights on the dash (as a functionality test) and the second time, if you have no errors, all the lights go off and it makes the car READY.
     
  18. cscharff

    cscharff Junior Member

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    Hey guys My name is Clem and I have just done the same thing. And I replaced the 12V at the same time. I was sweating having to tow it to the dealer.
     
  19. dolj

    dolj Senior Member

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    Presumably, you mean you failed to compete inserting the safety interlock correctly. The question is, why are you removing it in the first place? It is totally unnecessary when you are just replacing the 12 V battery.
     
  20. vovila

    vovila New Member

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    Just wondering if you changed the hybrid battery first time after 332,000 miles? I purchased hybrid prius recently and was curious how long can hybrid battery last. Thanks.