Hybrid Battery Reconditioned Reset Problems??

Sounds like there are still battery issues being noticed and reported. Reading the codes would be the first step. Many issues are due to workmanship: improper torque, unconnected or misconnected wiring/connectors, misdiagnosed modules, poor replacements, etc.

GOOD LUCK!

 

+1 to fotomoto

If the car is turning on indicator lights then you need to read what codes are set- particularly any sub-codes.
If you think that there is a problem with the HV battery voltages then you need to log the block voltages with either a techstream scantool or use a compatible bluetooth scan adapter with an app like Dr. Prius or Hybrid Assistant. You need to see what the voltages are when the pack is under heavy discharge and charge conditions. You may need to clear codes once in the battery ecu after completing work- if it resets the warning lights then something is still wrong.

When you worked on your HV battery, did you: clean or replace the bus bars? inspect the voltage sense wires for corrosion or damage? use a torque wrench to tighten the bus bar nuts to spec? inspect the battery ecu connections for corrosion?

 

Try reading the codes with the Torque app. It could pick up codes that Dr Prius is missing. Toyota Techstream will read all the codes.

 

Those bus bars don't look too bad. The nuts that hold them to the battery studs should be tightened to 48 INCH-pounds. If they are too loose (or corroded) , you can get false weak block codes. If you go too tight you can damage or break the stud. Buy or borrow the correct torque wrench.

So what was the code ? and how low was the block voltage compared to the others, under what discharge amps, and what does that same block do when charging/ regen?

As far as clearing the battery ecu codes I believe that it is an option in the Special Features menu on Dr Prius.

Posted via the PriusChat mobile app.

 

I have read the numbers with Dr Prius and it seems block 14 is low. That’s the code it says also.

It sounds like you have found your answer. The part that stinks is that block 14 is the one closest to the ecua and requires the most disassembly to get to.

But....definitely make sure it isn't a wire/sensor/connection/plug/socket issue before you go through the hassles of disassembly.

 

I hope you put the grease on after assembly and not before. Any anti-oxidation measures should be applied (lightly with a brush) after assembly so you don't introduce insulation to where it is not needed.

 

For folks considering reconditioning/balancing, I made a Wiki page after recently performing this on a Gen II:

Prius High Voltage Battery Reconditioning | PriusChat