P0AC0, P0a0d after reassembly... More hints?

I just finished my fourth HV pack reassembly/install. First time to see these codes (P0ac0 , P0a0d)

Priuschat wisdom suggests the orange interlock (esp two small pins in back), or a ground issue.

I haven't pulled out my multimeter yet.

Other than that:
* interlock appears fine
* There is one small (?) difference... Could this be it?

Six large bolts connect the battery pack to the frame.

This time, the large bolt under the pack electronics did NOT want to fully seat. It seems aligned, but almost as if a thread is damaged

Can the ecu/etc detect one of six bolts not perfectly seated?

Anything else to check?

Sooo close yet so far. (this reassembly was to reorder modules to best balance. No other changes...)

 

It's fixed.

Strange things...
* Meter and examination found zero issues.
* First fix: I was clearing the code using Dr Prius. It immediately returned. I tried other ways...
- Hybrid Assistant does not have a code function
- Torque Pro cleared code, and it stayed cleared

Then I noted 12v battery was low.
(Question: is there any reason a prolong charge would drain the 12v battery?)

I am pretty sure this can be attributed to (im)proper clearing.

One more note: one time, I managed to forget to do the orange plug properly for a moment. It is easy to check of course. (this time I failed to do the ninety degree turn before plugging it in. Of course very loose...) Just be careful to do it right.

 

Further comments for now:
* My AGM (12v) battery is definitely wayyyy weak. Will replace soon. It's original (2011)!
* I'm working with Jack (Dr Prius) on improvements to its code-clearing. HA and DP definitely use different methods

When I get a few more Round Tuits, I'll post my new simpler methodology for pack/module assessment/balancing. Part of what I now do involves (for at least curiosity if not diagnosis ) running the Hybrid Assistant monitor during most if not all of a Prolong discharge cycle! (But NOT during Prolong Charge.)

Here's a simplified example.

The graph below shows what happens to block voltages during Prolong Discharge. This kind of data during discharge makes it obvious which blocks have weaker cells, how soon they will drop, etc etc. After the discharge is done, all that data is hidden by the fact that module voltages rapidly go up to an almost-normal level, masking most differences.



To accomplish this, I can't have 12v disconnected of course. It doesn't actually cause ANY issues, as long as a few precautions are taken:

• Never go to Ready mode with Prolong connected, period (this alone can cause a code)
• Don't have the car on (aux mode) while charging, at least while the pack charge level is low. There's no value to doing so in any case.
• Do minimize any current drains (radio off, lights off, etc)
• If you have any concerns, attach an appropriate charger to the under-hood 12v attachment point(s).

 

It puts in about 0.3 to 0.4 amp. If voltage is below ~200v, it cycles between that and a tiny amount.

(Since a car in action can generate or use up to 100A, this is a VERY gentle charge )