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P3000 after a long struggle

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by UTadventures, Jul 16, 2024 at 1:46 AM.

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  1. UTadventures

    UTadventures Junior Member

    Joined:
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    Vehicle:
    2008 Prius
    Model:
    Five
    This is a bit of a TLDR, but I am stuck.
    2008 w/180k. I replaced a few modules about 18 months ago, and had no issues until about 5 weeks ago. I chose to try to recondition the cells (and utilize my best cells and the best of the lot I bought last time). After almost 4 weeks of cycling cells with great results I replaced the worst and reinstalled the HV battery. Alas, the 12v was seriously discharged, and a quick jump got it started. All codes gone. Drove and ran for 20ish minutes. When I turned it off, everything was dead again. Repeated a jump with no issues, then put the battery on a charger and tested it after a second run (5.7v, yikes). Anyway, trickle charged for 2 days and reinstalled. Started right up, but then immediately threw the P3000 (makes me think it’s not a cooling issue.)
    I do not have Techstream, but free DrPrius, and CarScanner apps.
    Here’s what I’ve checked:
    Other than the code, drives as normal (though fuel gauge is also blinking empty despite being very full)
    HV Battery 220 v
    All cells have greater than 4.0 Ah capacity, majority well over 5.0.
    All cells within 0.12v after cycling up to 80% and down to 20%(balanced for a week waiting for the bus bars)
    12v: 12.4v engine off
    All new bus bars and nuts
    All connections and related fuses (high desert car with zero rust)
    Hybrid pack cooling blower works (tested at 12v, and from 0.8-2.0 amps)
    oh, and I noticed when raising the temperature of the battery fan threshold, the red triangle stays off, until the temps rise and the car tries to turn the blower on. Then the code is thrown again within 5 seconds.
    This is my third/ fourth time battery out, so it’s easy now, BUT,
    What am I missing?
     
  2. bisco

    bisco cookie crumbler

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    have you checked the battery cooling fan connector for pin corrosion?
     
  3. UTadventures

    UTadventures Junior Member

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    Yes, zero corrosion on any connections, just on the copper bus bars, which were replaced with zinc coated ones.
     
  4. UTadventures

    UTadventures Junior Member

    Joined:
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    Vehicle:
    2008 Prius
    Model:
    Five
    Update as of 7/14/24@11:23 Utah time. I checked the voltage to the hybrid battery fan motor connection. 0.0 volts when the car is on, but no cooling is required, then using Dr Prius app to set a lower temp, I clicked it on. I can instantly hear a click of the relay (all clean connections), and the voltage jumps to 13.85. But I hook up the motor, and nothing (besides a thrown code). So it’s gotta be the motor, right? Except when I bring the motor in and hook it up to my hobby charger that can output any voltage and amperage, it blows air. Set At 12v and 1 amp, it is drawing about 0.95 amps. I hate to throw parts at it, if the motor works. Connections are clean on both ends. Still stumped…
     
  5. rjparker

    rjparker Tu Humilde Sirviente

    Joined:
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    Vehicle:
    2012 Prius v wagon
    Model:
    Three
    Measuring power in circuit to chassis ground or to the blower’s ground wire? Bad continuity to ground or even the two control wires could be the issue.
    IMG_5679.jpeg
     

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