2007 prius almost all warning lights are on

You are likely correct, one cell in one of the modules in block 11 has died.

Each block has 2 modules.
Each module has 6 cells.

 

You're off to a good start... You've only spent $700 for it... You've already diagnosed it... Yet another classic hybrid battery repair opportunity that could only cost you $30 if you're lucky. OR pass it off to "professionals" and pay $2K... How much DIY do you want to do?

There's 28 batteries in a prius pack and each battery is about 8 volts. Your job is to get data on every one of them, or even better recondition all of them by discharging and charging three times, then replacing the bad ones.

 

I use these chargers: iMAX B6 V2 Changer and you can use 12v 50W lightbulbs to discharge faster than the 10w resistor in the charger. These chargers are only $30 but you need to buy your own power supply, unless have an old 15v laptop power supply laying around. Also having more than one charger speeds things up dramatically... I currently have 7 chargers and 7 light bulb dischargers. It speeds things up big time.

As for modules, if you can find a pack at a junk yard for super cheap and work on that pack first, it makes simply swapping out packs when problems come up a way more viable approach. As for replacement modules, my buddy Joe in Oregon has $30K in testing equipment and teaches hybrid repair at local college. His $30 replacement modules are way better than others and he's vary personable and will take time to talk on the phone if you need help: Hybrid Battery Conditioning | Reconditioned Hybrid Car Batteries Service

 

SKyRC V2 chargers have a faster processor and higher wattage and it makes it way faster. Beware though, chargers that are 2 or 4 chargers in one have odd ways of splitting up the wattage between each charging channel and you may end up buying a really low powered charger that takes a long time even though you're charging 2 or 4 modules at once... Also modules that need reconditioning charge real fast and that's not good so...

 

Yes, correct, that's how a module with a failed cell behaves.

You have a failed cell in one of the modules in block 11.

Time to get your plan of action together. It is not going to get any better by itself.

 

There is no new one.

You can charge that module to the cows come home that wont fix it. It wont hold a charge that's the issue.

During a rebuild every single module has to be charged then load tested to see how it behaves under load. The weak sisters that fail a load test must be replaced. But its just a whack a mole job really becasue you will be buying and using the same old vintage used modules that came in your car they just have not failed at that time yet. There is no new G2 modules unless you buy a band new pack from the dealer. Time/age is a bitch to a battery no matter what state its been maintained.

Then after you get all your kinda good old modules together you really need to outboard charge the entire pack using a charger to balance the pack as a whole. So its a big long time consuming job not to mention replace all the rotten buss bars and nuts and temp sensors to do it right.

 

hmm not sure what your saying.

 

At first it seems that way, but as the years go by and you acquire more gear and experience and know the joy of helping people save thousands of dollars that they can't afford to spend, it's not time consuming at all...

It's similar to people who live out of town in rural areas, or if you get a short term job outside of town... When you first do the drive it seems to take forever to do all that driving, but the more you do it, the quicker it seems to go. As in time is relative.

 

Yep... When a battery pack fails it can give you a false error code that points to a bad inverter when in truth the only problem is the battery pack. That happened to me Summer before last. I still have the replacement inverter sitting on my shelf. I'm thinking I need to sell it because I've yet to find anyone with a Gen2 who needs a used replacement inverter, which of course means it will be hard to sell.

Please let us know what you learned from the damage and how the rest of us can avoid it from happening? Did you clear the error codes too many times and kept driving as the pack overheated? Or was it less negligent than that?