Can I use a 2006 HV battery pack in a 2009?

Discussion in 'Gen 2 Prius Technical Discussion' started by rfelley, Feb 14, 2021.

  1. rfelley

    rfelley Junior Member

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    I've been trying to help a friend get back on the road. Their car went to the dealer after the Master Warning, Brake and VSC warning lights came on. The dealer said, "pulled codes P3000, P0AFA, P0AC0. Hybrid codes C1241, C1300, C2300, C2318, B1421. Hybrid battery has cell in reverse polarity and fault with hybrid ECU. Aux battery has only 5 volts. Recommend replacing battery, hybrid battery and HV ECU."

    Car has 117,000 miles. I did not find any cell in reverse polarity. ECU sensing wire terminals have some corrosion and maybe the ECU isn't getting proper voltage signal???

    So, they towed it to me and asked me to assess. I put the HV battery on my "Prolong" charger and after 36 hours it would not charge past 228 volts. I put it back in and test drove. On initial start, battery had 6 blue bars. Same warning lights still on. I drove 22 miles to O'Reilly's to purchase a cheap code reader that would erase codes. On the return trip, at about 30 miles in, I got green bars. Drivablility seemed close to normal throughout. Once back at my shop I cleared the codes, which, according to the INNOVA cheapie, now are only 1259 and 1310. They reset immediately. I'm thinking the HV ECU may truly have a problem but not sure if it might all be resolved by rejuvenating the battery (see below on that subject).

    I have a 2006 battery pack under the bench with 60,000 miles on it. It's been sitting there for about 6 years. I put it on the charger and it came up to 230v after a couple hours and is still charging. I'm tempted to throw it in the 2009 while I see if I can restore the 2009 HV battery with the Prolong system.

    I purchased and used the Prolong system for my 2007 when it started showing signs of a failing battery at around 230,000 miles with mileage down to 44mpg and recurring recalibration occurring more often. I am now approaching 300,000 miles on that one and getting a solid 50mpg.

    I'm asking if there is someone out there that has the definitive answer as to whether I can swap out the 2006 for the 2009. The 2006 pack has a part number of G9280-47100. The 2009 part number is G9280-47110. Also, the HV ECUs inside the packs have slightly different numbers. And thanks to PriusChat for being there.
     
  2. TMR-JWAP

    TMR-JWAP Senior Member

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    Yes. A 2006 pack will bolt right into a 2009 and work fine. I would definitely check the sensor harnessplug/ECU sockets for corrosion first though.

    If you want to get real picky, you could put the 2009 battery ecu into the 2006, as the 2009 is probably a 92 model ecu and the 2006 is probably a 80 model ecu, but it shouldn't matter in the big picture.
     
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  3. PriusCamper

    PriusCamper Senior Member

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    This gets me wanting to do research on subtle differences in Gen2 ECUs.

    Currently using a 2005 ECU in a 2007 vehicle with Dr. Prius Lithium Pack and makes me wonder if I swap different ECU's I'd get slightly different performance measures from Lithium test pack?

    But I guess first need to find out what they changed in newer iterations of Gen2 ECU's. Or maybe ECU doesn't play an active role and is mostly monitoring?
     
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  4. rfelley

    rfelley Junior Member

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    Thanks for that. You are correct about the HV-ECU part numbers. Sounds like you have experience swapping packs around. I'll let my 2006 get a full 24 hours equalizing charge and install tomorrow and let you know what happens. BTW, I forgot to mention in my long intro. that I did put in a new 12v battery.
     
  5. rfelley

    rfelley Junior Member

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    Well, after a good topping charge, installed the 2006 HV battery with its original HV ECU and no change. Codes 1259 and 1310 still showing up after clearing. Warning lights still on. Any ideas where to go looking next?
     
  6. ozmatt

    ozmatt Active Member

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    2005 - 2006 modules really were some of the best i ever tested, so much better than 08-09

    I have my 2010 gen3 pack loaded up with 05 modules
     
  7. rfelley

    rfelley Junior Member

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    I see I've using the wrong terminology for the battery ECU (calling it the HV ECU). Does anyone have a known good HV ECU (not battery ECU, but the one under the right side of the dash) to sell? According to two friendly shops near here that scanned for me they are pretty sure the HV ECU has problems as most codes point to it along with the scid control ECU.
    As a reminder, I've replaced the traction battery with a known good one and am still getting the same codes. So, at the very least I've confirmed that what the dealer recommended, replacing the traction battery, was not necessary but they DID diagnose the HV ECU at $964.43 for the part plus labor to install.
    One of the local shops said even if I did replace the HV ECU, the dealer would need to flash it. I think he was referring to something I read about elsewhere in Prius Chat about pairing this ECU with the immobilizer ECU which seems pretty straight forward so long as the auxiliary battery is in good shape.
     
  8. PriusCamper

    PriusCamper Senior Member

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    A couple things...

    --Hybrid Battery ECU is the most accurate description because HV ECU implies the ECU operates at high voltages but it doesn't, it's part of the car's 12v system and may have lots of control over the high voltage system via 12v relays, it doesn't operate with high voltage current.

    --Nothing needs to be flashed or paired... There are people on priuschat that have thought that was the case but after working on a couple dozen packs over the years a healthy ECU with no corrosion damage simply is plugged in and does its job regardless of what Gen2 Prius you put it in.
     
  9. rfelley

    rfelley Junior Member

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    Thanks. I'm clear on the differences between the battery and HV ECUs now. So I think what my local independent tech told me about flashing (pairing) the new HV ECU (the one under the dash) with the immobilizer ECU is still a valid point. What you are saying I fully understand. The battery ECU needs no flashing and corrosion at the battery terminal sensing wires is a common problem. And if you know anyone with a good HV ECU to sell let me know. The dealer invoice says it's part #8989047092.
     
  10. TMR-JWAP

    TMR-JWAP Senior Member

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    Then your dealer is very confused because that is the part code for the latest revision of the HV Battery ECU....located inside the HV battery case.
     
    #10 TMR-JWAP, Feb 18, 2021
    Last edited: Feb 18, 2021
  11. dolj

    dolj Senior Member

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    This a common misconception based on an incorrect guess at for what HV is an abbreviation. The Toyota repair manual is clear that, in this context, It is hybrid vehicle, not high voltage.

    Secondly, there are 2 ECUs with similar names and tend to get confused by those not too familiar with the system

    There is the HV (hybrid vehicle) ECU and then there is the battery ECU. There is no ambiguity with the latter as the 12V battery does not have an ECU, therefore the battery ECU refers to the ECU that controls the hybrid vehicle (HV) battery. Coincidentally the hybrid vehicle battery also happens to be a high voltage DC battery.
     
  12. rfelley

    rfelley Junior Member

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    I'm glad you caught that because I thought it was a newer part number for the HV ECU. So the dealer really was off the mark entirely. I guess the only answer is to make that little investment in the patch cord and software and learn it all myself using Prius Chat's knowledge base. Thank you.
     
  13. rfelley

    rfelley Junior Member

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    Okay recapping now that I have done more. Car originally towed to the dealer after the Master Warning, Brake, VSC and engine warning lights came on. The dealer said, "pulled codes P3000, P0AFA, P0AC0. Hybrid codes C1241, C1300, C2300, C2318, B1421. Hybrid battery has cell in reverse polarity and fault with hybrid ECU. Aux battery has only 5 volts. Recommend replacing battery, hybrid battery and HV ECU."

    Installed a new 12v battery. Installed a known good traction battery with its own ECU. (I could not find a cell in reverse polarity in the original battery) No change, same codes and lights. I installed a known good Hybrid Vehicle ECU from my own 2007, paired with the immobilizer system as per other Chat guidance. Cleared codes. No change. Same lights, codes returned.

    Interesting item - my cheapie O'Reilly's INNOVA reader says no DT codes and when I go to the ABS section this reader shows C1259 and C1310. (C1259 - HV System Regenerative Malfunction, C1310 - 1 Active Booster Solenoid 2 HV System Malfunction) according to INNOVA. Then I ordered a ScanGauge 2 and it shows only one code - P3030 which points to the battery ECU and/or sensing wires. I cleaned and checked all the sensing wires and bus bars on the battery that is currently in the car. It took a topping charge nicely and I really don't suspect anything wrong with that battery and its ECU.

    So, at this point all I have been able to determine is that the dealer's recommendation would not have solved the problem(s). I don't have a disposable laptop to load Techstream and I get totally frustrated trying to figure out where to download Techstream and which lead to order anyway.

    Bottom line, can anyone recommend a shop in the Portland Oregon area that has the necessary talent to figure this one out?
     
  14. SFO

    SFO Senior Member

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    @PriusCamper lives fairly close by in WA, and travels through your area at times.
    Some sellers may include techstream on a CD with the sale, or will offer you a link to download it from. The techstream software is also available all over the interwebs. Just buy the least expensive mini-vci cable on fleabay (around 20 usd), find a US seller and the shipping will be quicker and may be free. Load up VirtualBox with a windows image, and then you won't need to worry about having a disposable laptop, you can also try Wine (unknown if techstream is compatible), which doesn't require windows.

    If the techstream curve is too much, then maybe a small OBD2 bluetooth adapter with an App like Dr Prius or Hybrid Assistant.

    You can research which OBD2 adapter not to buy here : Hybrid battery diagnostic and repair tool for Toyota and Lexus
     
  15. PriusCamper

    PriusCamper Senior Member

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    Greetings... So when you swapped out the pack with a known good one, it was the entire pack? OR did you swap out components?

    Because the former usually clears most of these codes and latter is less likely to do that.

    For example the module that was given the negative voltage reading but later on when tested directly doesn't give a negative voltage reading is almost always corrosion in the orange voltage sensing plug where it goes into the ECU.

    And six years is a long time for a pack to sit without charging so I suspect that it's likely both packs have issues.

    Also, the cheap auto parts store code readers aren't configured for Hybrid cars, especially hybrid battery subcodes and tends to fail to read important codes, though in your case it almost seems like you have the opposite problem.

    Anyways, how urgent is this? While I don't know of a mechanic in your area, I will be down there gardening in next week or two and could stop by with techstream and an OBD2 reader w/ Dr. Prius app. I kind of enjoy these types of challenges and you only have to pay what you can afford.

    Also the OBD2 reader for phone apps is inexpensive and there's lots of apps to choose from. Seeing a screenshot from Dr. Prius app would help us answer lots of questions about this situation. Here's buyer's guide: Hybrid battery diagnostic and repair tool for Toyota and Lexus
     
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  16. rfelley

    rfelley Junior Member

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    I used he word "pack" incorrectly. By pack I meant the entire traction battery. I am actually on the coast west of Portland in Nehalem. The owners of the car , on my advice, are looking at purchasing a 2013 Prius and giving up on this one. If you wish to help it will be necessary to involve them in the discussion. Thank you for your sincere response.
     
  17. PriusCamper

    PriusCamper Senior Member

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    Oh... In that case sounds like you need to sell this messed up one then? I've a couple friends looking to buy a fixer upper Prius for a low price, so I can approach them on their behalf if you like? Have the owners text/call me: 360-789-7843
     
  18. PriusCamper

    PriusCamper Senior Member

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    Final update on this thread... The Owner of the vehicle was put in touch with my friend who wanted to buy it but asking price was $2850, which we thought was too high considering the fact it needs a bunch of work.

    Then this morning my friend says the guy messaged him and said that due to a death in the family he needed to sell it quick and was only asking $1500, so we jumped on it right away and it was sold to someone else faster than we could get to it.

    Almost had an amazing deal... Oh well... At least it's starting to look like Spring has sprung and the cold dark winter is ending. May there be lots of other great prices on used Gen2 Prius for us all in months and years to come!
     
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