Dead Hybrid Battery?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Jodep, Apr 3, 2018.

  1. Jodep

    Jodep New Member

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    Hi Everyone,

    I have a 2006 Toyota Prius with 200,000 + miles on it. Recently I started the car and the Red Triangle, VSC, Check Engine and (!) brake warning light came on. I was away from home and decided to first drive it to the nearest gas station, other than the warning lights everything felt normal and was functioning. I skimmed through the manual at the gas station to see what the error lights represented and most pointed to errors with the brake system. Since the brakes felt fine and the car drove fine I drove it home and made it back without any issues.

    When I checked the check engine codes, I had several misfire codes (think I have a bad spark plug) and then a N/A code. Assume the N/A needs to be read with the techstream software. After checking the codes I disconnected the 12 volt battery and reconnected. This cleared all the error lights from the dash board and they did not come back while sitting idol in the driveway for about 15 mins. The following day I drove the car to work and back, roughly 90 miles, and everything worked fine. The next day I drove to work and made it there but when I started the car to leave work I got the Red Triangle, VSC, Check Engine and (!) brake warning light.

    At this point I drove off my work site to a quiet road across the street. The error lights where present but the car still felt fine when driving and I successfully made it up a slight incline with no issues. I then parked and decided to disconnect the 12 volt battery again to see if the errors clear again. This time they did not clear and I immediately noticed a severe loss of power when accelerating. I was able to get it rolling at 50/60 mph and it stayed at that pace until I reached a incline, at which point the gas engine needed to work extra hard to make it over the inclines. I noticed that the hybrid battery icon on the display was empty during the drive home, but also noticed that the arrow icon that indicates the wheels and engine are charging the battery never appears. It essentially appeared as if the hybrid battery was removed from the equation (theoreticaly speaking in the display graphic).

    Now when I press start the car turns on and allows me to drive it but there is absolutely no power and the Hybrid Battery Fan is always running.

    Now, if you made it to this point I thank you in advance for any insight you may provide. But due to the instant loss of power after I disconnected the 12V battery the 2nd time to clear the errors is it possible that a fuse blew that is preventing the flow of electricity between the hybrid battery and the other components? I am waiting on my techstream software and usb cord but I am hoping someone may be able to shed some light on whether there may be another component I can checked before determining if I need a new Hybrid Battery.

    Thanks!
     
  2. SFO

    SFO Senior Member

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    Are you the Original owner?

    You can research some of the maintenance history by logging in with the VIN at : Toyota Owners Official Web Site

    While you're in a holding pattern, now might be a good time to clean up the HV fan.
     
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  3. fotomoto

    fotomoto Senior Member

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    Classic sign the HV battery has failed and is being protected by the software and only using the ICE. The car might run "normal" again upon next start up or it might go straight into this "turtle mode". Reading the codes will tell you for sure. We see these kind of reports, on average, daily now. :(

    GOOD LUCK! (y)
     
  4. ericbecky

    ericbecky Hybrid Battery Hero

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    Without code info to confirm, it sure sounds like a hybrid battery failure.

    Elm 327 Bluetooth OBDII reader
    Android phon/tablet
    Torque Pro app

    With these 3 items (less than $75) you will quickly be able to read and clear codes. Plus see hybrid battery data like voltage, state of charge etc.

    A worthwhile investment. Especially if you plan on keeping this car.
     
  5. Jodep

    Jodep New Member

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    Thanks for the insight everyone! I got the codes below from Techstream. ‍♂️
    - P0A80
    - P3019
    - P3000
    - C1241
    - C1259
    - C1310
    All with either HV or Hybrid Battery in the error description. Ordering a new battery and going to swap it out.

    Any tips on the job? I don’t have HV gloves, do most mechanics use them?
     
  6. SFO

    SFO Senior Member

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    Clean the HV battery fan.

    Did you purchase a New HV battery from the Toyota Dealer?
     
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  7. Jodep

    Jodep New Member

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    Do you recommend cleaning the fan as a best practice during the hv battery replacement jod or do you think there is a possibility a clogged fan is the source of the problem?

    Planned on buying the battery through Napa, haven’t placed the order yet.
     
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  8. fotomoto

    fotomoto Senior Member

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    See link in my signature on when I had to deal with this. It has a youtube link with a good how-to on battery removal.

    GOOD LUCK!
     
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  9. Andyprius1

    Andyprius1 Senior Member

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    Gloves are a hype, for safety! The people that recommend gloves do so for liability reasons and I understand that. Pull power disconnect. Before you touch any two metallic surfaces always check with your multi-meter.
    Clean all corrosion and your hands often.
     
  10. Andyprius1

    Andyprius1 Senior Member

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    Just open fan access, and you will see what it needs.
     
  11. ericbecky

    ericbecky Hybrid Battery Hero

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    For personal safety you can get HV gloves.
    Or ignore safety and just do it anyway.

    Take the time to properly torque the high voltage connections.
    Too often people are simply lazy and completely on what "feel about tight enough". Really?
    Buy or borrow an inch-pound torque wrench and do the job right by properly tightening them to spec.

    It is not worth snapping a post due to over tightening.
    Or creating a fire from high voltage arcing due to undertightening.
    I have personally seen both of these scenarios many times.
     
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  12. SFO

    SFO Senior Member

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    Always recommend keeping the HV battery fan in a cleaned state, even when not replacing the HV battery. If the fan was never cleaned, and with 200k miles.. there is a possibly it contributed to the problem.

    The fan is near to the 12v battery, and servicing or inspecting it before tackling the HV battery replacement might not be a bad idea.

    I would **avoid** the Napa product. If cost is an issue, contact http://hometownhybrids.com/ and see if they offer free shipping to Hawaii or if you can work out a deal on such : @Hometown Hybrids
     
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  13. Jodep

    Jodep New Member

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    What’s the torque spec for those?
     
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  14. Jodep

    Jodep New Member

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    Hi everyone,

    My replacement battery is due in this weekend and I’m getting pre installation butterflies.

    Couple questions about this job.
    - is there a specific order for disconnecting the high voltage cables from the battery, ie positive or negative first?
    - with a Dorman battery can I simply reconnect the high voltage cables the same way they where connected on the previous battery?

    Thanks for any last min tips you can offer!
     
  15. ericbecky

    ericbecky Hybrid Battery Hero

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    There is a Dorman video that shows the safety equipment to use.
    They also have a tech line you can call.
     
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  16. Mendel Leisk

    Mendel Leisk Lapsed Cargo Cultist

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    @ericbecky can you post the critical fastener torque specs?
     
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  17. Raytheeagle

    Raytheeagle Senior Member

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    48 inch pounds IIRC.
     
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  18. Mendel Leisk

    Mendel Leisk Lapsed Cargo Cultist

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    That's for the bus bars between cells?
     
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  19. Mendel Leisk

    Mendel Leisk Lapsed Cargo Cultist

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    Yeah, here we go:

    upload_2018-4-28_9-30-32.png

    Hang on, making a CARE package...
     
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  20. Mendel Leisk

    Mendel Leisk Lapsed Cargo Cultist

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    Pretty much everything in here:
     

    Attached Files:

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