Does anyone have the instructions for the 2k1Toaster Battery?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by '04Prius, Jan 5, 2021.

  1. '04Prius

    '04Prius Junior Member

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    Hello,
    After playing whack a mole a few times, I decided to replace my entire battery pack with one from newpriusbatteries.com. It just arrived, and I unpacked everything, and there’s no instructions as far as torque specs or anything in the box. I emailed the support email, but in the meantime, I was wondering if someone else had installed this pack and still had a copy of their instructions. I’d like to get the car back together ASAP.

    Thanks!
     
  2. SFO

    SFO Senior Member

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  3. jerrymildred

    jerrymildred Senior Member

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    On his webpage near the bottom, he tells the basic steps and recommends just following the instructions in the various Youtube videos.
    http://newpriusbatteries.com
    (Caution: I've read here on PC that there is at least one video out there that gives the wrong torque specs for the module terminal nuts.)
     
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  4. '04Prius

    '04Prius Junior Member

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    I saw the basic steps, I’m a little confused on a couple things. The first is that it says that each module should be numbered 1-14, and as far as I can tell, none of mine are numbered. Although, if every cell is brand new/similar, order shouldn’t matter, right?

    Also, do I assemble the new battery before putting it in the enclosure? The basic steps make it seem like I do, rather than putting it on the enclosure first.

    Proper torque for the modules is 48 inch pounds to hold them into the enclosure, right? Is this the same as for the bus bars?
     
  5. jerrymildred

    jerrymildred Senior Member

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    I'd better not guess. I have not assembled one. Hopefully, @2k1Toaster will reply soon.
     
  6. '04Prius

    '04Prius Junior Member

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    Hopefully. I’m kinda stuck until then. I went through everything in the box again to double check I didn’t somehow miss them, but no luck
     
  7. SFO

    SFO Senior Member

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    Wonder if @edthefox5 has something laying around?
     
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  8. alftoy

    alftoy Member

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    Maybe this youtube video will help.

     
  9. '04Prius

    '04Prius Junior Member

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    Unfortunately he pretty much skips the entire step of assembling the battery pack, and says it’s made fairly obvious by the instructions :/ I’ve looked at a couple of other videos, and they aren’t really any help other than talking about how incredible the instructions are lol. I think I’ve figured out how they are numbered, so I can at least place them in the enclosure, but after that I’m kinda stuck again as far as torquing anything goes. I haven’t even tried to look at the harnesses they provided are.
     
  10. edthefox5

    edthefox5 Senior Member

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    Hi I have the instructions but at work. I can put them up tonight when I get home but there online on there site.

    I know what your saying about the numbering I stumbled on that too the instructions are jacked. Relax it will come to you. Take pictures with your phone of everything on the old battery especially the polarity positions of the primary relay. Mark those wires on the relays.

    I know its old hat to all the battery guys but the first time you not only see the inside but have to also replace the entire insides is kinda daughting.

    Look at the stock battery and all its series connections and under stand what there doing with the wiring it is very simple after you look at it for a while. Look at the 2 wires that connect the safety switch. If you install the first battery with matching polarity on there ends as the original battery it has to work. Next battery is reversed.

    Make sure you take out the ECU metal can its the one on its end. Remove it from the chassis and take the cover off and look closely at the board for any corrosion. Look very closely at the 3 sockets for corrosion and look at there 3 plugs. If any corrosion stop right there you will have to get some new gear.

    One of the connectors on the ecu has all 4 thermal sensors on it, Remove all the sensors and carefully put that whole cable aside that's installed last.

    The way the new battery's are built its hard to install it wrong they are very highly engineered. Just there instructions suck.
     
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  11. '04Prius

    '04Prius Junior Member

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    If you have them, that would be awesome! I dug through the website and didn’t find much other than the standard installation flow. I’ll check all the ECUs for corrosion. Thanks!
     
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  12. edthefox5

    edthefox5 Senior Member

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    here you go:
     

    Attached Files:

  13. '04Prius

    '04Prius Junior Member

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    Awesome! Thank you! Although now I realize I put all the modules in backwards (wired correctly, but 1 at the ECU instead of 14).
     
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  14. 8AA

    8AA Active Member

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    If you have the batteries oriented in series with the correct polarity on the main power cables, the numbering isn't important. The instructions indicated that the modules should be arranged so that Number 01 was down by the ECU. If I did that, I would have had the wrong polarity at that end of the pack. I could flip the modules around, but then the high terminal posts would be low and vice versa. I also considered changing the end caps, but then the batteries would be upside down and the serial numbers on the bottom. I was planning on doing that but instead contacted NewPriusBatteries.com and verified that the modules could be reversed in their sequence as long as the polarity was correct.

    My 2004 Prius now has the NPB modules with Number 14 by the ECU and Number 01 at the opposite end. As long as the notches on the end pieces are oriented to accept the bus bars, the batteries are hooked up in series, and the polarity is correct for the main power cables going into the ECU box, you are good to go.

    I am concerned that you say that you have the modules installed with Number 01 by the ECU and that it's wired up correctly. Unless there was a change in configurations during the 2004 model year, the short power cable going into the ECU is positive on my car and the longer one (connecting to the far end module) is negative. Unless the markings for the NPBs have changed, Module 01 would have the negative post on the high side of the module on the side with the power cables, which would be reverse polarity. Couple of different ways that this might be correct, but it wouldn't have been on my car.
     
    #14 8AA, Jan 9, 2021
    Last edited: Jan 9, 2021
  15. '04Prius

    '04Prius Junior Member

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    Interesting. I have mine oriented with 1 closest to the ECU, and 14 on the far end. If I had it the other way it put the main positive and main negative terminal on the wrong side of the pack. The short cable is positive for me as well.

    Although now it’s throwing a sensor error. Either one of the temp sensors is bad or I have a bad hybrid control ECU. I did not open it up and check for corrosion as mentioned earlier in the thread, although the plug and socket looked fine.
     
  16. 8AA

    8AA Active Member

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    It's completely possible that the numbering on the NPBs has changed to avoid confusion with the earlier models. I didn't want to be too insistent since I couldn't be sure that all cars are the same regarding the polarity. Mine also has the short cable going to a positive terminal.

    Sorry that I can't help with your sensor error. Based on a recommendation here, I did inspect the connectors on the ECU and opened it up to check the inside. I was fortunate that there was no corrosion, and everything looked brand new. The terminals and hardware on the original modules were another story, but they were all replaced. It was great getting all new hardware with the NPB Kit.
     
  17. 8AA

    8AA Active Member

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    Did you mean the wrong side of the pack or the wrong end of the pack? If I had put the modules in with Number 01 closest to the ECU, the positive terminal would have been on the wrong side of the pack (where the safety plug is located) and instead of being up high, the terminal would have been down low.

    Is it a temperature sensor error, or could it be something else? Were you careful with the metal plate that straddled the cables connecting HV to the front of the car? If the plate doesn't make a good connection to the case, it will return an HV Isolation fault.

    HV Isolation Plate.JPG
     
  18. 8AA

    8AA Active Member

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    My module at the ECU end is Number 14 and you can see the positive symbol. (Sorry, it is a little hard to differentiate the ECU components with the clutter in my garage. :) )

    Module ECU end.JPG
     
  19. '04Prius

    '04Prius Junior Member

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    The code that it’s throwing is P0A9B, which is “Hybrid battery temperature sensor circuit A failure” I believe. I think either a.) I didn’t clip one of the sensors all the way in or b.) the ECU is bad due to corrosion (I didn’t fully open it as edthefox suggested earlier. I’m going to take the car back apart tomorrow and see what I can find out. There was no corrosion on the plug.

    And that plate is interesting. My car has a bit of strange history (it used to have a lithium battery at one point), and it did not have that plate when I took it apart. I’ve put 95k miles on it, and it hasn’t thrown any isolation errors in that time so I don’t think it’s that. Although now that I know it exists, I might try and get one from a wreck to put it back together correctly. It must have not gotten put back when it was messed with before I got it.
     
  20. Mendel Leisk

    Mendel Leisk Sunday driver DIY’r

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