Hi everyone, I have been getting different error codes for different modules in the hybrid battery, some of which I knew were okay, so I replaced all the connectors. Now I am getting a pending fault on a couple of blocks (5 and 9). I tightened the connector nuts but not too much. The faults are not current but pending. Is it worthwhile to wait to see if the faults disappear on their own? On one of the modules of block 5 it was difficult to put the nut in. It was tight as soon as I would screw it in, so I know I will replace that module with a new one. But I've done this at least 6 times for the past month, and I've been getting erros on different modules seemingly at random. Is there something obvious that I might be missing? Thank you. UPDATE: It seems that the pending fault was because the nuts were not tight enough. In an effort to avoid overtorquing the nuts after replacing the bus bar connectors, I left them minimally tight, but I would guess the vibration of the car would loosen them, causing spikes in voltages in specific blocks. That would explain why the errors would happen at random and on modules that I knew were okay. It would also explain why on the highway the errors would be more likely: the vibration is greater at higher speeds. I only tightened up the nuts on all four modules in blocks 5 and 9, and I haven't got an error so far. If I get another error, I'll simply tighten the nuts on the modules that trigger the error. I won't be replacing modules. I hope this helps somebody. Thank you.
The nuts on the bus bars should be tightened to 48 INCH pounds. Buy yourself a small 1/4" torque wrench and use it to tighten the nuts.
Because poor electrical connections never start fires, right? Many homes burn to the ground every year because of poor electrical connections. Why would you purposely make 56 poor connections in a high voltage, high current battery? You are practically begging to break down on the side of the road. As mentioned, tighten them to 48 INCH pounds. Go to Harbor Freight and buy a $15 1/4" drive torque wrench and an 8mm socket. Do it once and be done with it, before you damage the terminals on the modules from arcing and heat generation..
