Lots of codes after battery rebuild

Discussion in 'Gen 2 Prius Technical Discussion' started by dirt657, Apr 12, 2019.

  1. dirt657

    dirt657 Junior Member

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    Friend of mine told me his HV battery was bad and that he had a P0A80 code. He had a bad 12v and didn’t have jumper cables when I went to get the battery from him so I didn’t get to read the codes with techstream until today. Took the battery apart, had tons of dog hair all over the place so I shop vac’d everything. The fan was also the worst I’ve ever seen. I cleaned it out well. Did a full rebuild on the battery. Replaced the 2 bad cells, got the rest to show over 5000mah each on the discharge, threw it all back together. Put it in the car to test and it wouldn’t start. These are the codes it gave me.

    P0A0D-350 High Voltage System Inter-Lock Circuit High

    P3000-123 Battery Control System

    P3030 Disconnection between battery and ECU

    C1259

    C1310 HV system malfunction

    I have 2 spare parts batteries at the house, I just need to know what I need to replace to get this thing working right. Any assistance is appreciated. Trying to get my buddy back on the road.
     
  2. SFO

    SFO Senior Member

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    Was the HV battery fully charged and balanced before reassembly?

    Was the HV battery case properly bolted/grounded ?

    P0A0D-350 points to the orange colored HV battery service plug, if properly installed then check the small wires/connections to such. Be sure to check all plugs and connectors for corrosion.

    Here is the workup for P3000 with an INF 123 : https://share.qclt.com/%E4%B8%B0%E7%94%B0%E6%99%AE%E7%91%9E%E6%96%AF%E5%8E%9F%E5%8E%82%E8%8B%B1%E6%96%87%E6%89%8B%E5%86%8Cpdf%E6%A0%BC%E5%BC%8F/repair%20manual/04pruisr/05/21bpm/3000123.pdf

    Here is the workup for P3030 : https://share.qclt.com/%E4%B8%B0%E7%94%B0%E6%99%AE%E7%91%9E%E6%96%AF%E5%8E%9F%E5%8E%82%E8%8B%B1%E6%96%87%E6%89%8B%E5%86%8Cpdf%E6%A0%BC%E5%BC%8F/repair%20manual/04pruisr/05/20zmw/cip3030b.pdf

    You may need to dig into the pack and check the harness for breaks and corrosion. Be sure the module nuts were also properly torqued.
     
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  3. TMR-JWAP

    TMR-JWAP Senior Member

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    A common issue is the HV interlock not being installed using all three steps. Another problem is the interlock circuit plug was missed during reassembly. When you install the HV battery, there are 3 wire harness plugs that connect to it from the car. The smallest one is the HV interlock. It plugs into a receptacle directly above the orange plug. The receptacle has about 6 inches of wire and then it's own plug that connects at the bottom of the interlock plug receptacle. Sometimes this plug is forgotten about when a battery is put together. If not installed, the car thinks the safety disconnect is not installed.
     
  4. dirt657

    dirt657 Junior Member

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    It was properly balanced and bolted right into the car. I’m gonna disassemble it and look into it in the morning
     
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  5. dirt657

    dirt657 Junior Member

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    So if I just swapped a new ECU and wiring harness in that would probably take care of the problem, right? Lol
     
  6. ericbecky

    ericbecky Hybrid Battery Hero

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    The orange service plug is not properly I served and slid down.
     
  7. TMR-JWAP

    TMR-JWAP Senior Member

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    I don't understand why this would be considered a solution.
     
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  8. terramir

    terramir Member

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    I think you either didn't connect all the connectors back in place properly and well yeah what eric said you did not slide the service plug back down into locking position. i.e. put in pull orange lever up 90 degrees then push down on it. I have forgotten that once before as well got a whole bunch of codes for just not doing that.
    terramir
     
  9. Phildo

    Phildo Member

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  10. dirt657

    dirt657 Junior Member

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    I can 100% tell you the plug was pulled down all the way
     
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