Removing PluginSupply conversion (problem)

Discussion in 'Prius PHEV Plug-In Modifications' started by SteveWlf, Mar 28, 2018.

  1. SteveWlf

    SteveWlf Old-on-Hold

    Joined:
    Oct 20, 2012
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    Location:
    Montesano, WA
    Vehicle:
    2007 Prius
    Model:
    II
    I successfully installed the PluginSupply about 6 years ago and got about 2.5 trouble free years out of it. I then had problem with cell balancing and the charge would shut down. After replacing several cell I gave up and disconnected the main leads to the main HV battery and remove the whole lithium add on pack to save weight.
    I have now moved to Leaf and now 2017 Bolt and put the my 2007 Prius up for sale. I now have a buyer but need to remove the remainder of the modification so it might be easier for dealer or other mechanics to service without the confusion of the modification wiring.
    All went well in removing the rear wiring and remaining components. I removed the OBDII connection and the OEM systems still worked fine. Next was the front controller and there I just disconnected the two connectors. Now, the system will power up but there is now the RED Triangle is present and initially it would go into fwd and reverse, but the engine won't come on. This tells me that the engine kill circuit has disabled the engine.
    The front controller had two connections going to the OEM engine control module behind the glove box. I tried hooking the front controller back up and to basically return the system to the mode it was with the modification installed.
    Didn't happen. Now I have the additional warning indicator, "little car with exclamation mark" on the main display, upper left corn. The dash system powers up and the HV battery shows near full charge, but it will only go into park or neutral, but not into drive or reverse.
    I have tried several things but I think the motor locked out of the normal run mod as it might if I had turned it off, which should be restored to normal if I just turned the whole system off and back on again.
    As last resort I have searched online and found the Master Re-Boot procedure and tried that a few times and still nothing and now my keyless remote doesn't even lock and unlock the doors. Nor can I start the car with the fob in the dash slot. However, I can still start the car with the fob removed from the dash but still in the car. However, the same Red Triangle and Little Car/Exclamation Mark symbol.
    Problem seems to have to do with those wires going the the OEM engine control module, etc..
    I have a buyer waiting but I need to figure this thing our and to take it to the dealer would require it be towed in plus having to go through all that I have explained here to a service tech that only knows what is in the book.
    PluginSupply has gone out of business and their installation instructions have now all vanished so I only have a few notes to work with.
    Sure could use some help.

    Steve
     
  2. Raytheeagle

    Raytheeagle Senior Member

    Joined:
    Jul 1, 2016
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    Location:
    Bay Area, California
    Vehicle:
    2019 Prius Prime
    Model:
    Prime Plus
    What’s the 12 volt battery voltage reading? Has the car sat for a long period of time? Any pictures of the wiring? Do you have a way to read the codes the car is showing (like Techstream)?
     
  3. SteveWlf

    SteveWlf Old-on-Hold

    Joined:
    Oct 20, 2012
    262
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    Location:
    Montesano, WA
    Vehicle:
    2007 Prius
    Model:
    II
    New 12v batt and readings are 12.5vdc...
    Car has been in service continuously since Plug in Supply battery pack was removed. I removed all the added wiring and components for the rear first and only had a problem when I disconnected from the front controller from OBDII port and disconnected the two pairs of wires going from the ICE kill switch over to the ECU on the right side by the front door post. I know one set was to the kill pin on a plug and the other, I don't know what it was for.
    I have checked all the fuse related to the engine ECUs, etc.
    I'm now going to dig into the connections to the ECU I just mentioned and see where these added wires go.
    I can no longer read any of the OBDII codes since I did a Hard Reset yesterday. (non productive though) Still have the Red Triangle and Little car with Exclamation mark. So the fault persists!%#!#[email protected]!%$
     
  4. dolj

    dolj Senior Member

    Joined:
    May 14, 2012
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    Location:
    Wellington, New Zealand
    Vehicle:
    2006 Prius
    The Master Caution Light (MCL – Red Triangle) and the Hybrid System Fault icon (Little car with Exclamation mark) are on/displaying means there are codes to read. I don't know if it would help you to read them, but you don't know what you don't know.
     
  5. SteveWlf

    SteveWlf Old-on-Hold

    Joined:
    Oct 20, 2012
    262
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    Location:
    Montesano, WA
    Vehicle:
    2007 Prius
    Model:
    II
    I finally stripped the mod wiring all the way back to the connection to the ICE connector, removed it all together (since that is a normally unused pin). The second two conductor wire was spliced into another connector, so I restored that OEM wire with a butt splice.
    I think the problem has was being caused by the 2nd conductor of the ICE kill pair. One was to the new mod pin and the second went to vehicle ground. I found that connection loss and possibly only functioning as a ground intermittently. (My "bad", on the original install.)

    Thanks for your attention and comments on this post.

    Steve
     
    Raytheeagle likes this.
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