2006 CEL question

You're not really 100% sure the quality of the modules you are buying. Buying another module won't necessarily guarantee you anything better than the ones you have now. They are used modules from another pack.

Since you have what seems to be good modules, why give them to another person to sell back to someone else? Now that you've taken it apart once, the 2nd time (whenever that will be), will even be easier. And with the HA charger, you can balance the pack every few months with relative ease.

If you don't mind, don't turn in the good block mate from block 3. I'll pay you the $15 for it. I'll get it from you, close to your work location

 

What's the serial number on the 2 you bought? The 4th digit will tell you the year the pack was produced. Your modules were from 2006, which should have a serial number 4th digit of "h"

 

Still odd that you had two weak blocks even though one was definitely bad because of one module with
a dead cell in it.

I guess you'll find out when it's back in the car and you've put some miles/hours on it to see
if the DTCs stay away or not.

 

The "g" is from a 2005 module. So theoretically, your original 2006 modules will be stronger than the ones you bought. But that's not always the case.

I recently bought 2 "H" modules for my 2005 "G" pack. The "H" modules I bought were much stronger than my original pack.

 

You will not read battery voltage until you re-install the service plug - that orange handle thingy that you removed
before you started to remove the battery from the car.

If you did re-install the service plug, did you do it correctly - in, up, and then down to lock it?

You will probably have 230V since you charged your modules above 8V if I recall correctly.

Did you use a torque wrench to tighten down the 56 nuts on the modules to 48 inch-pounds? That's the main
reason you needed a 1/4" drive torque wrench.




Don't re-install the battery into the car until you've confirmed the torque values are correct. If you don't you might
get arching and sparking when the battery is charging or discharging at 100 amps. One person discovered that the plastic
carrier for a bus bar had melted on two of the modules in his battery . Don't know the outcome (or remember) with that.

 

There's no danger of installing the service plug with the battery case open. Here's a photo of a helpful hobbit checking the voltage on his battery. As you can see on the right side of the photo - the service plug is installed.


You will get the same voltage at the two orange cables inside the BCU case.

Of course you do need to have the service plug removed to connect the two orange cables inside the battery control unit compartment but you don't need to do that if you're merely checking the voltage.

Just don't forget to remove the service plug again before you put the battery back in the car when you reinstall the other two orange cables that are behind the rear seat that connect battery power to the car.

 

That is odd. I haven't seen that on the batteries I've worked on. Always reads 0V there with the plug removed.

Wish I could offer some guidance here - maybe ericbecky or S Keith know what's happening.

 

Better get the input of a few other people before you proceed. It isn't normal and its cause is lurking somewhere
inside that battery.

 

No danger.... um I don't think most people exposed to 215v DC wouldn't say there is *no* danger.
In fact this is where it may be the most dangerous.
Should a child, pet, or knowledgeable coworker touch the wrong areas by accident, it would be quite bad.

You should be on high alert when checking a battery in this manner.

 

What I meant was for the skilled individual working on it. I don't have a crowd around me when doing these repairs/rebuilds.
In fact, I yell at anyone who invades my work space to get lost when I am working with live voltage.

And, of course you wouldn't want to leave it plugged in and unattended for the kids to play with

 

My favorite is when I've had someone behind me take a FLASH photo while I was working on an exposed battery pack.
Scared the %$&* out of me!