Gen 1 Prius as a hobby

Discussion in 'Generation 1 Prius Discussion' started by ginkelvanmichiel, May 7, 2023.

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  1. ginkelvanmichiel

    ginkelvanmichiel New Member

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    After looking around I've decided to replace the gen 1 cells for more recent gen 2 cells. They will be selected and balanced for me. So that will be one great pack again! Imho there are to many bad cells at this point in the original pack.
     
    #21 ginkelvanmichiel, May 17, 2023
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  2. Martin1973

    Martin1973 New Member

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    My gen 1 has a mixture of gen1 and gen2, they slightly different sizes.so need to drill out the bottom bolt holes , but they seem to work OK together.
    I couldn't source any gen 1 cells and someone had already replaced some with gen2 packs.
     
    #22 Martin1973, May 26, 2023
  3. ginkelvanmichiel

    ginkelvanmichiel New Member

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    Today I took out the HV battery. Easy job! Checked the modules and of course there is a lot of leakage and corrosion.
    3 weeks ago I bought 38 GEN 2 cells with 6 months warranty; they are all tested and balanced so that they should work fine without any errors.

    Next thursday I will visit a hybrid shop and then the magic will happen! Hopefully next weekend my Prius is up and running again.
    IMG_7854.JPG IMG_7855.JPG IMG_7860.JPG IMG_7862.JPG IMG_7867.PNG
     
    #23 ginkelvanmichiel, Jun 3, 2023
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  4. ginkelvanmichiel

    ginkelvanmichiel New Member

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    And with succes: the new modules are fitted, HV battery back in, and today I took the car out for a 85 miles spin. As a charm! So hopefully the modules will keep up for some time now!

     
    #24 ginkelvanmichiel, Jun 9, 2023
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  5. bisco

    bisco cookie crumbler

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    Looking good, congrats!
     
    #25 bisco, Jun 9, 2023
  6. ginkelvanmichiel

    ginkelvanmichiel New Member

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    Well... the car runs smooth again!
    Next thing is the AC.Does anyone know what could cause this problem?

    When I turn on the AC whilst driving on the petrol engine, it works (gets really cold) for about 5 or 10 minutes, and then the AC light starts blinking and It won't work anymore.

    Is this a malfunctioning sensor or could it be worse? I think it is strange that it does cool quite well, but then shuts off.
     
    #26 ginkelvanmichiel, Jun 16, 2023
  7. bisco

    bisco cookie crumbler

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    Are the cooling fans working?
     
    #27 bisco, Jun 16, 2023
  8. ginkelvanmichiel

    ginkelvanmichiel New Member

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    Where are those fans located? Are they activated by a sensor? Maybe there’s corrosion on it or something like that.
     
    #28 ginkelvanmichiel, Jun 16, 2023
  9. bisco

    bisco cookie crumbler

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    Idk on gen 1, but later, they are on a radiator in front and may be on full time with ac, or temp activated
     
    #29 bisco, Jun 16, 2023
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  10. ChapmanF

    ChapmanF Senior Member

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    I am going to guess that when you read the A/C trouble codes (car off, fan switch off, car ON, press A/C three times, fan switch to auto), the A/C button blink code is going to be 22, and it's going to be because your A/C clutch could use adjustment. Any 2001 Prius is likely to be up for that by now, if it hasn't already been done.

    That takes about ten minutes and costs about a US dollar, as described here.
     
    #30 ChapmanF, Jun 16, 2023
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  11. ginkelvanmichiel

    ginkelvanmichiel New Member

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    Thanks! It looks like this is the problem. So, I got a job to do tomorrow :).
     
    #31 ginkelvanmichiel, Jun 16, 2023
  12. Louis19

    Louis19 Active Member

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    Thanks for the incredible ride ! :)
    Back to the future !:D
     
    #32 Louis19, Jun 16, 2023
  13. ginkelvanmichiel

    ginkelvanmichiel New Member

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    Today I dismantled the ac clutch. Didn't look too good. Very corroded and the flywheel itself had a deep groove in it. Replaced the shim with a thinner one and went driving. Unfortunately it failed again. Hm. I may have to dive deeper into the system. If it runs, it cools perfectly. But after a while it just stops.
     
    #33 ginkelvanmichiel, Jun 17, 2023
  14. Trombone

    Trombone Active Member

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    Not discounting that you might have a clutch problem with the A/C compressor, the symptoms you describe are very similar to my '02. I replaced the A/C relay and have not had the problem since. I used a generic relay from Auto Zone. hope this helps.
     
    #34 Trombone, Jun 17, 2023
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  15. ginkelvanmichiel

    ginkelvanmichiel New Member

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    Where is the relay hidden? Easy task to swap it :)
     
    #35 ginkelvanmichiel, Jun 17, 2023
  16. Trombone

    Trombone Active Member

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    Consult Owner's Manual. It has pictures of locations for fuses and relays.
     
    #36 Trombone, Jun 17, 2023
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  17. ChapmanF

    ChapmanF Senior Member

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    Do you have a dial indicator to measure the clutch travel, and a caliper to measure the old shim(s) coming out and the new ones going in?

    What you want is to get the clutch travel to be 0.50 mm (± 0.15 mm). This is easier done by measuring and subtracting than just putting in a thinner shim to see what happens.

    The grooving of the clutch mating surfaces is a thing that always happens. They still fit each other perfectly (because, after all, they did that to each other); they are simply no longer flat.

    That is what makes the dial indicator the best way to measure the clutch travel for a used clutch. For a brand-new one, you could use a 0.50 mm feeler gauge, but the grooved surfaces of a used one will foil that approach. The dial indicator can still show you exactly how far the plate moves to engage, even with the grooves.

    In the US, there are shops like Harbor Freight where a usable dial indicator can be had for a minimal cost.
     
    #37 ChapmanF, Jun 17, 2023
  18. ginkelvanmichiel

    ginkelvanmichiel New Member

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    I will have a look again tomorrow. Maybe I can check the clearance. The thing I think is strange, that the system works for a couple of kms, and then stops working. After fuelling the car up, it did work again. And stopped soon after.
     
    #38 ginkelvanmichiel, Jun 17, 2023
  19. Trombone

    Trombone Active Member

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    #39 Trombone, Jun 17, 2023
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  20. ginkelvanmichiel

    ginkelvanmichiel New Member

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    I've been working on the car, and it seems that the clutch is worn out. It just can't get enough grip to make the AC work. I think I need to replace the pressure plate as well, but I don't know if the clutch and pressure plate are sold seperately from the compressor.

    If there's enough grip, I don't know why the AC shuts off after some time. It gets really cold, fans are working.
     
    #40 ginkelvanmichiel, Jun 30, 2023
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