Hello all, First time posting here, so please be gentle... HISTORY: I have spent the last few weeks replacing some bad modules in my 2007 prius, following this thread: Gen II Prius Individual Battery Module Replacement | PriusChat This has been my order of steps: - Remove HV battery - Replace 3 bad modules - Re-assemble battery for balancing - Discharge/charge each module 3x using HiTec AC-Plus - Discharge all modules back to 7.85v - Wire modules in parallel to balance (24 hours) - Re-assemble pack and re-install into car - Replace 12v battery, as it was bad THE PROBLEM: I have the HV battery bolted in and the leads to the car attached, but when I plug in the safety switch, I get a good 220v on the battery side of the connectors, but I am getting nothing on the car side. Consequently, when I turn the car on, I am only getting auxiliary electrical, but nothing from the HV battery. The car is still showing a number of indicators (pictures attached) and will not switch out of park. I am hoping I have just missed something simple. For the amount of time I have invested in repairing this HV battery, I will be very disappointed if I am not able to get it back up and running. Any suggestions would be welcome. Thanks in advance! BG
Thanks JC! That was the problem. Though, now that I have addressed that, I am now having new issues. I (fully) engaged the safety switch, turned the car on, and went for about a 1.5 mile test drive to see if I could get it to throw a code. I got two: P0301: Cylinder 1 Misfire (I am hoping this is just because the car has sat unused for almost 4 months and had a rough start the first time) P3021: Battery Block 11 Becomes Weak (This is not a surprise. Based on the data from my discharge/charge cycles, I new Module 11, along with a couple others, was a bit weaker than the rest. Didn't realize it was weak enough to throw a code.) Also, I am still seeing the following warning indicators: - Master Warning Light - Check Engine Light (presumably because of the P0301 code) - Hybrid System Warning Light on the display NEW QUESTION: Once I replace the remaining weak modules and clear the error codes, and those warning lights likely to go away?
Just to be clear. Block 11 is the 21st and 22nd modules starting the count opposite the battery computer. Brad
The modules are counted from the computer end. Mods 7 & 8 are block 4. I didn't see where you load tested any of the modules. That is a critical step to weed out any weak ones. Especially important if you see a mod with a noticeably lower voltage after discharging/charging. I have even seen one that showed about the same voltage as the rest and would not hold up under a load.
No, this is wrong! For Gen II Prius, years 2004 to 2009 the count starts opposite the battery ECU. Brad
UPDATE (good news): Thanks, all, for the help! Since my last post, heres what I have done: - Removed the HV Battery (again) - Replaced four more weakening modules (Now all my modules are in great range in terms of capacity) - Charged/tested new modules using HiTec X4 AC Plus - Re-balanced pack overnight using custom wiring harness - Soaked terminal nuts overnight in vinegar to remove corrosion - Removed all 27 of the copper terminal connectors from the bus bars and cleaned with a brass bristle wire brush - Re-assembled and re-installed Pack is running great so far. I have run about 10 miles so far with no issues or trouble codes. My plan is to run it the rest of this week (50 miles or so), then if I still show now problems or trouble codes, put the back end back together this weekend. Thanks again for the help, everyone! This forum is great!
Suggestion on where to get one? I am not really even sure what this equipment is that your are referring to. I am currently monitoring battery amperage and voltage using the xgauge function on the ScanGaugeII. I am assuming a Mini VCl would do something that the ScanGauge cannot?