Hi community, I recently changed 5 modules in my 2005 prius HV battery pack. I put the pack back in the car and it cranked up (success 1). It ran for a few minutes and sparked a hybrid low voltage error. I utilized the DrPrius app and it said there were problems with module 1. I took the battery back out and cleaned the cables a little more deeply. I put back in and it ran good for about 30 min. Then similar error and Dr Prius said issues with module 6. I screen spotted this time (forum wouldn't let me upload pic, so this is a google drive link): . At this point, I was wondering what may be the issue. I decided to clear the code and force charge/discharge the battery by driving. I did this for about 5-6 times clearing the code each time to use the battery up. I then rechecked the Dr. Prius app and had this weird reverse red graph on module 2: . Does anyone know what a reverse red voltage would mean on the app? Does anyone have any suggestions for what I should do next? FYI, I reconditioned each module with a hobby charger to determine which were still usable and put 5 new ones in from an Ebay seller. I discharged all cells then recharged them putting all the positive and negative terminals on one side. I also have an issue with speedometer, gas gauge, etc. It doesn't light up. I've seen videos on how to fix this and sellers on ebay who will fix it for me. My car though also has a display screen that is not displaying well. I am referring to the screen that shows the battery level. My wonder is if that same circuit board may control the screen/display area as well. Perhaps it is not getting the voltage it needs to display brightly? Perhaps my first step would be to exchange the whole board to see if that fixes the screen? Appreciate any wisdom from the community, Basil
That reverse data is most likely corrosion on the pins inside the battery ECU that needs to be cleaned. You might need to replace the voltage sensor harness as well, which is the path the corrosion travels to get into the ECU. As for your modules, using Dr. Prius app to diagnose the bad ones doesn't work very well... Have you load tested each module yet? As in record voltage drop after 2 minutes connected to a halogen headlight bulb (55w / 12v) ?
Your Block 2 has a bad sensor pickup. Either the tab at the module is cracked, the wire is broken or something at the plug connection is bad.