2007 ICE won't start, Red triangle, numerous codes

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by DanHoug, Oct 7, 2024.

  1. DanHoug

    DanHoug New Member

    Joined:
    Aug 15, 2024
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    Location:
    northern Minnesota
    Vehicle:
    2007 Prius
    Model:
    N/A
    Long story short... was given a 2007 Prius that was very erratic and flaky. would drive fine then all dash lights come on and either limp home with revving engine or totally dead. 12v batt disconnect would set everything right until next mishap, either days or weeks. now the ICE won't start and kicks out of READY mode when it seems it would call for the ICE to start, like when AC is turned on. the back story: this car had the seam leaks, was wet with standing water in the back end under the carpets. i've done the following:
    - repair leaks of course
    - removed traction battery, cleaned all buss bars, cycled 6 cells on drone charger that were ~6.5v
    - cleaned every connection in battery, checked for burned pins and dendrite growth on batt ECU
    - cleaned batt fan, repaired corroded plug
    - 12v battery new 2023 and load tests good
    - cleaned ECU connectors with DeOxit D5
    - tested and cleaned all fuses
    - replaced relay block B with spare, cleaned pins both blocks
    - substituted Network, Battery, HV, and Engine control ECUs with different

    Techstream output shows these immediate codes upon clearing codes:
    Hybrid Control > P3000 > Detail code 3 > 123
    > U0100 > Detail code 1 > 211
    > Detail code 2 > 530
    HV Battery > U0100

    i'm at my wits end with this car. when it was running, the traction battery tested good with the Dr Prius app, even before cleaning the terminals and rejuvenating cells. mpg was good,

    as it stands now, a 12v disconnect will reset things long enough to go into READY. the car can be shuttled back and forth in EV but as soon as what seems would be the ICE start, READY goes off and car is unable to move until another 12v disconnect reset.

    feel free to ask questions and lead me down to info you might need to help diagnose this.

    -dan
    Bemidji MN
     
    #1 DanHoug, Oct 7, 2024
  2. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
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    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    What about corrosion on the orange plug of the HV control ECU did you take the back silver plate off that ECU and see those big fat bus bars running to the green board usually they're corroded with that white corrosion that we're talking about they need to be cleaned off too sometimes just swapping that ECU to see what happens can be a good idea if it's really corroded in a couple of the pins looked really bad and if you took the silver back off the bars from the pins leading to the board usually a few of those look like hell also. The detail code for your p3000 maybe check it again and see if it changes to another detail code there are a few for that code and other than that check all your assembly on your battery sounds like something is not right because when it just getting to start and shuts everything down it seems like there's some kind of a problem and you would get the code engine failed to start especially with Toyota software and I'm not sure why we're getting u 100 codes
     
    #2 Tombukt2, Oct 8, 2024
  3. DanHoug

    DanHoug New Member

    Joined:
    Aug 15, 2024
    2
    0
    0
    Location:
    northern Minnesota
    Vehicle:
    2007 Prius
    Model:
    N/A
    the orange plug is clean and corrosion free. i did disassemble the battery ECU case and it looked great and the pins surprisingly corrosion free. also tried another battery ECU from a 2005 but it was the same PN. i agree that it seems strange that when there's a call to start the ICE, you hear the traction battery relays open and ready light goes out. battery is assembled correctly.
     
    #3 DanHoug, Oct 8, 2024
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