2003 Prius Won't Start after HV Battery Replacement

Discussion in 'Generation 1 Prius Discussion' started by jmotley, May 18, 2016.

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  1. greasemonkey007

    greasemonkey007 Active Member

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    You really should think about load testing all the modules. If any drops considerably more voltage under a load, it's probably not any good. There's lot of info on here about how to do that. Let us know what you find. I have spares if you need some, or I can build you a battery out of 2nd gen modules if you'd like.
     

    Attached Files:

    #21 greasemonkey007, May 19, 2016
  2. DRACO

    DRACO Member

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    Well keep us posted OP
     
    #22 DRACO, May 19, 2016
  3. jmotley

    jmotley New Member

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    If it doesn't work on my phone I'll make it work on a laptop somehow.
     
    #23 jmotley, May 19, 2016
  4. jmotley

    jmotley New Member

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    Will do, thanks for the reply. OBD2 Scanner should be in tomorrow. Getting real tired of looking at that little bastard in the yard haha
     
    #24 jmotley, May 19, 2016
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  5. greasemonkey007

    greasemonkey007 Active Member

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    I know the feeling!
    Good luck!
     
    #25 greasemonkey007, May 19, 2016
  6. jmotley

    jmotley New Member

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    Is there any general safety thread with some instructions on how to safely handle these batteries? I will consider myself lucky to have had no accidents the first time I had them out.
    Still waiting on OBD2 adapter. Wired one would not work with Torque Pro, but I found Techstream online for free so I am sending it back and have an adapter that should work with Techstream on the way. Don't ever let anyone tell you laziness doesn't cost! Lol
     
    #26 jmotley, May 21, 2016
  7. ChapmanF

    ChapmanF Senior Member

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    By searching PriusChat, I think you can find a PDF copy of Toyota's instructions that went with the Gen 1 battery terminal sealing campaign (SSC-40G). The instructions (30 or 40 pages, not just the dealer announcement letter) give a really good description of battery teardown, reassembly, and safety.

    -Chap
     
    #27 ChapmanF, May 22, 2016
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  8. jmotley

    jmotley New Member

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    Thanks for the reply I will give that a look.
     
    #28 jmotley, Jun 1, 2016
  9. jmotley

    jmotley New Member

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    Alright guys after being sick for a week I finally got a Techstream compatible connector and got it to work with Techstream on my laptop. I have a screenshot of the HV Battery readout from Techstream,I'm not sure what the Voltage for each battery block is supposed to be but it looks like some bad news.

    [​IMG]
     
    #29 jmotley, Jun 1, 2016
  10. jmotley

    jmotley New Member

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    The phone to USB didn't work but in the process I found Techstream and it looked much more promising so I downloaded it and got a supported USB interface for my laptop. It works, and I have HV Battery readouts but I'm not sure what to look for.
     
    #30 jmotley, Jun 3, 2016
  11. ericbecky

    ericbecky Hybrid Battery Hero

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    Ummm... you've got some MAJOR problems there.
    Missing voltage readings for blocks 3 through 19.
    You must have something wired wrong.
    Did you reverse polarity on one of the modules. (Have it installed 180 degrees incorrectly.)
    Go back and check.
    They should alternate. Positive. Negative.

    If you are not sure, open the pack and post a picture of the modules nearest the computer.
     
    #31 ericbecky, Jun 3, 2016
  12. jmotley

    jmotley New Member

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    I noticed that they alternated when I was testing each battery's voltage the first time I had the battery out. So I'm almost 100% sure that I installed the new battery correctly, but I used a drill to disassemble and reassemble the unit and read somewhere that the nuts that attach the bus-bars require only 7 inch-lbs of force. Is it possible that I broke the tabs that measure each battery's voltage on the bus-bars by using a drill?
     
    #32 jmotley, Jun 3, 2016
  13. ericbecky

    ericbecky Hybrid Battery Hero

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    Now you have some data
    I would look over all the physical connections very carefully.

    Next I would move on to the orange connector that plugs into the battery.

    The fact that the problem start at block 3, start your investigation there.

    Take some photos of all sides of that block and post them.
     
    #33 ericbecky, Jun 3, 2016
  14. S Keith

    S Keith Senior Member

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    Anything is possible. What's certain is that something is horribly, horribly wrong.
     
    #34 S Keith, Jun 3, 2016
  15. ericbecky

    ericbecky Hybrid Battery Hero

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    Don't be shy. Post some pics.
    We've all made mistakes before. Post what you have going in there so others can learn as well.
     
    #35 ericbecky, Jun 3, 2016
  16. S Keith

    S Keith Senior Member

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    You sure you didn't put all the modules in blocks 3 and up in parallel?
     
    #36 S Keith, Jun 3, 2016
  17. DRACO

    DRACO Member

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    Don't worry OP, 2nd time around is much easier, just don't skip any safety pre-cautions.
     
    #37 DRACO, Jun 4, 2016
  18. jmotley

    jmotley New Member

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    Alright as soon as I get the battery out today I will do that.

    Ok, I read on another thread that it was 7... guess that was bad info?

    I figured I would make some mistakes since I've never worked on a hybrid before, but that's all a part of learning right? lol

    I don't remember moving any modules other than the one that I replaced, but I will post pictures of the entire unit.

    Thanks
     
    #38 jmotley, Jun 4, 2016
  19. jmotley

    jmotley New Member

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    Got some pictures of my battery today, looks like I should've cleaned the terminals on the batteries and the nuts that attach the bus-bar the first time around...
    1.
    [​IMG]
    2.
    [​IMG]
    3.
    [​IMG]
    4.
    [​IMG]
    5.
    [​IMG]
    6.
    [​IMG]
    7.
    [​IMG]
    8.
    [​IMG]
     
    #39 jmotley, Jun 4, 2016
  20. DRACO

    DRACO Member

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    Those bus bars look suspect, especially with all that green patina, that could definitely cause poor continuity.

    Also, it may not look it but that corrosion could migrate down the sensors into the wiring as well.

    I bet those modules voltage are fine once you remove them,

    Before
    [​IMG]

    After ( back bus bar cleaned, the front sensors are a waste of time since you can not get down to the wires very well )
    [​IMG]
    I also soak and cleaned the nuts for extra measure

    with new busbar
    [​IMG]
     
    #40 DRACO, Jun 4, 2016
    Last edited: Jun 4, 2016
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