Need help! In a predicament in Dallas, TX.

Depending on the tool......tools made out of non-conducting materials is helpful.
Or where that is not possible, only the working point of a metal tool is exposed; the rest is insulated.

 

I don't think you fully appreciate the situation you are getting into.

Not a lot of people have that model of vehicle.
I suspect that only a tiny, TINY number of them have seriously considered working on their own HV battery......much less actually DONE it.
This is a Prius forum. It won't attract those people.....probably.
So you are left pretty much on your own.

When most people encounter a label that says something like:"No user serviceable components inside. DANGER of injury or death......." they pay attention to that and don't mess with it.

 

I'm sorry for your predicaments. I wished I was at your location, but sorry, I'm in Lagos, Nigeria.

Its quiet an easy job. I have handled highlanders, and rx400, etc.

Both share the same kind of battery pack.

Here are some steps that might help you:
1. Have the 12V battery negative terminal disconnected, then remove the set ice plug that's by the rear seat behind the driver.

2. Commence removal of the rear seats, using 14mm socket and wrench, and all the plastic stuff surrounding the all the driver, middle, and passenger side battery banks.

3. Disconnect all the wire connectors attached to the battery pack ECU, and the relay block(contactor's or something?).

¶¶You can remove the blower fan connector as shown in your pictures, by pressing the clip on the connector, and pulling the connector from its hooks.

Not that hard to unclip em from the blower fan connector.¶¶¶¶

Attention:
a. Pls ensure you wait for 1.5minutes or so, to allow the HV capacitors to discharged before touching the orange cables.

b. Ensure you have class 0 gloves, just in case.

4. You have an orange small safety clip on the side of the battery.
Use the service plug sharp edge, to unscrew this tiny orange coloured safety clip that's on the pack top housing.

Do not pry it with a screw driver. That would damage the clip.

5. There's a small plate covering the pack housing, on top of it, where the contactors feeds voltage to the inverter(orange cable in that location). It has about 3 10mm bolts on it.

Remove those bolts, and you've access to the contactor's and the orange cabling.

Use 10mm size socket to remove the 10mm nuts on the orange cables, and you're done.

6. After you're done removing all the wire harnesses connected to the battery ECU, contactor's, etc, you are now safe removing the pack from the car.

The bolts holding the pack down, are 12mm bolts, and some 10mm bolts also.

Please remember, that after you're done unscrewing all the bolts holding the pack to the rear of the car, you got to seek for an assistance to help you out with the pack, if that's what you wanna do.

You have any further questions, I'm willing to help.




Fig1: HV battery pack showing the contactor's
Fig2: Pack on work table(including Camry, and Prius), showing the blower fan
Fig3: Pack showing the middle bank removed
Fig4: Inlets for pack cooling
Fig5: How the whole batter pack looks like before removal




Dxta

 

I don't think anyone scared you. Maybe you were just so scared of the job.

 

That is called survival instinct, only experts who know exactly what they're doing B4 hand don't get that feeling. After one touches a pack enough with a multimeter one begins to think they are safe ( 0 volts) everywhere one looks.
All it takes is one surprise !
I take it SLOW when it comes to messin around packs. I wouldn't do it at all if I could afford to pay someone else to do it.
Hybrid system mechanics at Dealers that sell hybrids have to have hybrid certification(s) that include owning all the manditory safety equipment like the gloves and the insulated tools, and high voltage warning signs/cones.

 

You could've asked Matt questions before having him go out to you, he's very helpful

 

I know @Raytheeagle has used the Prolong system and helped others. Did Matt help get the Prolong harness installed?

 

I am not sure if the Toyota Hybrids forum would have been more helpful. I think you likely got more assistance here.

Toyota Hybrids | PriusChat

 

most of the customizing engineer types ( hobit, doc willie, 4prongpaul, evan, danny, mikeD ) no longer post
very often here. Hell not many post in regards to techstream/TIS either.
Thank god ericbecky still is offers up his expertise sometimes.

If we'd have know about your concern of having 0 volts after removing the "service plug"
we could have directed you to one of these videos for example

there are others that more closely represent your car to can easily be found if you know what to look for.

I hate using this phrase, Oh well, " that being said" there is nothing ( in my mind anyways ) that can
compete with experience when doing anything on the car you own, Espeically hybrids since they will conform to
the drivers behavior, in some respects. Some hybrid systems adjust more than others to driver behavior.

I have no personal experience with traction pack balancing. I have D cell pack experience, but that is
no way applicable to the procedures you will need to learn.
I hope someone reading this can offer good suggestions for how to setup the prolong that has given them excellent results.
I have a GC01 charger/discharger system developed my mikeD specifically for the insight, but also has functions for civic
prius and if I'm not mistaken stick/module based charge/discharge with monitoring.

I remember MikeD explaining to me the difference between the D cell type packs and the prius modules
and even thought I have a few prius NiMh modules I don't know if they are second or third gen mods or how they
behave in a pack ( other than what MikeD told me about )
I wish I had some personal experience I could share regarding traction pack re-balancing. Maybe someone can pick up form here and post what works well for them. Or maybe recall some MikeD experiences they've had as well....

But remember, not all packs behave the same, so your learning and observation experiences that you post here will help others that have done it before either confirm their beliefs or scratch their heads and also help others in the future if they stumble upon this thread 3 years from now.
As my ole man used to say

Greetings and Salutations

 

By "things similar" you aren't speaking of the ShamWow! are you? Because I am pretty sure they work. A guy on TV said so.

 

I had @jeff652 indtall the harness into our 2010 last year.

I wrote a list of questions to ask him as I knew I would forget when I was there and chatting.

I’ve done the reconditioning process several tones and share the equipment with another member here.

What questions do you have?

 

How do you connect one of those things to your battery ?
I must have missed the episode where they explain that.

 

I should have double checked the Subject before posting again

Gotta remember this is a highlander thread

Highlander lithium traction pack with 3 stacks of modules/fans connected in series
with junction block(s) and associated hight voltage contactors , hall effect sensor(s) etc

an not a prius pack thread,.

Just imagine if you were one of us wondering how the three fans are taken out ?