2005 P3000-388 after battery replaced

Hello All,
Its been many years since I have requested advice from this wonderful forum. I have owned and bought/sold 10 Priuses, Gen 1 and 2, and successfully repaired them, including reconditioning the hybrid batteries. I am pretty familiar with all systems
Here is a quick rundown of my issue:
1) Bought Prius with 225k and a Hybrid battery that had bad cells here in Hawaii where I now live. Error said "Hybrid Battery Failling". Drove it 60 miles to my home where I removed the battery and proceeded to do a full balance and capacity check to the best of my ability using smart chargers. No cells have less that 4200Mah and all were ch/dch 3 times.
2) Carefully reassembled the battery, having all clean busbars and applying Noco NCP2 to all connections to prevent corrosion (Used on previous batteries, High humidity area) and carefully checking all sensor tabs to make sure they did not break wire. Tightened down all nuts on busbars.
3) Reinstalled battery into car, checked all connections, applied Noco NCP2 and inserted orange safety connector and snapped down pull tab.
4) Took 4 tries to get car to start, display shows FULL battery and has 1/2 tank of gas. Says "Problem", Red triangle of death and red battery sign on top left of display. Techstream 13 keeps crashing every time I try running a battery diagnostic to check cells. Then, it stopped crashing and said cannot connect to ECU.
What info I could get is the Hybrid battery failed and Hybrid battery needs replacing. Couldn't save the diagnostic file because it kept crashing. I'll have to get my old XP computer and try running an older version of Techstream that worked I guess. Win 10 must have an issue with Techstream 13 or XHorse MiniVC driver.

Thoughts? Bad Battery ECU? Bad connection somewhere? What am I missing?

Mahalo everyone

 

Hi All,
Sorry Been travelling for a week now i'm back.

OK, im going to pull the battery again tomorrow and re-check everything including clean the connector to the battery ECU. The car initially started the gas engine and ran, then coded saying "problem". What I could get out of Techstream was "replace hybrid battery". I'm going to try running the Techstream software in Win 7 compatibility mode to see if I can get it to run the diagnosis correctly.

Odd that the display on the car shows a Full battery, yet says battery fault.

 

Hi there,
So I set the Prius aside for a while as my wife was moving over with me full time.

Anyway, I pulled the battery again, pulled all the connections to the cells and checked all sensing wires, put everything back together and still having problems. All connections are spotless and clean. P3000-388, 389 still. ICE starts and runs, is normal for a bit then all of a sudden throws the Triangle and VSC lights and engine increases RPM but doesn't show charging battery. I managed to get a screenshot of the battery ECU and seems very strange that every other cell block reads 15.xx Vdc and the others read 19.xx Vdc. Is there such thing?? These are 8Vdc cells?

The other day I ran the car 160 miles with no issue until I stopped at the store for 10 min, then as I was pulling out the triangle came up. I cleared the DTC to get home. The battery showed healthy the entire way and never showed less than 5 bars ever. Most the time it was green.

I had a strange occurrence last time I used the car. I drove out of the driveway, triangle came on then power was jerkey. I stopped put the car in reverse and it wouldn't power reverse. Engine raced, then I put it in drive and barely got it to move, and with going in and out of drive was able to get it powered back home. POS!

Wth??? Never had a Prius do this to me and I have 10 Gen1 & Gen2 rebuilds under my belt.

Thanks for any insight.

 

Ok thanks TMR,

I just ordered a sensor harness to rule that out and was looking at Ebay for a ECU too. So the "092" is the model number or version? How would I find that?

Thank You!!

 

Hi Andy, Sorry it took so long to respond. TMR-JWAP helped as I got a new Hybrid Battery ECU and wire harness. Solved the Triangle, but still it will come up on occasion. May be a HV leak somewhere. Hoping not MG1.
Thanks,