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"add fuel" and engine won't start after replacing/reconditioning hybrid battery.

Discussion in 'Gen 2 Prius Main Forum' started by Help07Prius, Nov 9, 2024 at 12:47 AM.

  1. Help07Prius

    Help07Prius New Member

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    I need help. I tried reconditioning the hybrid battery on my 2007 prius. After I put the battery back in, connected the 12v negative and the safety interlock on the battery I got a grinding noise, 3 clicks, and an "add fuel" warning message when I started the car. The engine won't come on and all dash lights are on. There is fuel in the tank.

    I checked codes and I got a U0111 and a P3004. I checked the connection to the ECU and it was loose. I cleared the codes and the P3004 still remains and the same thing: 3 clicks, "add fuel" and blinking fuel light, and the engine never starts.

    I don't even know where to start, is there a possible simple mistake? What is that white connector by the fan with 4 wires? I noticed that both the wires that were a bit corroded. I did use contact cleaner earlier today on that connector. Both the wires are connected to each other according to my multimeter (as in, if I test one pin, both pins on the other side beep).

    The car ran fine but had a weak bank before I took the battery out and put it back in, giving a P0A80 code and a P3000 code. I should also mention that I've had the battery out for 9 days. I do remember it was very, very difficult for me to remove those 3 cables from the battery.
     
    #1 Help07Prius, Nov 9, 2024 at 12:47 AM
    Last edited: Nov 9, 2024 at 1:59 AM
  2. Help07Prius

    Help07Prius New Member

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    I was able to check the codes and I got a UA111 data bus, battery energy control module A, no communication (which I was able to fix by pushing on it harder) and P3004 (which I can't resolve and all of the symptoms are the same as before).
     
    #2 Help07Prius, Nov 9, 2024 at 1:01 AM
    Last edited: Nov 9, 2024 at 1:55 AM
  3. Help07Prius

    Help07Prius New Member

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    I didn't have any of these errors before removing, reconditioning, balancing and putting the pack back in. I can't find anyone else with a P3004 error and car not starting and showing all lights after attempting to recondition the battery. What could have gone wrong? The screen does show the hybrid battery at about 75% full when it comes on. The module voltage is about 7.96v, it was 7.98v when I took it out. I replaced all the bus bars and nuts and was very careful with each one. What troubleshooting should I do? What could have gone wrong? I'm at a total loss and I think I just totaled the car. :(
     
    #3 Help07Prius, Nov 9, 2024 at 1:27 AM
    Last edited: Nov 9, 2024 at 1:54 AM
  4. Help07Prius

    Help07Prius New Member

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    Update: I used a multimeter to test the two high voltage terminals WITH the interlock fully seated and either my voltmeter isn't working or there is 0 volts across the terminals.Wouldn't there be at least some voltage even if the interlock wasn't connected? What could break the circuit at 0.0 volts at the terminals?
     
    #4 Help07Prius, Nov 9, 2024 at 3:25 AM
    Last edited: Nov 9, 2024 at 4:57 AM
  5. vvillovv

    vvillovv Senior Member

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    The contactor(s) in the batteries brain box .... All those switches, precharge resistor(s), fuse(s) in the battery case where the Prius BMS is. It's a safety feature found in most if not all EVs and hybrids.
     
  6. Tombukt2

    Tombukt2 Senior Member

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    Move your test leads back to the other side of the relay that's where the voltage is right now until you push on the brake and hit the start button that's when you hear the relays click and the wires that you put the nuts on when you put the battery in will now be energized You can measure there. Seems to me you need to be looking right at your battery pack and all of its connections and so on I've never seen an ad fuel light in my generation twos I have four of them so I'm not sure about that maybe I have and just don't remember it I've run them out of gas till the triangle comes on and they're not running I do that on purpose when I get one so I can see what the gas gauge looks like empty I never have to put bout 1.5 gallon gas in the tank that I have in the trunk when I'm doing this and the car starts right back up never any funny business I just push it and make it ready sit there a few seconds obviously because the car has to pump fuel from the tank all the way up to the fuel rail and it's empty and it does it graciously if you're 12 volt is worth a damn and then put it in drive and step on the gas and the engine comes right on without any problem
     
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  7. Tombukt2

    Tombukt2 Senior Member

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    I believe that code is directly related to your power cables so I would be checking all of the orange cabling Make sure on the battery which is hard to mess this up that those orange cables are connected properly and they have continuity or they beep with your tester touching end to end some of them one or two of them get quite stressed get the copper turns black and starts building up the green and white organism so you want to check that they can be cleaned and work fine then the cables that go from the battery all the way up to the inverter are you unplugged up at the inverter for any reason You can unplug the two cables from the back of the inverter take them off the battery with a long set of test leads measure each one of those cables for a resistance and I think you may be able to check the shielding of the cables others have had problems with these cables that run from the battery all the way up to the inverter others have had to replace them
     
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  8. highmilesgarage

    highmilesgarage Active Member

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    you accidentally did something wrong, you need a scanner that can show the INF code otherwise you'll be shooting in the dark..
    p3004 sc 131 cracked 12v post, blown service plug fuse, no start | PriusChat
     
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  9. Help07Prius

    Help07Prius New Member

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    Solved, I took the case back off the battery and tested the voltages across the cells until it went to 0. I was careless and tired last night when I was reassembling the battery and had forgotten to put one of the bus bars on. The bus bar was before the interlock in the circuit. Battery appears to be working fine now with no codes. Now I just have a cylinder misfire on cylinders 1 and 2 when I start the engine cold, which I had before. I'll start a new thread for that, but I've already replaced all 4 spark plugs, ignition coils, the MAF, and cleaned the throttle body as well as ran liqui moly Engine flush. The engine had previously ran completely dry of oil and had almost seized.
     
    #9 Help07Prius, Nov 9, 2024 at 3:40 PM
    Last edited: Nov 9, 2024 at 3:45 PM
  10. mr_guy_mann

    mr_guy_mann Senior Member

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    I would suggest cutting and splicing the wires at the white connector. Those are for the battery fan, and the fuel pump.

    Then I would clean and "caulk" the cracks in the seam sealer around the upper part of the tailgate body frame. Look around the lift piston mounts up to the rain gutters on the roof a few inches under the black rubber strips.

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