2002 Prius fault code P3030

P3030 is for a bad sense wire in the HV battery. You'll need to remove the battery from the car, take the cover off, and see what's going on. Two source that you might find helpful:

http://priuschat.com/forums/generation-1-prius-discussion/84017-nhw11-traction-battery-autopsy.html

Luscious Garage | Blog | Toyota Prius code P3030 “High Voltage Line Snapped”

 

Also check the 12V battery, it should be more than 12V at rest before you turn the key.

If not, charge it up....then disconnect the negative wire for a few seconds to "reset" all the computers....then try to start again. Does it code right away?

 

Yep, you need to pull the traction battery, and it does explain the no-start.

 

Pull the HV battery out of the car, then check the bus bars and sensing wires. If you need just a couple of sensing wires I can send them to you for cheap. I have quite a few extras. Pmail me..

While battery is out you should probably remove both sides of bus bars and clean all the terminals etc....or buy new ones.

 

Working on a 2002 Gen I.....

We just replaced the Gen I cells with Gen II cells, when done we get the P3030 code. Car starts fine but gets the red triangle and the car on display.

When we did the conversion, we found a broken tab, and replaced it by cutting off one (from Gen II harness, with a short piece of wire) and soldered in the new wire and a new tab,... off the of the Gen II wiring loom. Is it OK to solder in a tab and short piece of wire???
Or could we have missed another broken tab?

Please help!

 

Yes it is okay. But use a meter double-check that repair, as well as the rest of the tabs.

 

I bought a new wiring loom for that side of the battery, and the error code problem has gone away.

Re-installed the Gen I battery, that we retro fitted with Gen II cells and it's working perfectly. Charging the traction battery as it should.

The whole process wasn't particularly difficult (although my son and I have considerable mechanical experience.) We were careful during the process to not fry ourselves...or the car.

My cost for two Gen II batteries (2004 and 2006).... (for 38 of the Gen II individual cells) was $600 at salvage yards, plus about $100 for the wiring loom at Toyota. Did all the work ourselves otherwise. Total cost $700, but found a place that will buy the old cells for recycling and may get $100....so total cost for the "new" traction battery will be about $600.

 

Awesome. You guys did a great job. I'm hoping for many more years of trouble free driving for you and your Gen I.

 

The 2002 was my sons car (our first Prius) and when the traction battery died. (at the 81,000 mark, as has been documented as the threshold) He got the red triangle, and lost electric power from the hybrid battery.
We at first thought we might have to junk the car...but after doing some research, and getting a manual on the conversion, I decided to give it a whirl.
I wasn't about to spend $3,200 for a new battery from Toyota!

We converted the Hybrid battery with Gen I cells, to newer 2004 and 2006 cells (to have the necessary 38 cells required.) (2004 to 2009 have 28 cells)

I've come to find out that the "manufactures" out there, that are converting Gen I batteries are also replacing the one side wiring loom as part of the rebuild. If you do one of these conversions, you would find out that this wiring loom with all the connectors, was also "glued" on with some sort of adhesive (as well as a stud/nut connection).

When removing it, it also had corrosion, and a lot of the glue substance. Was pretty much impossible to get it cleaned up, with out breaking the very fragile connectors.....and we got an P3030 error code after re-installing... the first go around. (and RED triangle of death !)

The P3030 you hear so often ( basically the code means there is a problem with the wiring loom that attaches to each of the 38 cells.)

After getting the new wiring loom from Toyota, and installing it on the battery, and of course, putting the whole thing back into the car......it worked the first try !:cheer2:
We're pretty happy it all worked out.

I'm a rebuilder, and have rebuilt some other Prius's (not the battery but with body damage) Have a 2010 IV that has side damage that will be my driver. I already rebuilt a 2008 for the wife, and a 2004, 2006 and another 2008 that will be sold. (sold one a week ago)

 

I just got P3030 on my 2002 Prius. Wouldn't happen to have a couple of those sensing wires still laying around, would you, 3prongpaul? I bet I could even get away with simply feeding a piece of copper wire wire straight to the terminal on the module, no?

 

Yes, I have plenty but I recommend you take the battery apart first, if the bus bars are all corroded I recommend buying new ones from Toyota which include the sensing wiring and cleaning up your battery terminals. If you are trying to spend minimal money I can sell you used ones or you could simply use clean wire. Also check your battery ECU. In damp climates the ECU shorts out where the sensing wires plug into it.