Replacing HV wiring harness

Discussion in 'Generation 1 Prius Discussion' started by dpeverhart, Jul 19, 2013.

  1. dpeverhart

    dpeverhart Member

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    Since Toyota didn't have the replacement wiring harness in stock and it took nearly two weeks to get it, and I didn't take a picture of the old one before I removed it, I don't remember where these wires attach!

    Does anyone have a picture to show where these two wires go. I removed the black wire from the old harness and the new harness has one wire already on it. I'm looking at the battery assembly and I see three different places to attach these two wires and I don't want to make a mistake. I can take a picture and post in a few hours if that helps.

    Thanks
     
  2. slimfrancis

    slimfrancis Member

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    take a picture and i'm sure we can help you.
     
  3. dpeverhart

    dpeverhart Member

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    I think I have them attached at the only possible place so I'm not sure what the problem is. I'm including a picture of where the wiring harness connects. #1 is the main connection and #2 is a black wire that appears to be a ground. HV connections1.jpg
     
  4. slimfrancis

    slimfrancis Member

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    you're missing the little short positive cable (5'' long orange cable w/ red tape wrapped on it) it goes over the last module terminal you see pictured (just North-North-West of #2) and attaches to the top of your relay (that screw directly above your #1).

    see this picture here:
     

    Attached Files:

  5. theshark

    theshark Member

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    Keep us updated!!
     
  6. dpeverhart

    dpeverhart Member

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    Thanks! From the picture it looks like that wire is part of the wiring harness, is that correct? If so, mine does not have it.
     
  7. dpeverhart

    dpeverhart Member

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    Ok never mind my last question, you answered it already. It's a separate piece. However, I feel almost positive that this piece was not there when I dismantled the battery. This car had been worked on and they were unable to get it running before I bought it, probably because they were missing that short wire.

    Now the question is, can I make one of these wires myself and if so, what materials would I need? What gauge wire etc?

    Thanks
     
  8. slimfrancis

    slimfrancis Member

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    you definitely need that cable and i wouldn't make one as you're dealing with 300 volts running through there. i'm pretty sure toyota will sell that cable.
     
  9. jdenenberg

    jdenenberg EE Professor

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    If this discussion is about the wiring to/from the HV disconnect relays, I have a disassembled 2004 HV battery case with all of the cabling and can supply the cables. PM me if they fill the bill.

    JeffD
     
  10. yotatoter

    yotatoter Member

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    I have a couple of those laying around also.send me a PM and I will send you what you need...
     
  11. dpeverhart

    dpeverhart Member

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    Well thank you both for the offer, I appreciate that. I already put an order in earlier at the local Toyota dealer. It's only a $10 part.
    Thanks again.
     
    Rick atl likes this.
  12. dpeverhart

    dpeverhart Member

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    Today I picked up the short wire that connects from the last module to the relay and installed it. Car started right up and drove about 30 miles with no problems so far. Before I bought this car, the dealer said it needed a new battery. I bought a new wiring harness and the short wire for a total of about $150 and 5 hours labor and the car runs great!
     
  13. slimfrancis

    slimfrancis Member

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    excellent! i'm glad to hear you have it all sorted out. enjoy your ride! hopefully the dealer knocked quite a bit off the price for you since the car had a "bad hv battery", lol