07 Prius won't start after repairs

All of these codes have to do with the high voltage battery system (First one is service plug failure, second two are contactor related and the last one is motor performance). The ABS DTCs are also related because it expects regenerative power.

Is the service plug in? Have you inspected the battery box area around where the contactors are? You should also inspect the high voltage power cabling that runs along the drivers side of the vehicle.

Andrew

 

When you insert the orange interlock switch, you have to pivot the lever 90 degrees. Then you must slide the lever (either up or down, I forget which) to lock it in place. See if that helps.

 

I'm sure I read somewhere in the past, that if your going to weld on the car your supposed to dissconnect the HV battery.

 

Lucky, I worked at a station and 1 particular lazy cameraman decided the camera pedestal steering ring made a great chair, until his weight broke the ring. They brought in Joe Welder who did not know squat about electronics, and promptly grounded the welder to the camera. After he finished welding the ring, the steering system now worked great, unfortunatly the arc FRIED the electronics in the camera.
Guess who had to repair the system...... I never saw so many blown 2N3904's and 2N3906's, until I got to Hollywood and blowing up cameras with AC was a common occurance. I got so I could fix the system in about a day!!!

Nice job on troubleshootong the system and finding the 4 broken wires. It could have been a lot worse!!

Electronics and Welding really do not play together well!!

 

I'm getting these codes after having the HV battery out:
P0ADC-266
P0AE7-224
P0AE0-228

not checked the engine ECU yet... I did get another one (something about DC inverter but i'm not sure which)

i'm guessing it's something similar to the OP problem - just can't find any issues with wiring. hoping not to need to take the battery out again unless i have to. if the OP is still around, can you describe which wires you'd damaged? it might point me to the general area of where to look.

EDIT: so I found what the codes mean (posted below). deducing i hadn't messed with the ECU, and the other common cause was the wiring harness I pulled the pack out again to check the wiring.

Each pair was reading a voltage at the plug for the ECU, but I don't know if there is some other magic going on (like some shunt circuit) so ended up cleaning up all the terminals to see if it helped.

Seems to have done the trick, codes are gone and have had the car 'ready' for about a day and took it for a 50km round trip.


Trouble Code: P0AE7/224
Hybrid Battery Precharge Contactor Control Circuit High

Possible Causes:
Wire harness or connector
Hybrid vehicle converter (DC/DC converter)
Hybrid vehicle control ECU

Trouble Code: P0AE0/228
Hybrid Battery Negative Contactor Control Circuit High

Possible Causes:
Wire harness or connector
HV relay assembly
Hybrid vehicle control ECU

Trouble Code: P0ADC/226
Hybrid Battery Positive Contactor Control Circuit High

Possible Causes:
Wire harness or connector
HV relay assembly
Hybrid vehicle control ECU

 

After replacing your hybrid battery, if the Battery isn't grounded these codes will show up. P0AE0, P0ADC, P0AE7.
If the orange interlock switch isn't pushed all the way down after engaging it this code will show up. P0A0D.
They may very well be intended for other DTC but they will show up in either of these senerios.

 

did you drill through the harness as well?

 

I get these codes same 3 codes about once a week. Can anyone tell me where the hybrid battery is grounded at?

 

The battery should be grounded when it is bolted down. See the bolts circled in red in the attached diagram. There are another 5 on the other side. I believe you will get satisfactory grounding with at least 2 bolts torqued down, if you need to do some testing, before completely bolting it all down.

 

This is what P0AE0 means. It happened to me. I rebuilt my '07 Prius battery and then messed up and put a bolt in a hole in the drivers side under the back seat. If you do this you will render the battery and all the repairs you just did on it useless, because that bolt will go right through the front relay in the HV battery and ruin the relay. Take the battery apart again and remove the front relay and look for a hole like this... picture included. you will need a new one.