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Help with dreaded p0aa6 code

Discussion in 'Gen 2 Prius Technical Discussion' started by OmaramO, Sep 26, 2018.

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  1. OmaramO

    OmaramO Junior Member

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    Hey everyone!

    So one of my cars which has been driving fine for along time all of a sudden got hit with the dreaded p0aa6 code. I assumed one of the cells was leaking but when I opened up the battery case I found the main connections burnt and no cells leaking... not sure how to proceed from here any help is appreciated! P.S sub codes are 526 and 614. aPzqAxmzRTqBjM5VGwXTZA.jpg Q708AFggRLWSSlHXLrnUuQ.jpg
     
    #1 OmaramO, Sep 26, 2018
  2. DLC82SV

    DLC82SV Member

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    That doesn't look good at all. I wonder what's causing all that resistance?

    Posted via the PriusChat mobile app.
     
    #2 DLC82SV, Sep 26, 2018
  3. OmaramO

    OmaramO Junior Member

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    I’m really not sure. I could definitely tell that someone has already worked on this battery before (missing bolts and cells with different numbers on them). Not sure if it was from someone putting the wrong bolts on these terminals or over tightening them (they were both stripped also).
     
    #3 OmaramO, Sep 26, 2018
  4. bisco

    bisco cookie crumbler

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    how many miles on her?
     
    #4 bisco, Sep 26, 2018
  5. OmaramO

    OmaramO Junior Member

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    #5 OmaramO, Sep 26, 2018
  6. bisco

    bisco cookie crumbler

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    i suggest the service manual, unless someone has a better idea.
     
    #6 bisco, Sep 26, 2018
  7. OmaramO

    OmaramO Junior Member

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    From what I’ve found so far I know p0aa6 is a isolated fault code which I’ve had happen one time before on my aunts Prius. But that one when I opened it up there was obvious electrolyte under one of the cells and I replaced it, cycled it, cleaned the case and it was good to go but this one is more of a mystery.
     
    #7 OmaramO, Sep 26, 2018
  8. bisco

    bisco cookie crumbler

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    can't the p0aa6 also be tranny or a/c?
     
    #8 bisco, Sep 26, 2018
  9. OmaramO

    OmaramO Junior Member

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    From my understanding I believe it can be a isolated fault anywhere in the hybrid system (battery, tranny, inverter). Could the resistance coming from the tranny or inverter cause the wire to burn like this? I just assumed it a had something to do with the battery because that’s where the burn was
     
    #9 OmaramO, Sep 26, 2018
  10. TMR-JWAP

    TMR-JWAP Senior Member

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    You can tell just by the photos that the lugs were never tightened. Oops, read a few more posts and it appears the poster may have loosened them. But he did mention they were stripped. If they were actually stripped, there's no way they could have been properly torqued. That would easily be the source of the arc/heat damage.

    The main lugs don't look to be severely damaged. A little cleanup and they'll probably be fine. I would try just installing a replacement set of main relays and correct fasteners. You may need to replace the lug on the white wire if it's significantly damaged.

    Should be a relatively easy fix.
     
    #10 TMR-JWAP, Sep 26, 2018
    Last edited: Sep 26, 2018
  11. DaneH5

    DaneH5 Member

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    The nuts look loose on the connections
     
    #11 DaneH5, Sep 26, 2018
  12. OmaramO

    OmaramO Junior Member

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    Yes you are correct this picture was taken after I tried to loosen them and noticed that they were just turning and going nowhere from being stripped. So today I changed both main relays and put two new nuts on the connectors and cleared all the codes. Unfrontunatly the same code came right back on after only 1 minute of the car idling.
     
    #12 OmaramO, Sep 26, 2018
  13. DaneH5

    DaneH5 Member

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    Have access to torque app to see the traction battery info??
     
    #13 DaneH5, Sep 26, 2018
  14. TMR-JWAP

    TMR-JWAP Senior Member

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    Another thought....how did you determine no modules were leaking? I've had several that had no visible leaks when the top cover was removed, but puddled crusties were under the modules in the bottom pan area.
     
    #14 TMR-JWAP, Sep 26, 2018
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  15. strawbrad

    strawbrad http://minnesotahybridbatteries.com

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    The 614 sub code shows that the leak is not coming from the battery modules. It's area starts at the battery terminals and continues to the inverter.

    https://attachments.priuschat.com/attachment-files/2018/09/154191_614_code.pdf
     

    Attached Files:

    #15 strawbrad, Sep 26, 2018
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  16. OmaramO

    OmaramO Junior Member

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    I don’t have the torque app I use techstream to monitor the battery.

    I looked all around the connections on the bus bars and around the connections on the bottom of the case. I also flipped it upside down to see if I could find any corrosion.

    In this case what would you suggest doing? Should I just try to clean the battery terminals better?
     
    #16 OmaramO, Sep 27, 2018
  17. DaneH5

    DaneH5 Member

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    Individual cells all look good then??
     
    #17 DaneH5, Sep 28, 2018
  18. davecook89t

    davecook89t Senior Member

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    #18 davecook89t, Sep 28, 2018
  19. ericbecky

    ericbecky Hybrid Battery Hero

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    Take time to buy an inch-pound torque wrench to properly tighten all the electrical connections.

    If bolts or posts are stripped they should be replaced. Else you risk a fire caused by arcing.

    Guessing the tightness when it comes to High Voltage connections is crazy.
     
    #19 ericbecky, Sep 29, 2018
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  20. OmaramO

    OmaramO Junior Member

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    Thank you for the input! I should have clarified in the post but this was the first time I had opened the battery. Someone else had worked on it before. I torque all the 8mm on the battery to 50 inch pounds.
     
    #20 OmaramO, Nov 4, 2018
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