Lots of codes - need wisdom

Hi all - I need some help deciphering exactly what is going on with my 2006 Prius. First, some background. The car has about 230,000 miles and I bought it about 15,000 miles ago. I have been driving it about 400 miles a week. I had the belt changed two weeks ago. No issues until yesterday. Doesn't even burn a quart of oil between oil changes. I have been averaging about 43.8 MPG.

So, while my wife was driving it yesterday, the car gave a red triangle, the "VSC" light and the light with the exclamation point in it. She drove it home and it drove fine. I checked the codes with Torque Pro. I got the following:

Codes thrown:
P0441
P1453
P3190
Codes pending:
P0455
P0A80
P1451

I cleared the codes and the car drove fine last night and this morning (~25 mile commute). When I left work, it seemed to have less pep, so I clicked the "Energy" button. The battery was at 1 bar. It began charging. By the time I stopped at a light, it was at 2 bars. However, as I sat at the light, it jumped up to green, all bars. As I drove it began dropping like normal. During the trip home, I saw a couple of times where it would jump up to full or down to one bar but then return to normal looking (for my car, the purple range). As I turned on to the last road after the highway, I got the triangle and lights again. This time, I used the Techtream software. I received the following codes:

P1453
P0441
P0455
P0A80
P1451
P3018
P3000
C1259
C1310

I did a check of the 12v battery and it was 12.3 unloaded, 11.9 with headlights, 11.8 with high beams, went back to 12.3 when load stopped. I know that is a little low, but don't believe that is the cause.

I have attached a screenshot from Torque of the voltages on the high voltage battery. While charging, module 8 did charge faster. When not charging, it dropped down faster. So, I can believe that there is an issue there. My question is, would that cause all of the codes above? If so, I can work on replacing the battery. However, if it is something else major or multiple issues, I need to re-think whether the car is worth it with so many miles on it.

Also, as I was testing with Techstream, I noticed that it sounded like the car was missing a cylinder or something. Just wasn't running smoothly. Not sure if that is something new or has been happening for a while.

Thanks for any insight you all can give!

 

Thanks! It seemed weird to me that the different areas would how up at the same time so I was worried that maybe it was something more major - like the main computer or something.

I'll track down the info for troubleshooting it and see what I can fix. Hopefully I'll have a running car again soon with even better gas mileage!

 

Well, I have another code. I decided to try the Prolong system before getting a new module for the battery. After the charge/discharge cycle, I received the red triangle again. Looking at the voltages, it definitely looks like module 8 needs to be replaced. However, when I checked the codes, I received a code P0A9B. Here is the data from Techstream:



So, is this just because of module 8 being bad or could there be something more going on?

Thanks!

 

Thanks, @dolj! That is very helpful. I'm not sure why it was set since according to the documentation you gave, the values need to be outside of -49F - 203F and according to Techstream, they are: TB1: 134.1F, TB2: 163.2F, TB3: 127.2F. But, I will be replacing module 8 today or tomorrow and will perform the checks they mentioned. I have a dead Prius also, so I can replace the thermistors and harness if necessary.

 

Ok, I got the battery opened and have some more questions.

How do I tell the age of the battery (manufacturing date)? Here is a photo of the numbers from the top of the case:


The modules in the battery are numbers:
28XE9A00039A
28XE9A00044A - 28XE9A00054A
28XE9A00057A - 28XE9A00066A
28XE9A00113A - 28XE9A00117A
27XENA07753A

I am assuming that the 27XE module had been replaced at some point but the rest are probably original, correct?

Here are some shots of the bus bars and connections:


According to the guy I bought it from about 6 months ago, he had cleaned all of the bus bars, etc. Does that look like it is possible to get that much corrosion in 6 months (in Southern Indiana, running about 400 miles/week since we got it)? Could this corrosion be causing the codes I am seeing in the above posts - at least the HV battery ones?

Since we need a dependable car, I have decided to buy the new battery modules from NewPriusBatteries instead of playing whack-a-mole. Hopefully I'll get them soon and can get the car going again.

Also, doing the test on the hidden menu for the aux battery, the battery was at 12V no load and dropped to 11.6V with high beams on. I know that means it needs to be replaced. Could that be causing any of the issues in previous posts? Guess I'll find out once I replace the battery.

Thanks for all your help guys. I am learning a ton as I go, which will help as I am contemplating getting the other Prius I have running using the removed modules form this Prius that are good.

 

Hmm. Actually I found a thread with the info necessary to tell the dates on the cells. It looks like they are all from the same pack, manufactured on 10/27/2003 or 10/28/2003. The case has a date of 11/7/2003, so it appears that it is all original. However, two questions come from that -
1) why is a battery from 2003 in a 2006 Prius? and
2) The info says that the first digit on the case sticker gives the model the battery was made for with "F" being Prius. Mine has "H". What model is that for?

 

Yep, I guess that makes sense. I must have been too tired when I made that statement.

 

Ahh. Rationality. If only there was more of that in this world!

Thank you for explaining that. Also, since module 8 is the failing one, maybe the hot temperature is coming from there. I'll find out when I get the battery pack apart.

 

@dolj and @ChapmanF, thank you both. I am in the process of ripping the battery apart to install new cells. While it is apart, I will check the sensors and wiring. Once together, I'll do the test you recommend and put the car in On and check the values before making it Ready.

 

@ericbecky Really? This much corrosion? Wow. I wouldn't have believed that was possible in 6 months.

I am currently looking at getting bus bars and nuts for rebuilding the battery on my other Prius. Is it better to get nickel-plated ones? I have found some on ebay, but not sure if they are good quality or not.

Thanks!