1. Attachments are working again! Check out this thread for more details and to report any other bugs.

After HV battery repair, car won't start

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by popptj2001, Sep 11, 2013.

  1. popptj2001

    popptj2001 Member

    Joined:
    Jul 29, 2011
    79
    50
    0
    Location:
    Texas
    Vehicle:
    2007 Prius
    Model:
    III
    After replacing one of the HV batteries defective out of the 28 in my Gen 2, I reinstalled a working battery and the car won't start. With the car turned on, I went ahead and measured current on the HV battery side and get 220, and on the car side terminals there is no power. The service switch is working correctly and engaged. For some reason the voltage is not being relayed to the car side. Any suggestions? Tks.
     
    Nir likes this.
  2. koolingit

    koolingit Member

    Joined:
    Mar 17, 2009
    158
    51
    0
    Location:
    Mocksville NC, USA
    Vehicle:
    2009 Prius
    Remember when you took the orange safety plug out? You had to put your finger through the ring and lift before you could swing the plug down. So --- when you're putting the plug back in, you have to press the ring down after swinging it up. Every body forgets to press down after swinging up!
     
    douglasjre likes this.
  3. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

    Joined:
    Jul 29, 2011
    3,159
    989
    0
    Location:
    Tucson, AZ
    Vehicle:
    2005 Prius
    Model:
    Four
    Here's a guide, see step 9. on pg 21-118.
     

    Attached Files:

    koolingit likes this.
  4. popptj2001

    popptj2001 Member

    Joined:
    Jul 29, 2011
    79
    50
    0
    Location:
    Texas
    Vehicle:
    2007 Prius
    Model:
    III
    Tks everybody, but did did install the service key correctly. For some reason after letting the car sit for an hour did the trick. I went back out and started. Maybe the replacement battery module I installed which was 7.4 volts has to adjust to the other 8.0 volt modules? Any thoughts?
     
  5. Graham Fitton

    Graham Fitton New Member

    Joined:
    Sep 9, 2013
    5
    3
    0
    Vehicle:
    2000 Prius
    Model:
    I
    It might be your 12v battery was a bit low.
    Besides running the electronics,it is required to make a 10.8v relay to connect the HV battery when you turn the car on.
     
    Nir likes this.
  6. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

    Joined:
    Jul 29, 2011
    3,159
    989
    0
    Location:
    Tucson, AZ
    Vehicle:
    2005 Prius
    Model:
    Four
    Pride is a terrible thing. :)
     
    cthorsman, Beachbummm and koolingit like this.
  7. Beachbummm

    Beachbummm Senior Member

    Joined:
    Sep 12, 2013
    1,160
    392
    0
    Location:
    Florida
    Vehicle:
    2008 Prius
    Model:
    Five
    OK OK Im also a dumbass, I forgot to put the ring down again..after taking the cover off 3 times and checking the 12 volt batt twice and 15 mins of chewing on the steering wheel before I desided to look here for help...as stated above, pride is a terrible thing...a $45 cell and 4 hours later my car is alive again, now to get the ac fixed..
     
    Nir and usnavystgc like this.
  8. popptj2001

    popptj2001 Member

    Joined:
    Jul 29, 2011
    79
    50
    0
    Location:
    Texas
    Vehicle:
    2007 Prius
    Model:
    III
    I completely replaced my hybrid battery two weeks ago and wanted to follow up here. The car would not start after installing an almost new hybrid assembly. I waited 10 minutes, then the relay kicked in and the car started. For some reason there is a delay. My 12 volt battery is also new. I should mention I have 332,000 miles. Should be good for another 300,000??? haha
     
    usnavystgc likes this.
  9. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    110,166
    50,060
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    hope so, all the best!(y)
     
  10. cthorsman

    cthorsman Member

    Joined:
    Aug 28, 2009
    74
    27
    0
    Location:
    Maryland
    Vehicle:
    2004 Prius
    Model:
    N/A
    I am one of the many who forgot to push the orange safety plug handle down.
    Hopefully this bump will help others find this quickly.

    Cross my fingers, hope all is well tonight when I push it down firmly.
     
    bisco likes this.
  11. Gary S

    Gary S New Member

    Joined:
    May 3, 2019
    3
    3
    0
    Location:
    Cheshire, CT
    Vehicle:
    2008 Prius
    Model:
    N/A
    I just jointed the fools club not pushing down the safety plug down and struggled mightily until I saw this tip. Great help!!!
     
    Nir and bisco like this.
  12. Nir

    Nir Junior Member

    Joined:
    Jun 8, 2014
    8
    0
    0
    Location:
    israel
    Vehicle:
    2010 Prius
    Model:
    N/A
    So i did tried to fix my prius gen 2, found one bad cell and i shuffled all modules, i was able to get the car running for few min , but then it went back to die again, i assume that all cell are not fully balanced yet, what should i do?

    i tried to measure the pack voltage and it was 0 ( also when i pulled the battery out) is there another relay?
     
  13. Nir

    Nir Junior Member

    Joined:
    Jun 8, 2014
    8
    0
    0
    Location:
    israel
    Vehicle:
    2010 Prius
    Model:
    N/A
    So assuming the plug is connected properly , what could be the other reasons for stat issues? why the computer cannot read any problem?
     
  14. Gambitsource

    Gambitsource New Member

    Joined:
    Nov 9, 2019
    22
    2
    0
    Location:
    San Diego
    Vehicle:
    2007 Prius
    Model:
    LE
    I was wondering if you had to drain and recharge the modules to get the car to work?
     
  15. Gambitsource

    Gambitsource New Member

    Joined:
    Nov 9, 2019
    22
    2
    0
    Location:
    San Diego
    Vehicle:
    2007 Prius
    Model:
    LE
    Question on the Aux battery. If I test the battery with a multometer when unplugged from the car and see a 12.4 Volt vs when the car is on and it is 11.9 or sometimes 11.4 would that be a bad battery?
     
  16. mullerkp

    mullerkp Junior Member

    Joined:
    Nov 18, 2008
    2
    1
    0
    Vehicle:
    2005 Prius
    This was so helpful. For 15 minutes, when the car did not want to start and only lit up warning lights on the dashboard, I was completely frustrated, bigly! I took this plug out close to 10 times and put it back in, but "push down, after swinging up", that had never come to my mind. So easy. Now it woks. Thanks so much !!!

     
    bisco likes this.
  17. dolj

    dolj Senior Member

    Joined:
    May 14, 2012
    7,855
    3,968
    0
    Location:
    Wellington, New Zealand
    Vehicle:
    2007 Prius
    Model:
    N/A
    Another thing to remember, if you happen to have also removed the 12 V power by disconnecting the 12 V battery, for the first start attempt you also need to press the power button with your foot pressing on the brake pedal twice. The first time it illuminates all the warning lights on the dash (as a functionality test) and the second time, if you have no errors, all the lights go off and it makes the car READY.
     
  18. cscharff

    cscharff Junior Member

    Joined:
    Jul 4, 2011
    2
    0
    0
    Location:
    Northfield, NJ
    Vehicle:
    2009 Prius
    Model:
    Two
    Hey guys My name is Clem and I have just done the same thing. And I replaced the 12V at the same time. I was sweating having to tow it to the dealer.
     
  19. dolj

    dolj Senior Member

    Joined:
    May 14, 2012
    7,855
    3,968
    0
    Location:
    Wellington, New Zealand
    Vehicle:
    2007 Prius
    Model:
    N/A
    Presumably, you mean you failed to compete inserting the safety interlock correctly. The question is, why are you removing it in the first place? It is totally unnecessary when you are just replacing the 12 V battery.
     
  20. vovila

    vovila New Member

    Joined:
    Dec 17, 2020
    2
    0
    0
    Location:
    Scotts Valley, CA, USA
    Vehicle:
    2008 Prius
    Model:
    Two

    Just wondering if you changed the hybrid battery first time after 332,000 miles? I purchased hybrid prius recently and was curious how long can hybrid battery last. Thanks.