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The battery fires at ECU sense connector thread

Discussion in 'Generation 1 Prius Discussion' started by ChapmanF, Mar 19, 2015.

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  1. OBJUAN

    OBJUAN Member

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    The sense wires at the battery will be corroded as well. I made a new harness with the Aliexpress connector, 22AWG silicone wires and brass crimp rings. Had to salvage the larger square flat terminals to use on the main Neg and Positive cables, save the others as spare. I used water proof heat shrink to seal the sense wire ends at the battery. Good Luck
     
    #161 OBJUAN, Oct 16, 2022
  2. Travis Sanders

    Travis Sanders Junior Member

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    So I did solder the wires on my gen 2 directly to the board today. I wasn't nearly as easy as using a heat gun would have been to replace the connector. It took quite a long time so all time included maybe it would be around break Even to simply buy the overpriced connector from eBay. But then you would still have the high voltage right next to each other problem in the connector which would eventually cause the same problem especially in wet areas or places of high humidity like the tropics where I am. So maybe soldering the wire is on like I have will be a permanent solution.
     

    Attached Files:

    #162 Travis Sanders, Oct 18, 2022
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  3. ChapmanF

    ChapmanF Senior Member

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    The 290 would be a worst-case figure between two pins that are farthest apart electrically, but it looks like some thought went into how those pins are physically arranged in the connector. I looked at that some back in post #2:

    My lazy look there did, of course, come with an important asterisk:

    That's still a thing somebody less lazy than I am could do.
     
    #163 ChapmanF, Dec 3, 2022
  4. dabard051

    dabard051 Tinkerer-in-Charge

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    Going through all the pictures of corroded/damaged ECU connector pins, it's always the two on the left that suffer the most damage.
    Does someone have a guess as to why that is?
    Do those pins have the highest average voltage w/r/t ground, even tho they carry no current (i.e., sense only)?
    If I remember correctly from earlier in the thread, the green stuff that grows is malachite, which has interesting conductivity v temperature characteristics.
    reference:
    Malachite (Cu2(CO3)(OH)2) | CH6Cu2O5 - PubChem
    Malachite Morphology — Part I | Rock & Gem Magazine
    https://en.wikipedia.org/wiki/Malachite
    I can't find an authoritative source for electrical and/or mechanical characteristics of malachite, so l ask for help from any chemists...
     
    #164 dabard051, Dec 3, 2022
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  5. ChapmanF

    ChapmanF Senior Member

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    The pinouts and most of the guesses are back on page 2 of this thread

    The battery fires at ECU sense connector thread | Page 2 | PriusChat

    including the link supplied by hobbit.
     
    #165 ChapmanF, Dec 3, 2022
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  6. OBJUAN

    OBJUAN Member

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    the battery negative posts all leak, a bit of condensation will make it travel.
     
    #166 OBJUAN, Dec 9, 2022
    Travis Sanders likes this.
  7. Freeport

    Freeport Junior Member

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    Possible to use dielectric grease on the connectors to alleviate corrosion?
     
    #167 Freeport, Feb 20, 2023
  8. Travis Sanders

    Travis Sanders Junior Member

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    Yes I tried it a few years ago and haven't had any issues on one of my cars. But it will collect dust and I thought that could be problematic
     
    #168 Travis Sanders, Feb 21, 2023
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