Removing No.2 Frame Wire: situation not matching service manual

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by klikkolee, Feb 1, 2025 at 5:47 PM.

  1. klikkolee

    klikkolee New Member

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    My 2007 Prius has been throwing code P0AFA. The technician at the dealer suspects corrosion of a connector to the Battery ECU, and as best as I can tell, the relevant connector would be the one between it and the No.2 Frame Wire. Today, I removed the battery from my vehicle and opened it, intending to remove the ECU and No.2 Frame Wire so that I can attempt to clean the contacts.

    I found a digital copy of a service manual, ostensibly applicable to Gen 2 Priuses in general. I can't find a page in it directly stating which year it's applicable to, but it has been exactly accurate up until this point. During the prerequisite step "REMOVE MAIN BATTERY CABLE" on page HB-103, the manual calls for me to remove the terminal nut which connects the No.3 System Main Relay to the battery cable. However, this terminal currently measures approximately 100V to the case. Similarly, the terminal nut which connects the No.2 Main Battery Cable to the No.2 System Main Relay measures about 30V to the case (I didn't note down the signs). It would not be safe for me to remove those nuts if accidental contact between the case and the tool is a 100V short. I don't see anywhere on either frame wire that is obviously connected to the case, so this might just be a floating voltage, but I can't figure out how to check this.

    The step also calls for me to remove a "shield wire", but I can't identify any other wire on or near the Main Battery Cable. The associated drawing is not clear. Is it something to do with the Battery Current Sensor?

    The battery in question is a refurbished battery from Green Bean. I'm wondering if they did something different from the manual when assembling.

    I would appreciate any advice on this discrepancy and how to continue
     
  2. klikkolee

    klikkolee New Member

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    Here are some photos for reference. Most of the nuts holding the frame wires on are heavily corroded, so I won't be surprised if I can't clean them and need to replace them.

    IMG_20250201_150635702.jpg IMG_20250201_150721439.jpg

    I would also appreciate guidance on removing the Wire Harness Protector Covers. The manual does not give any instructions, and while peeling them upwards did most of them off, I broke small pieces off of both frame wires.
     
  3. mr_guy_mann

    mr_guy_mann Senior Member

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    Are you sure that your multimeter is working correctly? If there's voltage reading from anywhere on the High Voltage system to case (chassis) ground that should set a P0AA6 isolation fault in Hybrid Vehicle control ecu.

    If you want to be sure that the battery is isolated, then remove the heavy gauge cables from the module studs. Then remove the ecu. You're interested in the orange connector.
    ecu%20connector.jpeg

    Posted via the PriusChat mobile app.
     
  4. ChapmanF

    ChapmanF Senior Member

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    If there are leaky modules in the stack, you can measure voltages to the case. Proceed as if there were a P0AA6 code: glove up, use insulated or electrical-tape-wrapped tools, and be extra careful until the connections are off.
     
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