Hybrid battery failure (again)

There should also be a fuse in the orange service plug. So maybe see if the fuse is still good. Fuse is not in Gen4 service plugs.

 

Notice the final push to lock the service plug into place and get the wires connected properly.

 

You should find out if the car can read all the module voltages using ODB2 reader and app and see if they are in normal range. If all normal range then maybe clear the code to see if it shows up again.

 

Recently purchased (and tested) from ebay an OBD2 blue tooth adapter that shipped from china for a single USD.

What kind of adapter are you currently working with now?

 

This is all part of their plan. China supplies these items at below cost because they are packed full of malware and spyware. This spyware loads itself into your car ecu. Once the hammer comes down and the big war starts, every car with that programming immediately starts and drives itself full speed into the nearest telephone/communication pole, effectively destroying all of America's power and communication distribution systems within minutes.

 

If you already manually tested all battery modules and all are in normal range, then it's not likely the batteries. It could be bus bar panel as mentioned. If the car drives I wouldn't drive it for too long. Because we don't know how the Prius BMS will charge or not charge the HV pack. You don't want it to over charge the pack, which I don't think it will do. It may not even attempt to charge the pack at all and go in pure gas. Consider taking the bus bar panels to a hybrid shop that can test it and maybe get you a replacement. It could also be something else.

 

This should help on finding the blocks in question......

Once you have verified the batteries (strip it all down bare and check each manually with a volt meter while wiggling the terminals at the same time) and the blocks in question are good, considering you had significant corrosion I would get new bus bars and wiring for your battery to save yourself time on the fix. Don't mess with the old ones, not worth the time and effort because they are relatively cheap to buy.

82165-47040 WIRE, FRAME https://tinyurl.com/yahv3kvr
82670-47070 BLOCK ASSEMBLY, JUNCTION

Make sure whatever you get is either brand new (preferred) or guaranteed off a working Prius which should eliminate any issues.

Let us know how you make out.

 

I think you're right, they flip-flopped them between Gen 1 and Gen 2 versions (changed comment above to reflect this). It doesn't change any of what I said above anyway though because when you have it all torn down any problems will become quite obvious. I still suspect you have a broken voltage sensing harness. You could also run a load test on each of the modules while wiggling terminals but I have a feeling the dramatic differences in voltage seen over the OBD is because the sensing wires are toast.

 

That sounds extremely suspicious to me.......

The good news is you got it running again, the bad news is it may come back if you don't get to the root of the issue. The Hybrid ECUs on these cars are very robust so something is damaging them over time because it's not normal to replacing them like that. I would also at least replace the battery sensing harness because if your ECUs are going bad (likely from corrosion) then I suspect the harness is on it's way too (could damage modules if the harness is sensing voltages improperly). Sounds like you may have had water getting into the trunk but I would spray the outside down with a hose and have someone inside look for leaks if the water is excessive.