i have one of these i got for free. had green crusties in same connecter. i just soldered it together since i knew it was my car and my repair. Never seen that homemade charger thing though (I don't really trust it). These are some of the coolest cars ever in terms of how modern the technology was and how the transmission is actually fun to drive (basically an electronic manual transmission that drives like a CVT)-- but is bulletproof. I get around town faster than most people with my foot smashed to the floor and get 30mpg. Handles not bad on twisties until you run out of battery voltage haha and you only have the engine trying to charge it. Really great cars for a beater around town car-- also use it to pull a 5x8 utility trailer for light duty stuff, bike rack, have pulled out tree stumps with it etc etc.
Here's a good tip for you as a technician myself - always twist the wires before crimping, that way they wont come undone or better yet pre-solder them so when crimping / the connection wont come undone.
I’ve rode in a Prius but never worked on one and had no idea how they function. Very interesting. Thanks Ivan. I remember the one on the brake system, that was an eye opener!
They're pretty interesting cars, I wouldn't mind picking one up, mainly because they have a community of tinkerer's behind them and I love fooling around with batteries and stuff. Guess you can mod them to run off the hybrid pack for longer, add plug in charging, and so on. They require a charged and happy HV battery to start the engine (same with many other hybrids, but not all) because the starter is the main electric propulsion motor or assist motor (like Honda).
@@volvo09 That's what I did a few weeks ago. Have been curious about them for a while and I like working on new things to gain experience... so I bought a cheap 2008 with an intentionally dead battery with relatively low miles for one of these (175k), scanned the battery and codes before I bought it and measured voltages, swapped out the dead cells in my garage the night I towed it home, and I"ve put nearly 2500 miles on it in the past 2 weeks
I helped a friend replace that hybrid battery several years ago. The new one was a Dorman. Followed instructions went good no problem. He’s still driving it no problem.
as soon as I saw the green crusties in part 1 my thought was "uh oh, where else did the water go?" As an electronics tech my first reaction would be to check where it came from and then check every single connector in the trunk area
Coolant clog codes can set when the system is low on fluid and doesn't detect flow, see that code on cars and trucks with separate cooling system for the turbos
Seems like the methodical approach paid out. Impressive how those shorts didn't burn the wiring and even the battery cells involved. Wonder what Part 2 will bring :-)
That's true but he's an 80 years old retired guy who flips Prius' for a hobby. I'm sure a lot of his parts cannon is in inventory. But very true for almost anyone get it diagnosed by someone like Ivan save a lot of money
In the first video I noticed what I thought looked like mold on the dash. Had this vehicle been in a flood situation? Or an interior water leak that caused a high humidity issue for the interior and promote the growth of mold and green corrosion?
I noticed that earlier... Telltale signs of a very humid interior. I wonder if the hatch leaks? I didn't see signs of water intrusion, but maybe it was cleaned up fast if it got mildly swamped.
You have too love working on a Vehicle that someone else has been messing wigh first...You never know what or wasnt done too it. UGH..You keep knocking it out of the park with this newer JUNK....My Hats off too you...Great job so far and Video
The scanner sees 2 cells at a time on the ecu. You can have one battery bad and it look good. Charge the battery up as much as possible. Test the battery by turning on the air conditioning on you will see with live data which one is bad.
Lets talk about the "green crusties". I am retired after 45 years in electronics and systems. There were several cases of contact and connector corrosion that we called "Green Gold" because the corrosion would even happen in a mil spec 30 micron gold pin and socket. And that was in a laboratory environment! It is expected that you find wiring corrosion in the harsh automotive environment. Green gold corrosion is a chemical process that requires several things e.g. dissimilar metals,H2O, salt, atmospheric gases and electrical current not to mention all the corrosive vapors that are present in an automobile. I have seen PCB edge connectors go open from microscopic crystal growth pushing the contact surfaces apart. Cars are built with the cheapest methods they can find. It is my belief that a critical corrosion control component is the use of anti oxidant grease. Its use is now required by the NEC for service panel main lines. So Ivan you should apply anti oxidant compound to every connector you make a repair to. That will reduce call backs. I fell victim to it in a Cobalt I had that went into cripple mode during a 2 foot blizzard. It turned out to be corrosion in the MAF sensor. I now put OX-Guard in every connector I can get at in my cars. So far so good! Keep up the great work, your videos keep my brain lubricated!
Great work ivan.i am glad you remembered to click down hv disconnecter plug.great repair.could you guide me to the plugin supplier?i will really appreciate that.cheers
Great video. Super interesting. I've got 4 prius for my courier business. 2 have over 400,000 miles with no problems. Hard to find people who can work on them.
Good going, Ivan! I was surprised how low the battery voltage system is on the Prius. Believe it or not, 600V and below is considered "Low Voltage" in industrial power systems. Even at that, nowadays a whole bunch of safety gear is required - so much as to nearly make it impossible to work. The controls in industry are headed from 110VAC toward 24VDC in order to (supposedly) make it safer, with the power sections being isolated, interlocked, and requiring all the safety gear if you hafta go in there. I suppose auto repair is lagging behind in regard to all the safety requirements. They do seem a bit over the top, if you're trying to get something done. Fire-resistant clothing, face shields (or even flash suits), voltage-rated gloves that have to be certified periodically, etc.
I am guessing the parts canon to fix the original issue of the crusty connector is what may have caused that orange battery sensing connector to get nuked? Testing doesn't cost it pays. Well done Ivan.
great video i have a friend that has one of these vehicles so far no problems over 100,000 miles on it
2 года назад
i have 255 on mine
2 года назад
Look forward to the update since I have this same car. Great job Ivan and thanks for sharing, the comment section on your videos is always fun as well (glad I finally know enough about a car since this is my daily to comment).
I wondered if you checked oil on the engine? As it never been driven, lol. Nice fix. I hate working on high voltages stuff. Dangerous in my opinion! Great job Ivan!!
Yeah, it's a mess. One thing here is that there are some physically questionable features. One is the wiring to the cooling fan. I would have pulled that apart right away. The other is the shorted terminal pins. If it looks wrong, fix it. I think Ivan gets too caught up in the diagrams. A messed up mess is something to fix. To hell w/ the diagrams.
DC is particularly nasty. Once it bites, it doesn't let go (meaning the pulsing of AC has a reasonable chance of causing you to be thrown off by muscle spasms)
Don't think I'll ever own an electric vehicle, hybrid or not, but, watching you t/s this is interesting. Your scan tool showed a problem on cells 2-5 and pointed you in the right direction. Green crusty connections are going to be the downfall of these EV's. GREAT VIDEO(S)!!!
What you've repaired there, I only got to see in training classes. Under the metal battery cover there are small metal jumpers from bat cell to cell. Corrosion can build up under and around the jumpers. The one Prius battery we got to take apart had some corrosion but like the instructor said this will happen, but it takes a long time and as we saw it didn't affect the battery pack output. We didn't get to do battery ECU and wiring diagnostics in that training or take individual cells out to clean the terminals and inspect them. BTW, we were told to wear soft cotton gloves over our hands, then the 1000 volt insulated protective gloves that would partially come up the forearm, then leather gloves over the rubber high voltage gloves to protect the HV gloves from rips and tares, however, the leather gloves would not cover the HV gloves all the way up to the end of the HV glove. That was so that incase the 201+ DC voltage went on the leather glove, it would run up to the exposed HV insulated glove and stop there. So long sleeve shirts were rolled up to expose the end of the HV glove. Sounds complicated but better than being hit by 201+ DC voltage! Looking forward to part three. Your doing great Ivan!
@@PineHollowAutoDiagnostics OK, ya got me on that one! LOL! During the training, we also removed, tore down, reassembled and reinstalled the inverter assembly at the front of the car. The 8 hour training of the 2 Prius vehicles there were 4 teams that did the removal of both vehicle's battery packs, tear down, component ID, tech tips by the instructor, reassembly and reinstallation of the inverters and battery packs, then engine start up with vehicle movement forward and reverse. Then the teams switched positions on the same vehicle from battery pack to inverter or inverter to battery pack and went through the same tear down and etc procedure with engine start up/vehicle movement. Great familiarity, but no hands on "testing!" I wish we had a second day to do that. Still it was one of the best training days I ever had! Hands on, not classroom works every time! Classroom's great for laptop training to use for Prius Diagnostics. Sorry for the long answer/rant.
Ivan I've never had a first gen Prius Battery apart but have done plenty of Camry's & am led to believe they're all the same 'blades'. I'm sure the Camry has either 17 or 18 'cells' so 34 or 36 blades & in my experience 'nominal' voltage is around 8.3-8.4 bolts for each blade so that's getting up around 300v DC (for a camry at least anyway). Be careful mate! I have attempted to make a few videos replacing bad 'cells' in them but never actually uploaded any.
I thought it was out-of-character for you to say, "I don't know if I can fix this." Then, I thought about why you would say that. I remembered those cars have high voltage components and then I saw you don your PPE. I know you are very astute about how you do things; those gloves can get pin holes in them allowing current to travel to your body. (Don't ask me how I know that.) Your body has about 50,000 ohms of resistance. I would hate for that control module between your ears get fried! Great video!
@@PineHollowAutoDiagnostics Yes Volt problems. But I sold Pruis in 2010 because of all the issues it had at just 50,000 miles. At least my Volt got to 120,000 before having issues!! And yes the all Great until they don't run!
One cause for rough engine is when you change engine mounts when you change engine. It'll take a little while before they are broken in so the engine might feel rougher than it is. But in this case it's hard to tell. I would definitely check the engine a bit to see that it's in good order just to be sure that it don't go bad soon.
@@PineHollowAutoDiagnostics Proven fact though, if you put a NOS kit in it after about 2 seconds it will be smooth as glass. Funny how wrist pins never fail🤣
There is something to be said about engine mounts though. I know on my car you have to torque the mount bolts in a specific order or you will set a permanent twist torque on the mounts and it will transfer every single cylinder event straight to your feels.
2 года назад
@@PineHollowAutoDiagnostics injectors clog on these pretty commonly or just bad old gas. give it the italian tune up
Hi Ivan, I've been in a Prius several times as a friend owns one. When the engine runs it runs very smooth. Great you found those pins shorted on the battery ECU and have it operating again with the replacement ECU. Looking forward to the crazy test drive video. My 2010 Fusion SE 3.0L is intermittently displaying a Tire Pressure Sensor Failure. Tire pressure checked and OK on all four. Can you suggest an inexpensive TPMS scanner so I can determine which tire has the faulty sensor? I can then go get the sensor changed. You and your family stay safe.
Odds are the failure is due to a weak battery. It's only been 12 years. (Assuming they're original.) It wouldn't be a bad idea to just replace them all.
@@russellhltn1396 They are the originals and have already been thinking about changing them all. Planning on keeping the car for several more years since it runs so good.
Great video. Sorry to criticise but; You should have used smaller crimps (they do come in different sizes). Also, there are far better crimping pliers available which would make it less likely that the crimp fails.
@@hikerJohn ratcheting crimping pliers. They crimp over a larger area and a lot higher pressure. Something like www.amazon.co.uk/Draper-35574-Ratchet-Action-Terminal-Crimping/dp/B0001K9TGA/ref=asc_df_B0001K9TGA/?tag=googshopuk-21&linkCode=df0&hvadid=226606326869&hvpos=&hvnetw=g&hvrand=11950477273968999200&hvpone=&hvptwo=&hvqmt=&hvdev=m&hvdvcmdl=&hvlocint=&hvlocphy=1007265&hvtargid=pla-450712511964&psc=1&th=1&psc=1
@@markperry4076 RUclips gave me your reply but it does not show in the comments. I put these in my Amazon "save for later" cart till I check prices at the Home Depot
I have a Lexus hybrid (2010), so I found this particularly interesting... Especially the homemade hybrid battery charger. As usual, you tracked down the issues with good logical diagnostics! We expect nothing less... Curious though, the green crusties ... two different connectors, and fairly advanced state, I wonder if this was a flood car ... Any thoughts?
Perhaps leaks in the body letting rain water in. Another might be condensation from the winter months. All the snow tracked in, heater melts it, but insufficient outside air to vent the moist air out of the car. So it condenses in the colder parts of the car (like the headliner). No leaks, but the area gets soaked. I think it's more likely in economy cars which would have anemic heaters, so the owners never turn on outside air.
2 года назад
these are known to get water in the trunk area from leaking seals. they can literally fill up with water. not uncommon even on a california car to find green crusties in that fan connector (happened on mine) i would bet 75% of cars have green crusties on that connecter of these gen priuses but that haven't actually cause a full blown loss of power
The charger voltage has to be higher than the hybrid battery voltage in order to charge the battery. Great job on the diagnostics. Toyota’s hybrid system is excellent.
And the mechanical robustness is phenomenal. The CVT basically works as a differential. No clutches, brakes and syncromesh rings. everything is engaged all the time and it's just the magic of the two electric motors changing speeds and direction that result in an infinite variable ratio.
Yeah I spotted that too. The voltage was going up but the SoC was going down. Very strange.
2 года назад
@@Firecul it needs to be in drive with your foot on the brake and pushing on the gas to be charging to hybrid battery any (or any substantial amount). That is one way to launch these priuses is to sit at the light one foot on brake smash the gas to the floor and let it charge up the battery then when light turns green just let off the brake and she launches. No launch control needed either :) but seriously ill get some people on the jump in much much faster cars and watch them get pissed when they get beat off the line by a prius and zoom past me.
@ I'll accept you know more about the Prius but why would the voltage be going up while the charge is going down?
2 года назад+1
@@Firecul not sure honestly, but just saying the SOC on these is a metric that most prius guys know is basically useless for diagnosing a good battery etc. Whether that means the number should just be thrown out or not I dk. but you would very quickly know if there is a real problem with the hybrid battery after driving it for a bit.
Nice job getting the battery pack back online. I would have done the exact same thing with the broken wire at the fan connector. The part that has me concerned now was that coolant system code. If I am not mistaken, I think the high voltage motor controller is liquid cooled on those things? I think I would at least take a quick peek at all the fluid levels before taking it out on the road test. Anyway, I hope the customer will approve of you doing all the drivability repairs. I'd hate to see it leave half done.
2 года назад+1
theres a storage tank which holds warm water when you shut off the engine so on start up there is less energy / time needed to get the engine up to warm temp. it is a fairly complicated system but essentially when the valve fails it doesn't cause a driveability issue but usually causes a takes your engine longer to warm up and is bad long term. you are right there are two separate systems one for the inverter and one for the cars gas engine. checking fluid levels is good idea, but these coolant valves do go bad very often, set a ce code, but don't affect driveability and you can wait awhile before changing it. I have video on my channel about how to change the valve quickly
@ I was thinking that since the engine had been replaced and was never actually driven since, it might be a smart idea to just go over the basics before a actual test drive. We don't know how competent the last mechanic that worked on it was with the reassembly.
2 года назад
@@Sandmansa yeah i mean ivan and others on youtube don't always document every single thing they do-- and like most mechanics he knows to check fluid levels and monitor temps (that is honestly just too basic for him to repeat on his channel all the time). So yeah it is a good idea, I would just say he 100% did that
2 года назад
plus this guy had owned a ton of these-- one would assume that he at least knows how to add oil to it and check fluid levels
While trying to check voltages at the hybrid battery ecu, did you have the big hybrid battery disconnected? Wondering because that wire with the pins stuck in it has orange insulation
Hi, the charger is part of maxx setup for recondition hybrid batteries, they have a discharger too, the say to start them before plugin! What scan tool are you using? I have the same problem.
What is that white plug you repaired do actually? Mine corroded and I replaced it with new plugs but my car still has the P3102 code. I put a brand new 12 volt battery as well
You put in some long hours Ivan :o) Why is the battery state of charge falling while the engine is running? After watching more I see it started climbing again.
@@PineHollowAutoDiagnostics I'm telling you, Ivan, we should strongly consider switching to these cars. Look at the prestige we could garner. Many famous people drive these. (I think Brian the dog on Family Guy drives one! All the Bluehairs at my church drive them. The taillights on the later models look like a miniature 1960 Oldsmobile 98.) We would be in good company. I could plan a vacation to Pennsylvania Furnace every year so you could do a 7 part video and fight all the melted connectors. The possibilities would be endless!
@@PineHollowAutoDiagnostics I agree. Got tired of shifting in the suburbs and I hate being behind other pui.but…… my 14 Prius is selling used what I paid for it new. My 20 Prius prime is selling used for $ 9000 more than what I paid new, thanks to the NYS taxpayers!
Good morning Ivan! I know I haven’t commented lately. I have still watched every one of your videos at least twice if not three times! You’re one of the best RUclipsrs out there and I can’t wait for your next video to be released! :-) Great job Ivan!
Ahhhh Captain Ivan “Ahab” yet again finds his beached whale Moby Prius and conquers the diagnosis…..but alas the whale wants to remain beached. Tune in next time when Captain Ivan faces down his most stubborn whale yet again. Godspeed Capt. Ivan. Godspeed.
Batteries that have been deeply discharged can flip polarity. This can be reversed but their capacity is severely reduced as they now permanently damaged. Something to consider…not that it’s relevant here but when you have bad imbalance between cells…
nice work, please use eye protection at least when working on high energy devices. It's hard to work on stuff blind. take a look a set of T&B WT111 crimpers or Klien-1005 there is just nothing better. Rich
While watching (not at the end yet) I did think it was strange that ALL battery voltage readouts are jumping around whereas there is no load on the battery - surely I'm not the only one that thought that was weird from party 1 as well ?
Dunno boss, maybe should of put some very large warnings on this video. I can imagine some unqualified yahoo's digging into the battery unit and getting seriously zapped.
Hello, I keep on getting error code POA1F... the voltage readings of battery modeles are allover the place.. the ecu is fine as replace with new one as the old one got corroded and was fried... now this error keep on coming... i dont know how to dress it.. should i change voltage sensing wires may be everything might become ok
Top work, love your forensic approach, you should follow in your father's footsteps and work for NASA or something, but then again modern cars seem to offer enough of a challenge with their crazy complexity!
they're well known to leak water into the hatch area, which runs down the battery "fan" wires, it will also fill full the "well" the auxilary(12v) battery sits in, possibly fills the other side and more when that overflows. if the vehicle sits not driven the inside will become a humid jungle, also it can freeze solid in winter, breaking the battery and itself, among other issues.
Well done ivan, it's close to being a car again :-D That engine sounds like an ill food mixer, oh dear lol. If nothing else, it will make some cakes :)
Ivan, you take anything on as a challenge. I have said it before and repeat it hear, I doubt seriously if you are being reimbursed for ALL the time you put into these unicorns which makes you suspect as a business person. However, you are gathering a knowledge base on so many different pieces of equipment that you may just find yourself in great demand and able to charge accordingly. Question is, will you charge a premium amount to work on things others will not even look at? You should. I admire your innate curiosity in regard to figuring out how things work and then using a very logical method to solve problems. I don't know another RUclips mechanical technician/diagnostician that takes on things you take on. Take for instance, Eric O. just did a What's up Wednesday and one of the questions was about will he eventually work on EV. Basically his answer was no, he'll be dead or retired by time they overwhelm the market. A similar question was in regard to European cars. His answer; I don't work on them. Why does he take a position like this? Because he is a businessman first and foremost. His job, as he sees it, is to maximize profit and efficiency while still doing a good job on the things he chooses to work on. You on the other hand seem to take on all comers. Totally different model. I hope your approach works for you financially because it sure is entertaining and educational. You are one of one in your field, Ivan.
You know this vehicle isn't a virgin - its had a hard life. If it needed a new engine then either it suffered from the coolant diverter valve sticking and being overheated or someone seriously abused it. The 1NZ engine is an absolute work horse. I've heard of people put 400,000 miles on them with regular maintenance. Needing a new engine after 200K seems premature to me. I've seen plenty of these as taxis with 250-350K on. The green crusties in the back? I know one thing Toyotas of this vintage suffer from is waterleaks in the boot. Typically cracks form in the paint/seam sealer between panels in the rear and you get a swimming pool in the boot. If it was damp long term condensation could have caused the green crusties in the connector.
![62kWh isolation problem [part 1]](http://i.ytimg.com/vi/Ug9YdxXqkJ4/mqdefault.jpg)
i have one of these i got for free. had green crusties in same connecter. i just soldered it together since i knew it was my car and my repair. Never seen that homemade charger thing though (I don't really trust it). These are some of the coolest cars ever in terms of how modern the technology was and how the transmission is actually fun to drive (basically an electronic manual transmission that drives like a CVT)-- but is bulletproof. I get around town faster than most people with my foot smashed to the floor and get 30mpg. Handles not bad on twisties until you run out of battery voltage haha and you only have the engine trying to charge it. Really great cars for a beater around town car-- also use it to pull a 5x8 utility trailer for light duty stuff, bike rack, have pulled out tree stumps with it etc etc.
Looks like the owner still needs to do a fair amount of work. Great diagnosis.
Here's a good tip for you as a technician myself - always twist the wires before crimping, that way they wont come undone or better yet pre-solder them so when crimping / the connection wont come undone.
I’ve rode in a Prius but never worked on one and had no idea how they function. Very interesting. Thanks Ivan. I remember the one on the brake system, that was an eye opener!
They're pretty interesting cars, I wouldn't mind picking one up, mainly because they have a community of tinkerer's behind them and I love fooling around with batteries and stuff. Guess you can mod them to run off the hybrid pack for longer, add plug in charging, and so on.
They require a charged and happy HV battery to start the engine (same with many other hybrids, but not all) because the starter is the main electric propulsion motor or assist motor (like Honda).
@@volvo09 That's what I did a few weeks ago. Have been curious about them for a while and I like working on new things to gain experience... so I bought a cheap 2008 with an intentionally dead battery with relatively low miles for one of these (175k), scanned the battery and codes before I bought it and measured voltages, swapped out the dead cells in my garage the night I towed it home, and I"ve put nearly 2500 miles on it in the past 2 weeks
I helped a friend replace that hybrid battery several years ago. The new one was a Dorman. Followed instructions went good no problem. He’s still driving it no problem.
Wow amazed it didn't catch on fire 🔥😂
as soon as I saw the green crusties in part 1 my thought was "uh oh, where else did the water go?"
As an electronics tech my first reaction would be to check where it came from and then check every single connector in the trunk area
Great to see your logical diagnosis always👍🏻
Crazy, how green crusties will engulf this fascinating Prius!.
Goodthing you figured it out!
The book of knowledge is getting thicker and thicker. One day you should publish a PDF/ book of its contents.
Wow ! Great job as always...looking forward to Pt. 3 !
I had the same issue a few times. Replace the harness as well highly recommend it
Coolant clog codes can set when the system is low on fluid and doesn't detect flow, see that code on cars and trucks with separate cooling system for the turbos
I like it when you try to start it and say, "Place your bets"!
Seems like the methodical approach paid out. Impressive how those shorts didn't burn the wiring and even the battery cells involved. Wonder what Part 2 will bring :-)
Should have brought the car to you to begin with. Willing to bet that the original hybrid battery was fine.
Absolutely if he had done that begin with It would have made Ivan's job so much easier.
Who knows - he might still have the cells he took out in a box somewhere. He works on a lot of these, he might end up using them on another Prius.
That's true but he's an 80 years old retired guy who flips Prius' for a hobby. I'm sure a lot of his parts cannon is in inventory. But very true for almost anyone get it diagnosed by someone like Ivan save a lot of money
How much do those hybrid batterys cost ?
@@nickmalone3143 $800 to $1200 from a 3rd party. Not hard to change yourself.
In the first video I noticed what I thought looked like mold on the dash. Had this vehicle been in a flood situation? Or an interior water leak that caused a high humidity issue for the interior and promote the growth of mold and green corrosion?
I noticed that earlier... Telltale signs of a very humid interior.
I wonder if the hatch leaks? I didn't see signs of water intrusion, but maybe it was cleaned up fast if it got mildly swamped.
Brave man messing with those batts. Good luck. The future sure is bright!
He has no fear, this one. Amazing! Check the oil / filter for crumbs.
You really like a challenge don't you Ivan? Congratulations and a great diag!
You have too love working on a Vehicle that someone else has been messing wigh first...You never know what or wasnt done too it. UGH..You keep knocking it out of the park with this newer JUNK....My Hats off too you...Great job so far and Video
Brilliant. The owner should be thrilled.
Ivan, not feeling too comfortable about the long term future of this car. Thanks for Sharing!
First for me seeing inside on of these.
Learned a thing or three!
The scanner sees 2 cells at a time on the ecu. You can have one battery bad and it look good. Charge the battery up as much as possible. Test the battery by turning on the air conditioning on you will see with live data which one is bad.
The green crusties strike again! Let's see that test drive Ivan.
Lets talk about the "green crusties". I am retired after 45 years in electronics and systems. There were several cases of contact and connector corrosion that we called "Green Gold" because the corrosion would even happen in a mil spec 30 micron gold pin and socket. And that was in a laboratory environment!
It is expected that you find wiring corrosion in the harsh automotive environment. Green gold corrosion is a chemical process that requires several things e.g. dissimilar metals,H2O, salt, atmospheric gases and electrical current not to mention all the corrosive vapors that are present in an automobile.
I have seen PCB edge connectors go open from microscopic crystal growth pushing the contact surfaces apart.
Cars are built with the cheapest methods they can find. It is my belief that a critical corrosion control component is the use of anti oxidant grease. Its use is now required by the NEC for service panel main lines.
So Ivan you should apply anti oxidant compound to every connector you make a repair to. That will reduce call backs.
I fell victim to it in a Cobalt I had that went into cripple mode during a 2 foot blizzard. It turned out to be corrosion in the MAF sensor. I now put OX-Guard in every connector I can get at in my cars. So far so good! Keep up the great work, your videos keep my brain lubricated!
Great work ivan.i am glad you remembered to click down hv disconnecter plug.great repair.could you guide me to the plugin supplier?i will really appreciate that.cheers
Great video. Super interesting. I've got 4 prius for my courier business. 2 have over 400,000 miles with no problems. Hard to find people who can work on them.
Great job Ivan!!
Good going, Ivan! I was surprised how low the battery voltage system is on the Prius. Believe it or not, 600V and below is considered "Low Voltage" in industrial power systems. Even at that, nowadays a whole bunch of safety gear is required - so much as to nearly make it impossible to work. The controls in industry are headed from 110VAC toward 24VDC in order to (supposedly) make it safer, with the power sections being isolated, interlocked, and requiring all the safety gear if you hafta go in there. I suppose auto repair is lagging behind in regard to all the safety requirements. They do seem a bit over the top, if you're trying to get something done. Fire-resistant clothing, face shields (or even flash suits), voltage-rated gloves that have to be certified periodically, etc.
I am guessing the parts canon to fix the original issue of the crusty connector is what may have caused that orange battery sensing connector to get nuked? Testing doesn't cost it pays. Well done Ivan.
It’s gonna be a trilogy!!!
great video i have a friend that has one of these vehicles so far no problems over 100,000 miles on it
i have 255 on mine
Look forward to the update since I have this same car. Great job Ivan and thanks for sharing, the comment section on your videos is always fun as well (glad I finally know enough about a car since this is my daily to comment).
I wondered if you checked oil on the engine? As it never been driven, lol. Nice fix. I hate working on high voltages stuff. Dangerous in my opinion! Great job Ivan!!
1:13 The 1.2V is only the nominal cell voltage. Fully charged it's 1.42V to 1.5V
Excellent work Ivan. And crazy test drive? I swear if you say that thing is faster than that mercedes I'm gonna pimp slap ya lol
I'm still clueless on reading those schematics but love watching these diagnostics. Learning a wee bit every time.
Yeah, it's a mess. One thing here is that there are some physically questionable features. One is the wiring to the cooling fan. I would have pulled that apart right away. The other is the shorted terminal pins. If it looks wrong, fix it. I think Ivan gets too caught up in the diagrams. A messed up mess is something to fix. To hell w/ the diagrams.
He fixed both. Just not on the timeline you would have chosen?
That battery will need some attention soon. Block 13 looks to be 1v less than others
Part 3 noooooooooo oh well its worth the wait! Yeah I get a little nervous around those batteries as well for good reason.
DC is particularly nasty. Once it bites, it doesn't let go (meaning the pulsing of AC has a reasonable chance of causing you to be thrown off by muscle spasms)
Don't think I'll ever own an electric vehicle, hybrid or not, but, watching you t/s this is interesting. Your scan tool showed a problem on cells 2-5 and pointed you in the right direction. Green crusty connections are going to be the downfall of these EV's. GREAT VIDEO(S)!!!
What you've repaired there, I only got to see in training classes. Under the metal battery cover there are small metal jumpers from bat cell to cell. Corrosion can build up under and around the jumpers. The one Prius battery we got to take apart had some corrosion but like the instructor said this will happen, but it takes a long time and as we saw it didn't affect the battery pack output. We didn't get to do battery ECU and wiring diagnostics in that training or take individual cells out to clean the terminals and inspect them. BTW, we were told to wear soft cotton gloves over our hands, then the 1000 volt insulated protective gloves that would partially come up the forearm, then leather gloves over the rubber high voltage gloves to protect the HV gloves from rips and tares, however, the leather gloves would not cover the HV gloves all the way up to the end of the HV glove. That was so that incase the 201+ DC voltage went on the leather glove, it would run up to the exposed HV insulated glove and stop there. So long sleeve shirts were rolled up to expose the end of the HV glove. Sounds complicated but better than being hit by 201+ DC voltage!
Looking forward to part three.
Your doing great Ivan!
How the heck do you have any dexterity left with 5 thick gloves on each hand 🤣🤣🤣
@@PineHollowAutoDiagnostics It took some doing, but we did it. Linemen on poles do this all the time.
Actually it was three layers. Thin Cotton glove, HV glove and Leather Glove.
@@mikechiodetti4482 lineman are probably not having to manipulate a small needle probe to test tiny pins on a connector 😅
@@PineHollowAutoDiagnostics OK, ya got me on that one! LOL!
During the training, we also removed, tore down, reassembled and reinstalled the inverter assembly at the front of the car.
The 8 hour training of the 2 Prius vehicles there were 4 teams that did the removal of both vehicle's battery packs, tear down, component ID, tech tips by the instructor, reassembly and reinstallation of the inverters and battery packs, then engine start up with vehicle movement forward and reverse. Then the teams switched positions on the same vehicle from battery pack to inverter or inverter to battery pack and went through the same tear down and etc procedure with engine start up/vehicle movement. Great familiarity, but no hands on "testing!" I wish we had a second day to do that.
Still it was one of the best training days I ever had! Hands on, not classroom works every time! Classroom's great for laptop training to use for Prius Diagnostics.
Sorry for the long answer/rant.
got to love Prius
Ivan I've never had a first gen Prius Battery apart but have done plenty of Camry's & am led to believe they're all the same 'blades'. I'm sure the Camry has either 17 or 18 'cells' so 34 or 36 blades & in my experience 'nominal' voltage is around 8.3-8.4 bolts for each blade so that's getting up around 300v DC (for a camry at least anyway). Be careful mate! I have attempted to make a few videos replacing bad 'cells' in them but never actually uploaded any.
I thought it was out-of-character for you to say, "I don't know if I can fix this." Then, I thought about why you would say that. I remembered those cars have high voltage components and then I saw you don your PPE. I know you are very astute about how you do things; those gloves can get pin holes in them allowing current to travel to your body. (Don't ask me how I know that.) Your body has about 50,000 ohms of resistance. I would hate for that control module between your ears get fried! Great video!
Seems like it needs the good ol' Italian Tune-up after a year of sitting!
You can't!
Great work 👏 👍 👌
What a project, great job brother 🫡
Um, now I need to see part 3. Well done
THANK FOR THE SHARE THE KNOWLEDGE
Great job.
Now if I could only get you here to help me diagnose my Chevy Volt problems.
You still driving that thing Mike? Trade it in on a Prius! 😅
@@PineHollowAutoDiagnostics There, see! You are already getting in the mindset!
@@PineHollowAutoDiagnostics Had 1!Traded it in to get the Volt. Prius was a total POS !!!! Never had so many problems with a new vehicle.
@@TheDisgruntledMechanic wait I'm confused... I thought you were saying "Chevy Volt problems" 🤔 THEY'RE ALL JUNK 🤣🤣
@@PineHollowAutoDiagnostics Yes Volt problems. But I sold Pruis in 2010 because of all the issues it had at just 50,000 miles. At least my Volt got to 120,000 before having issues!! And yes the all Great until they don't run!
Wow Ustad you are awesome
One cause for rough engine is when you change engine mounts when you change engine. It'll take a little while before they are broken in so the engine might feel rougher than it is.
But in this case it's hard to tell. I would definitely check the engine a bit to see that it's in good order just to be sure that it don't go bad soon.
Nah it actually runs like garbage 🤣
@@PineHollowAutoDiagnostics Proven fact though, if you put a NOS kit in it after about 2 seconds it will be smooth as glass. Funny how wrist pins never fail🤣
There is something to be said about engine mounts though. I know on my car you have to torque the mount bolts in a specific order or you will set a permanent twist torque on the mounts and it will transfer every single cylinder event straight to your feels.
@@PineHollowAutoDiagnostics injectors clog on these pretty commonly or just bad old gas. give it the italian tune up
The battery has 28 modules that should be in the neighborhood of 7.2v. So you should read approximately 14.4v per each of the 14 blocks.
very instructive, thank you
Hi Ivan,
I've been in a Prius several times as a friend owns one. When the engine runs it runs very smooth. Great you found those pins shorted on the battery ECU and have it operating again with the replacement ECU. Looking forward to the crazy test drive video. My 2010 Fusion SE 3.0L is intermittently displaying a Tire Pressure Sensor Failure. Tire pressure checked and OK on all four. Can you suggest an inexpensive TPMS scanner so I can determine which tire has the faulty sensor? I can then go get the sensor changed. You and your family stay safe.
Odds are the failure is due to a weak battery. It's only been 12 years. (Assuming they're original.) It wouldn't be a bad idea to just replace them all.
@@russellhltn1396 They are the originals and have already been thinking about changing them all. Planning on keeping the car for several more years since it runs so good.
Good to see working on “electrified “ cars that “self charge “ (Toyota speak) What next? Tesla model S?
Great video. Sorry to criticise but; You should have used smaller crimps (they do come in different sizes). Also, there are far better crimping pliers available which would make it less likely that the crimp fails.
What crimping pliers are far better?
@@hikerJohn ratcheting crimping pliers. They crimp over a larger area and a lot higher pressure. Something like www.amazon.co.uk/Draper-35574-Ratchet-Action-Terminal-Crimping/dp/B0001K9TGA/ref=asc_df_B0001K9TGA/?tag=googshopuk-21&linkCode=df0&hvadid=226606326869&hvpos=&hvnetw=g&hvrand=11950477273968999200&hvpone=&hvptwo=&hvqmt=&hvdev=m&hvdvcmdl=&hvlocint=&hvlocphy=1007265&hvtargid=pla-450712511964&psc=1&th=1&psc=1
@@markperry4076 RUclips gave me your reply but it does not show in the comments. I put these in my Amazon "save for later" cart till I check prices at the Home Depot
Looking forward to part 3.
I have a Lexus hybrid (2010), so I found this particularly interesting... Especially the homemade hybrid battery charger. As usual, you tracked down the issues with good logical diagnostics! We expect nothing less... Curious though, the green crusties ... two different connectors, and fairly advanced state, I wonder if this was a flood car ... Any thoughts?
Seems like the back was left open or maybe the seal for the hatch has failed and it had a boot full of water.
Perhaps leaks in the body letting rain water in. Another might be condensation from the winter months. All the snow tracked in, heater melts it, but insufficient outside air to vent the moist air out of the car. So it condenses in the colder parts of the car (like the headliner). No leaks, but the area gets soaked. I think it's more likely in economy cars which would have anemic heaters, so the owners never turn on outside air.
these are known to get water in the trunk area from leaking seals. they can literally fill up with water. not uncommon even on a california car to find green crusties in that fan connector (happened on mine) i would bet 75% of cars have green crusties on that connecter of these gen priuses but that haven't actually cause a full blown loss of power
The Amazing Ivan .
So the batt ecu is plug and play. Nothing fancy
lol "The fan is working, very cool"
Ivan, great stuff. Who thinks about the future when repairing a car. Normally is just get it fix fast and give me my car back. Future WHAT?
you weren't arc welding with those last voltage readings? :)
Genius
The charger voltage has to be higher than the hybrid battery voltage in order to charge the battery. Great job on the diagnostics. Toyota’s hybrid system is excellent.
And the mechanical robustness is phenomenal. The CVT basically works as a differential. No clutches, brakes and syncromesh rings. everything is engaged all the time and it's just the magic of the two electric motors changing speeds and direction that result in an infinite variable ratio.
I'm a little more than mildly concerned to see the SoC dropping like that when it's running... :S Definitely still more to do on this car!
there's a risk when replacing an engine with a used one.
Yeah I spotted that too. The voltage was going up but the SoC was going down. Very strange.
@@Firecul it needs to be in drive with your foot on the brake and pushing on the gas to be charging to hybrid battery any (or any substantial amount). That is one way to launch these priuses is to sit at the light one foot on brake smash the gas to the floor and let it charge up the battery then when light turns green just let off the brake and she launches. No launch control needed either :) but seriously ill get some people on the jump in much much faster cars and watch them get pissed when they get beat off the line by a prius and zoom past me.
@ I'll accept you know more about the Prius but why would the voltage be going up while the charge is going down?
@@Firecul not sure honestly, but just saying the SOC on these is a metric that most prius guys know is basically useless for diagnosing a good battery etc. Whether that means the number should just be thrown out or not I dk. but you would very quickly know if there is a real problem with the hybrid battery after driving it for a bit.
I think the hacked up wiring has something to do with the data pids going crazy
Nice job getting the battery pack back online. I would have done the exact same thing with the broken wire at the fan connector. The part that has me concerned now was that coolant system code. If I am not mistaken, I think the high voltage motor controller is liquid cooled on those things? I think I would at least take a quick peek at all the fluid levels before taking it out on the road test. Anyway, I hope the customer will approve of you doing all the drivability repairs. I'd hate to see it leave half done.
theres a storage tank which holds warm water when you shut off the engine so on start up there is less energy / time needed to get the engine up to warm temp. it is a fairly complicated system but essentially when the valve fails it doesn't cause a driveability issue but usually causes a takes your engine longer to warm up and is bad long term. you are right there are two separate systems one for the inverter and one for the cars gas engine. checking fluid levels is good idea, but these coolant valves do go bad very often, set a ce code, but don't affect driveability and you can wait awhile before changing it. I have video on my channel about how to change the valve quickly
@ I was thinking that since the engine had been replaced and was never actually driven since, it might be a smart idea to just go over the basics before a actual test drive. We don't know how competent the last mechanic that worked on it was with the reassembly.
@@Sandmansa yeah i mean ivan and others on youtube don't always document every single thing they do-- and like most mechanics he knows to check fluid levels and monitor temps (that is honestly just too basic for him to repeat on his channel all the time). So yeah it is a good idea, I would just say he 100% did that
plus this guy had owned a ton of these-- one would assume that he at least knows how to add oil to it and check fluid levels
I had the same problem but it was inside the ECU on the back of the socket
While trying to check voltages at the hybrid battery ecu, did you have the big hybrid battery disconnected? Wondering because that wire with the pins stuck in it has orange insulation
Hi, the charger is part of maxx setup for recondition hybrid batteries, they have a discharger too, the say to start them before plugin! What scan tool are you using? I have the same problem.
What is that white plug you repaired do actually? Mine corroded and I replaced it with new plugs but my car still has the P3102 code. I put a brand new 12 volt battery as well
Ivan - What do you use for organizing test leads? Thank you
You put in some long hours Ivan :o)
Why is the battery state of charge falling while the engine is running?
After watching more I see it started climbing again.
Greatest hybrid ever made. My 2 pui thank you. Will get the next gen this summer. Life’s too short to drive any ice only cars
To each his own! I like shifting my own gears and running cars for 30 years with minimal expense 😁
@@PineHollowAutoDiagnostics I'm telling you, Ivan, we should strongly consider switching to these cars. Look at the prestige we could garner. Many famous people drive these. (I think Brian the dog on Family Guy drives one! All the Bluehairs at my church drive them. The taillights on the later models look like a miniature 1960 Oldsmobile 98.) We would be in good company. I could plan a vacation to Pennsylvania Furnace every year so you could do a 7 part video and fight all the melted connectors. The possibilities would be endless!
@@PineHollowAutoDiagnostics I agree. Got tired of shifting in the suburbs and I hate being behind other pui.but…… my 14 Prius is selling used what I paid for it new. My 20 Prius prime is selling used for $ 9000 more than what I paid new, thanks to the NYS taxpayers!
Good morning Ivan! I know I haven’t commented lately. I have still watched every one of your videos at least twice if not three times! You’re one of the best RUclipsrs out there and I can’t wait for your next video to be released! :-) Great job Ivan!
Hi Robert! Appreciate your support very much 🙏🙂
Happy holidays! 🎄
Eagerly waiting for part3
Ivan used a wire crimp connector? I don't know what to believe in anymore.
Ahhhh Captain Ivan “Ahab” yet again finds his beached whale Moby Prius and conquers the diagnosis…..but alas the whale wants to remain beached. Tune in next time when Captain Ivan faces down his most stubborn whale yet again. Godspeed Capt. Ivan. Godspeed.
Batteries that have been deeply discharged can flip polarity. This can be reversed but their capacity is severely reduced as they now permanently damaged. Something to consider…not that it’s relevant here but when you have bad imbalance between cells…
nice work, please use eye protection at least when working on high energy devices. It's hard to work on stuff blind.
take a look a set of T&B WT111 crimpers or Klien-1005 there is just nothing better.
Rich
Each cell if below 7.2v will set that code. If a cell is .5 volts different it will set that code.
While watching (not at the end yet) I did think it was strange that ALL battery voltage readouts are jumping around whereas there is no load on the battery - surely I'm not the only one that thought that was weird from party 1 as well ?
Dunno boss, maybe should of put some very large warnings on this video. I can imagine some unqualified yahoo's digging into the battery unit and getting seriously zapped.
Darwinism?
You mean Technicians...dem all qualified to work on anything. Because dem are TECHS.
@@PineHollowAutoDiagnostics ...or Idiocracy.
"There is no 'try'. Only 'do' or 'not do'."
Hello, I keep on getting error code POA1F... the voltage readings of battery modeles are allover the place.. the ecu is fine as replace with new one as the old one got corroded and was fried... now this error keep on coming... i dont know how to dress it.. should i change voltage sensing wires may be everything might become ok
Top work, love your forensic approach, you should follow in your father's footsteps and work for NASA or something, but then again modern cars seem to offer enough of a challenge with their crazy complexity!
It must be a whole different ballgame with NASA having to wait 7 +/- minutes for a response when testing.
I'm not a huge fan of govt agencies 😅
I was thinking of corrosion seeing that mold on the dash board. I guess it’s been sitting somewhere moist
they're well known to leak water into the hatch area, which runs down the battery "fan" wires, it will also fill full the "well" the auxilary(12v) battery sits in, possibly fills the other side and more when that overflows. if the vehicle sits not driven the inside will become a humid jungle, also it can freeze solid in winter, breaking the battery and itself, among other issues.
A collection of Priuses, sounds like the name of a painting by Andy Warhol.
seems to be a lot of green gremlins....was this a hurricane flood victim car?
Why am I getting the feeling @7:40 that this is a flood car and the battery replacement came out of another flooded Prius
Well done ivan, it's close to being a car again :-D
That engine sounds like an ill food mixer, oh dear lol.
If nothing else, it will make some cakes :)
Toyota rav 4 hybrid 2018 codeP0A0D after front end fender bender
hey this guy can fix hybrids
Ivan, you take anything on as a challenge. I have said it before and repeat it hear, I doubt seriously if you are being reimbursed for ALL the time you put into these unicorns which makes you suspect as a business person. However, you are gathering a knowledge base on so many different pieces of equipment that you may just find yourself in great demand and able to charge accordingly. Question is, will you charge a premium amount to work on things others will not even look at? You should.
I admire your innate curiosity in regard to figuring out how things work and then using a very logical method to solve problems. I don't know another RUclips mechanical technician/diagnostician that takes on things you take on. Take for instance, Eric O. just did a What's up Wednesday and one of the questions was about will he eventually work on EV. Basically his answer was no, he'll be dead or retired by time they overwhelm the market. A similar question was in regard to European cars. His answer; I don't work on them. Why does he take a position like this? Because he is a businessman first and foremost. His job, as he sees it, is to maximize profit and efficiency while still doing a good job on the things he chooses to work on. You on the other hand seem to take on all comers. Totally different model. I hope your approach works for you financially because it sure is entertaining and educational. You are one of one in your field, Ivan.
You know this vehicle isn't a virgin - its had a hard life. If it needed a new engine then either it suffered from the coolant diverter valve sticking and being overheated or someone seriously abused it. The 1NZ engine is an absolute work horse. I've heard of people put 400,000 miles on them with regular maintenance. Needing a new engine after 200K seems premature to me. I've seen plenty of these as taxis with 250-350K on.
The green crusties in the back? I know one thing Toyotas of this vintage suffer from is waterleaks in the boot. Typically cracks form in the paint/seam sealer between panels in the rear and you get a swimming pool in the boot. If it was damp long term condensation could have caused the green crusties in the connector.
Ah yes, clear evidence that both the green crusties and the parts cannon are alive and well in the world of the EV.