I repair these cars all the time, the problem with the black inside the orange connector towards the end of the video is not heat as such it’s because moisture has travelled down the wire harness due to water leaking into the car due to the capillary effect, the wire, the water from the battery Terminals and gravity assists it down to the ECU. Usually the high voltages differences on these wires happen at the end connectors so you’ve got high voltage across the top and the bottom pins when the moisture hits this along with the oxidation it causes conduction, then this causes aching Which is DC so this causes blackening and either the wires burn out or the connector. So yes, heating is caused indirectly through DC arching. Hope that helps everybody best thing to do is replace and repair the wiring harness to the high-voltage battery for the sensor wires and replace the ECU .

I had the same connection issue. I pressure wash my car so a lot and I have to cross a river every day I drive and we have heavy rains...not sure exactly how water got in But it did...found out my prius also had cracks in the rear hatch frame where as they are the seals crack and water can enter car. Look up on forum to learn about the fix. So I changed the wire harness and the computer and everything worked..i also changed the copper bus bars to nickel plated bus bars and new nuts...been working fine since 2 plus years

Whenever the PCM or ECU is more than a 1.3 volt difference between the minimum block number and maximum block number u get the P0A80 if u getting other codes u could point u to maybe different issue just trying to help anyone so they don’t spend money on parts testing the HV voltage to confirm a P0A80 code

Hello there. Good video right there. Waiting for the continuation

Hello, what is the number of this orange connector please?

Could you answer this question please if you have experienced that? I replaced the batteries on two RX450H. After 2 years and 15,000 miles on each the permanent code wont go away and I do not get any code on the panel and the car works normal. It's just that the permanent Code P0A80 (Replace Battery Pack) wont go away. Thanks!

Working on my 2012 battery ECU / wiring harness. Similar desing and same issue, the ECU board looks fine and only a couple pins shorted in the orange connector. * Noted pins 1,3,11 are destroyed while pins 5,6,7 are singed slightly. On the wiring harness side pin 1 is ash with very little left to the wire crimp, pins 3, 11 are toasted but intact, the corrisponding 5,6,7 are singed as well. Curious to see if you have had better luck finding just the connectors for replacement. So far the best I can find is full replacement of the ECU and corrisponding harness, though neither need full replacment just connectors. The battery cells are wonderful for the usage its seen 228k, lowest cell voltage after 2 months of sitting is 7.45 with a high of 7.72. I'm trying to sell this car and would like to find better fix than throw more money at it, possibly auto wrecking yard and remove appropriate parts. If you would like more data or information i'll be checking back here for a couple days.

should the fan turn on as soon as the car is started?

So did it end up just being the one module that was low or was it something with that computer connection? Watched your other videos of the reconditioning so I figured you were working on this battery pack. Just didn't catch it if you mentioned what was the final result of the repair.

Good job 👍

Hi Steve, My name is Truc, with a 2012 Prius C showing permanent code P0A80. I have watched your videos and am confused somewhat. But I admit yours is the best I have seen so far. The car was running fine (even with the code P0A80) prior to my attempt to recondition the battery modules. When I reconnect the battery pack, all the dashboard lights lit up and the car won't run and I don't know why. Could you please summarize all the important steps to correctly diagnose and recondition the modules to make the car run again? Thank you very much for your prompt reply.

Video was ok but why were you hiding al resistance values and what pins you tested ? Seems like that was an important part and you went right passes it like you wanted to hide how to test it ??

Hey buddy what is the red and black box with the screen called that u are using to measure the electricity ?

Im just curious why you didn't check the 12V battery first. You could have found water underneath it or the battery may me LV. Also there is a vent behind the battery that should be checked. Fans working fine. maybe just a recharge on the 12v would do it.

Steve did you start the car for the fan to run? Thats what I need to do tomorrow.

Where’s your high voltage PPE sir?

Nice

Can you send me Next video?

Where is part two buddy? What is the end,???

What the name of that piece

I disliked your video mainly bc you completely skipped over the showing how you tested the modules to each pin. You could have at least showed two of the modules.