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

Looks like the owner still needs to do a fair amount of work. Great diagnosis.

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!

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.

Should have brought the car to you to begin with. Willing to bet that the original hybrid battery was fine.

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 :-)

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

Great to see your logical diagnosis always👍🏻

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.

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?

Wow ! Great job as always...looking forward to Pt. 3 !

Brave man messing with those batts. Good luck. The future sure is bright!

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!

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).

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.

Great job Ivan!!

very instructive, thank you

I like it when you try to start it and say, "Place your bets"!

I had the same issue a few times. Replace the harness as well highly recommend it

What a project, great job brother 🫡

Crazy, how green crusties will engulf this fascinating Prius!. Goodthing you figured it out!

Great job.

Great work 👏 👍 👌

THANK FOR THE SHARE THE KNOWLEDGE

You really like a challenge don't you Ivan? Congratulations and a great diag!

First for me seeing inside on of these. Learned a thing or three!

The book of knowledge is getting thicker and thicker. One day you should publish a PDF/ book of its contents.

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!!

Ivan, not feeling too comfortable about the long term future of this car. Thanks for Sharing!

Um, now I need to see part 3. Well done

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

Brilliant. The owner should be thrilled.

Looking forward to part 3.

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

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.

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 green crusties strike again! Let's see that test drive Ivan.

Seems like it needs the good ol' Italian Tune-up after a year of sitting!

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.

got to love Prius

Part 3 noooooooooo oh well its worth the wait! Yeah I get a little nervous around those batteries as well for good reason.

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.

Wow Ustad you are awesome

Eagerly waiting for part3

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.

great video i have a friend that has one of these vehicles so far no problems over 100,000 miles on it

He has no fear, this one. Amazing! Check the oil / filter for crumbs.

Good to see working on “electrified “ cars that “self charge “ (Toyota speak) What next? Tesla model S?

That battery will need some attention soon. Block 13 looks to be 1v less than others

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!

1:13 The 1.2V is only the nominal cell voltage. Fully charged it's 1.42V to 1.5V

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.

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 :)

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 ?

lol "The fan is working, very cool"

Now if I could only get you here to help me diagnose my Chevy Volt problems.

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?

Genius

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!

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.

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.

you weren't arc welding with those last voltage readings? :)

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)!!!

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 KZfaqrs out there and I can’t wait for your next video to be released! :-) Great job Ivan!

Each cell if below 7.2v will set that code. If a cell is .5 volts different it will set that code.

The Amazing Ivan .

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

I think the hacked up wiring has something to do with the data pids going crazy

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

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.

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

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.

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.

I'm still clueless on reading those schematics but love watching these diagnostics. Learning a wee bit every time.

So the batt ecu is plug and play. Nothing fancy

I had the same problem but it was inside the ECU on the back of the socket

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.

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!

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?

This looks like this is flood or water damage in this car. Wiring harness?

PART 3 ? WTF ? You know " SIR IVAN " You would make a GREAT DAIRY FARMER because you're " MILKING THE HELL OUT OF THIS PRIUS VID. " PART 3 MY AZZ. 😂 And YES, if you make cheese along with your MILKING ABILITIES, I would like some with MY WHINE. KRAZY TEST DRIVE, HOLY CROW ? " KILLIN ME SMALLS, KILLIN ME. " I think I'll go watch SMA because this vid. is TURNING SOUR, STARTING TO CURDLE, he doesn't SKIM any off of his vids. I'll be MOOOVIN ON. Ok that's all I could think of right now but THE GRASS IS ALWAYS GREENER, SIR IVAN. Henry from N.E. PA.

hey this guy can fix hybrids

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.

I was thinking of corrosion seeing that mold on the dash board. I guess it’s been sitting somewhere moist

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…

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!

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 KZfaq 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.

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.

Wow I wonder how long that connection has been messed up unreal I don't know about your choice of so-called electrical insulated gloves not sure if that's really rated for that be interesting to find out

"There is no 'try'. Only 'do' or 'not do'."

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

There’s a song playing in my head. Anticipation. By Carly Simon

A collection of Priuses, sounds like the name of a painting by Andy Warhol.

😊👍

Ivan used a wire crimp connector? I don't know what to believe in anymore.

Ivan, just watching the video and noticed you didn't strip the wire before attaching the crimp on connectors, is this how you are supposed to connect these, i have always stripped the wire, have i been doing it wrong all these years, it does seem to make more sense to keep the sheathing on the wire and have force of crimping split the sheathing to make the connection thus keeping a better insulated one...? I am by no means a certified mechanic just an avid DIYer...;)

Sort of a introduction to how cars will repaired in the future with the All EV power remember you saw this first on Pine Hollow Auto Diag Channel

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.