2006 GS450H HV Battery system

[pearothehero]

2006 GS450H came in running, check Hybrid on the dash.

Brought into workshop, Battery condemned, low voltage on at least 3 cells.

3k worth of HV Battery pack installed. Fired up and drove initially albeit with MILs along lines of check VCS, check ECB, ABS.

Inconsistent readings from the control module, part number 89892 30010 checked and had 3 pins snapped/corroded (seems very common), so hard wired direct to the board.

Now consistent 15.6v across all 20 cells but no start, consistent DTC P0AFA within the Hybrid Control Module suggesting the HV system is low Battery. On the driver display, 6 of the 8 Battery cells are showing suggesting an approx 75% charge

Before committing to a new £670 module has anyone come across this before please? 

Completed quite a comprehensive test plan already. This seems the only thing left. Thanks in advance for all your help.

[messi]

Hi I'm no hybrid expert, but I do know this, you know where the hybrid Battery is, there is this orange clip, when putting the clip back in, did you also push down so it clicks in properly?? If not, it wont start

[hazelnut]

So you are talking about the Battery sensor ECU? There's a few on eBay for £150.  Is it just a voltage reader ? or does it do balancing as well with internal resistors to discharge the good cells to match the worst?

 

[pearothehero]

7 hours ago, hazelnut said:

So you are talking about the battery sensor ECU? There's a few on ebay for £150.  Is it just a voltage reader ? or does it do balancing as well with internal resistors to discharge the good cells to match the worst?

 

Yes that's pretty much what I'm talking about. It's exact role I can't be 100% sure of but this particular part number isn't on eBay for that sort of money sadly