"Hybrid System Warning Light" Coming On

[czyfrme]

I will try to make this as clear as possible.

My "Hybrid System Warning Light" came on 4 times in one day (within 45 mins) about 2 weeks ago. (When the light comes on the car becomes undriveable and I have to coast it to a stop.) It had previously come on maybe twice since I bought the car @ ~83,500mi (I'm @ ~89,000mi now). I figured out I can reset the light if I reboot the system (restart the car) 4 times (at exactly the 4th time the light goes off). I called my Toyota dealer and had my car towed to them (the light was not on when they got it because I had reset it). They ran a check and got 2 codes. I don't know specifically what they are because I don't have my paperwork (it's at home, I'm at work). One code said that the engine didn't start within 8 seconds, the other code said that the engine had misfired. Their solution to this was to change the spark plugs. They did and I thought that had fixed it, but yesterday (about a week after the dealership service) the light came back on twice. The next time it comes on I'm just going to park it (with the light on) and have it towed to them again.

Has this happened to anyone else? Anyone have any suggestions, answers, maybe tell them what to look for?

Thanks for your time.

Leslie

[tochatihu]

Hi Leslie, the codes might help. Most common fix needed for classic Prius is TSB EG011-03. Most commonly only the ECU is replaced.

Your throttle butterfly may be partially blocked by soot buildup, and not able to move as directed by its motor.

Spark plugs, ingnitors, and injectors are rarely at fault. I am not totally convinced that your current Toyota shop is expert with hybrids. Is there a convenient alternative?

[czyfrme]

Ty for the reply tochatihu.

The codes as read on the receipt/invoice are as follows "P0300 and 3191".

Again, they changed the spark plugs, reset/erased/cleared the codes and sent me on my way.

I will say that when I am driving (please bear with me) and holding a steady speed (say 58mph), without taking any pressure off the gas pedal or anything, the car sometimes feels like it "slips" or has a loss of power or continuous speed and decelerates; and the electric motor mpg graph (i don't know what it's called, the fluctuating graph that tells you how many mpg you're getting) shoots up to 100mpg and then after a few seconds goes back to normal (normal @ ~58mph is about 50-ish mpg).

And there is really no convenient alernative. We have two Toyota dealerships around here, both of which are 20+ miles from where I live.

[czyfrme]

I also found this information from This Website.

"I wondered if any of my Classic owning friends would ever experience this. Yesterday, it happened. The accelerator-pedal became sluggish, making the car feel as though it was fighting an invisible resistance in front... as if a big hand was pushing against it, hence the name. It was pretty darn obvious what had occurred too. The dashboard and Multi-Display both lit up like Christmas trees. A bunch of warnings made it quite clear. Fortunately, taking the car to the dealer was no big deal. Owners have reported long spans between failures like that, so just driving there was a non-event. All went fine. And once there, they pulled 4 codes from the computer: P0300, P3191, P3101, C1259. It was a dead giveaway that TSB EG011-03 should be performed. It's a special service for this very situation, something unique to the older design (THS). The required ECU replacement was done without any trouble."

So the ECU could need to be replaced? Can it just be reprogrammed?

I am assuming since I bought my Prius from a private party that I don't have any warranty coverage?

How much is this going to cost me? I will start sharpening the saw blades... will that be 1 arm or 1 leg?...

[tochatihu]

This big hand syndrome is well-known to me, because I used to have a hobby-business of rebuilding accelerator pedals for the classic Prius. In my experience, accel pedal failure is not accompanied by such codes, while the TSB EG011-03 is.

Getting the ECM replaced should be no problem, but warranty coverage might be (because of odometer, not ownership history). Always worth the effort to make "a forceful request". Don't really know the retail price for that ECM, but it would not be cheap. No, can't be reprogrammed, they started making them that way in 2004.

The only other alternative I could think of is one from a salvage dismantled Prius. The part number should be 89661-47054 and nothing lower in the last 2 digits. Salvage price might be about $100?

It certainly could be that you have an accel pedal problem. I am in China, and Bob Wilson has my 'stock'. You can contact him at Greenhybrid or the yahoo prius technical group. I also posted DIY instructions in the yahoo toyota-prius-sat2 group files.

Good luck and let us know the proceedings.

Edit oops forgot that Bob Wilson posts here as well, so just ocnsult him w/question on the accel pedal

[jjkdh]

Hi --
I have recently purchased a 2002 Prius with similar problems, and am wondering if I have a lemon. It is beyond warranty.

The problem has (so far) been intermittent, and I am looking for patterns, and wondering if it could be something as simple as a loose connection or a bad fuse.

Can someone direct me to online instructions for accessing the fuse box in the dash? I've already checked the relevant ones in the engine compartment. (I note the windows don't work, except the driver's.)

The lights that come on include engine light, ! light, PS light, and sometimes the temperature gauge (blue!). Normally it happens after the car has been sitting out in the hot sun for awhile. I notice the temp reading on the dash is at least 8 degrees higher than it is outside (always).... It may drive, and it may stall out. (always it loses AC.) And sometimes if I drive it then, I lose throttle, and drop to coast. However, if I rev it a few times, it seems to come out of it, as if there's a fuel blockage.

Like you, if I stop and restart a few times, it usually goes back to normal, but not regularly on the 4th start, and the problem seems to be getting worse. Today it took close to an hour, and I was far from home or a dealer....

The guy who sold it to me took it to the Toyota dealer, then fed me something about the computer remembering the amount of fuel it took to start it before, when it was low. Nonsense. This happens regardless of fuel levels. (Of course, now he won't return my calls.)

Thoughts? Beyond warranty, so wondering to what extent this is repairable by me or a non-dealer mechanic. (Jeez Louise, the dealer charges over $100 for a single key!)

Also wondering if there's any chance this relates to a 2006 recall:
-------------------------------------------------------------------------------
http://www.internetautoguide.com/auto-reca.../341/index.html
-------------------------------------------------------------------------------
NHTSA Campaign ID Number: 06V266000
Recall Data: 07/19/2006
Components: ENGINE AND ENGINE COOLING
Units Affected: 34771

2002 TOYOTA PRIUS ENGINE AND ENGINE COOLING
Recall Date: 07/19/2006

Summary:
ON CERTAIN PASSENGER VEHICLES, DUE TO IMPROPER MOLDING OF THE RESIN BODY OF THE CRANKSHAFT POSITION SENOR INSTALLED ON THE ENGINE BLOCK, ENGINE OIL MAY PENETRATE THE SEAL AND ENTER THE SENSOR WIRING CONNECTOR. THE WIRE HARNESS CONNECTOR MAY NOT BE SUFFICIENTLY ATTACHED TO THE LOCKING TAB OF THE SENSOR WIRING CONNECTOR.

Consequence:
ENGINE OIL INSIDE THE SENSOR WIRING CONNECTOR COULD CAUSE EXPANSION DUE TO THE HEAT OF THE ENGINE AND COULD DEFORM THE SENSOR WIRING CONNECTOR. THE CONNECTOR MAY BECOME DISCONNECTED, WHICH COULD CAUSE THE ENGINE TO STALL WHILE DRIVING AND NOT BE ABLE TO BE RESTARTED INCREASING THE RISK OF A CRASH.

Remedy:
DEALERS WILL REPLACE THE CRANKSHAFT POSITION SENSOR FREE OF CHARGE. THE RECALL BEGAN ON JULY 26, 2006. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.

Potential Units Affected: 34771

Notes: TOYOTA PRIUS 60G
-----------------

thanks!

[tochatihu]

jjkdh, the crankshaft position sensor is under special service campaign 60G. Ask your shop if your vehicle (VIN) is covered. If not, ignore.

Ignore any discussion of fuel level 'memory'.

Your other electric windows don't work because your driver side override switch is set. Press the button again.

The other fuse panel is revealed when the driver door is open. See the owner's manual. It will also tell you the function of the window lock button mentioned above. If you find any blown fuses, replace them and try to find out what hurt them. Otherwise, direct you attention elsewhere.

Your symptoms remind me of accelerator pedal problems, but do not ignore the possibility of TSB EG011-03. Read and understand my messages above to Crazy4ME.

You need a Toyota shop competent in diagnosis, and to ACT ON what you have read here already. Sorry to be so blunt.

I am in China now and not able to be a NHW11 obundsman anymore. I wish that someone else would STEP UP to take that role!

[jjkdh]

Well, the service shop wants (of course) to sell me the most expensive attempt to fix the problem: replace the main computer.

I am hearing from others that there is no real fix for this. That it's happening to more and more of the 1st generation Prius' as the mileage gets up there. That it does indeed have to do with the fuel trim, but no one, including Toyota, has a good fix for it yet.

Anyone else out there getting this message?

--jj

[czyfrme]

The "Hybrid System Warning Light", "MIL" AND "Check Engine" light came on again last night, engine lost power and I coasted to the side of the road. "HSWL" & "MIL" went off on the 4th reboot (as always), but the "CE" light stayed on. It's being towed to the dealership today. I told the service man of the TSB EG011-03 and left some information I'd found around the internet in the driver's seat for his review.

Hopefully this will be a quick fix but I'm sure it will be expensive. Looks like it's back to Ramen noodles & peanut butter sandwiches for me.

[czyfrme]

If anyone is following this, I just got a call from my serviceman and they pulled a P3002 - "HV ECU Communication Malfunction" so they're replacing the HV ECU @ $650 plus approx. 2 hrs labor. Not as bad as I thought it was going to be, but still - ouch.