Intermittent Hybrid System Problems

Patrick Wong · 07-24-2008, 06:56 AM

If you haven't already found this string, please take a look at it, especially posts #15 and #18:
Fan blade orientation?

Hopefully that will provide most of the info you need. I don't think it is possible (or necessary) to adjust the fan position to improve air flow.

bingmel1 · 07-24-2008, 02:52 PM

Thanks for everyone who helped me on this problem.

After going through nearly two weeks of constant errors reappearing with no end in sight, despite taking the Prius to so-called "experts" (two Toyota Dealerships and two independent shops), I decided to do my own visual inspection of my car. The problems seem to be caused by a loose radiator fan blade (the seven-blade one, where the blade mechanism had slipped off the motor shank) and a leaking HV Inverter Coolant Reservoir at the Inverter junction itself (fluid drips slowly with the cap removed). Since the fan had jostled loose, I could not determine whether it provided proper airflow direction. Needless to say, I took my Prius back to the original body shop and pointed these issues to them. They will fix at no charge, since they provide a lifetime warrantee on their repairs, and hopefully this will be the end of this fiasco.

richard schumacher · 07-24-2008, 06:04 PM

Yeesh, I hope so! It sounds like those two dealers don't know enough about Priuses either. If there are no others nearby to try next time, pick the one you think is more promising and stick with them. Learning on yours is not ideal but better than no service at all.

bingmel1 · 07-28-2008, 09:14 PM

Well, this saga continues! After the shop fixed the radiator fan (also verifying air flow for both) and the leak in the HV Coolant System, these error messages still come on. I had the AC running prior to the codes returning, which leads me to believe that the shop may have used the wrong type oil after they replaced the AC Compressor. I'll take the car (AGAIN) to a Toyota Dealership for them to diagnose.

While I continue my investigations, can someone tell me how a shop determines whether the wrong type oil had been used? If the wrong oil had been used, what would the procedure be in completely purging the AC line of the old oil in preparation for adding the correct one? Would any other AC parts need to be replaced?

bingmel1 · 08-01-2008, 11:30 PM

Well, my car finally has been fixed! Aside from the earlier-mentioned parts that needed to be replaced, the latest Toyota Dealership I took my car in found a leaky o-ring within the HV Coolant Reservoir and a malfunctioning Radiator Water Pump (P/N G9020-47031). After replacing the two pumps, inverter reservoir, and various o-rings, the car now runs like a champ.

I'm glad the Inverter Coolant System now operates with no problems as the temps in Texas these days have surpassed 100°F. Thanks everyone for your help.

07-24-2008, 06:56 AM	#11
Patrick Wong DIY Enthusiast Join Date: Mar 2008 Location: Orange County, CA Posts: 1,993 My Car: 2004 Prius Package: #9 Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 28	Re: Intermittent Hybrid System Problems If you haven't already found this string, please take a look at it, especially posts #15 and #18: Fan blade orientation? Hopefully that will provide most of the info you need. I don't think it is possible (or necessary) to adjust the fan position to improve air flow.

07-24-2008, 02:52 PM	#12
bingmel1 Junior Member Join Date: Jul 2008 Location: The Woodlands, TX Posts: 8 My Car: 2005 Prius Package: Base Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	Re: Intermittent Hybrid System Problems Thanks for everyone who helped me on this problem. After going through nearly two weeks of constant errors reappearing with no end in sight, despite taking the Prius to so-called "experts" (two Toyota Dealerships and two independent shops), I decided to do my own visual inspection of my car. The problems seem to be caused by a loose radiator fan blade (the seven-blade one, where the blade mechanism had slipped off the motor shank) and a leaking HV Inverter Coolant Reservoir at the Inverter junction itself (fluid drips slowly with the cap removed). Since the fan had jostled loose, I could not determine whether it provided proper airflow direction. Needless to say, I took my Prius back to the original body shop and pointed these issues to them. They will fix at no charge, since they provide a lifetime warrantee on their repairs, and hopefully this will be the end of this fiasco. Last edited by bingmel1; 07-24-2008 at 02:57 PM.

07-24-2008, 06:04 PM	#13
richard schumacher nacreous lacquer Join Date: Mar 2004 Location: United States Posts: 4,126 My Car: 2004 Prius Package: #6 Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	Re: Intermittent Hybrid System Problems Yeesh, I hope so! It sounds like those two dealers don't know enough about Priuses either. If there are no others nearby to try next time, pick the one you think is more promising and stick with them. Learning on yours is not ideal but better than no service at all.

07-28-2008, 09:14 PM	#14
bingmel1 Junior Member Join Date: Jul 2008 Location: The Woodlands, TX Posts: 8 My Car: 2005 Prius Package: Base Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	Re: Intermittent Hybrid System Problems Well, this saga continues! After the shop fixed the radiator fan (also verifying air flow for both) and the leak in the HV Coolant System, these error messages still come on. I had the AC running prior to the codes returning, which leads me to believe that the shop may have used the wrong type oil after they replaced the AC Compressor. I'll take the car (AGAIN) to a Toyota Dealership for them to diagnose. While I continue my investigations, can someone tell me how a shop determines whether the wrong type oil had been used? If the wrong oil had been used, what would the procedure be in completely purging the AC line of the old oil in preparation for adding the correct one? Would any other AC parts need to be replaced?

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08-01-2008, 11:30 PM	#15
bingmel1 Junior Member Join Date: Jul 2008 Location: The Woodlands, TX Posts: 8 My Car: 2005 Prius Package: Base Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	Re: Intermittent Hybrid System Problems Well, my car finally has been fixed! Aside from the earlier-mentioned parts that needed to be replaced, the latest Toyota Dealership I took my car in found a leaky o-ring within the HV Coolant Reservoir and a malfunctioning Radiator Water Pump (P/N G9020-47031). After replacing the two pumps, inverter reservoir, and various o-rings, the car now runs like a champ. I'm glad the Inverter Coolant System now operates with no problems as the temps in Texas these days have surpassed 100°F. Thanks everyone for your help.