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2007 Prius Inverter Failure?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Eric H, Jul 27, 2015.

  1. Eric H

    Eric H New Member

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    2007 Prius
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    Hi All, first post here after finding much information browsing the forum over the years :) I am having some trouble with my previously indestructible Prius & could use some advice.

    Sequence of events for my trouble with my 2007 Prius with ~140,000 miles:
    1. Drive home Tuesday night last week, no problems, car functioning normally as always.
    2. Wednesday morning, I tried to start up but multiple panel lights flash on and off. Tried a few more times, but it stopped responding entirely & all panel lights went off. OK, I've replaced the 12 V battery before, so maybe I left the door ajar or lights on & need a jump.
    3. Hooked up my battery charger to the jump terminal as I have done before & tried again. Panel lights flash on & off, some warning lights (sorry, can't recall which ones). Charger current indicator jumps up and down and can hear a relay clicking on and off inside the engine. No start. I give up and head to work in my wife's car as I am already late.
    4. That night, pull the 12 V battery and check voltage. Very low, ~4 VDC. I hook the charger up and let it run overnight. Measures a little over 12 V in the morning.
    5. Reinstall 12 V battery and try to start again. A bit more sane response this time, panel lights don't jump around but the triangle/exclamation point of doom is lit, and the smaller version on the LCD also. No start.
    6. Got a tow truck to come out and take it into the shop. When getting ready to move it out to the street for the tow truck to load up, it starts up! Warning triangle is still present, but motors run fine and drives normally for the 30 feet. Truck was already there, so we loaded it up anyway and towed it to the shop.
    7. Shop calls and says I need a new inverter, $4800 repair. Ouch! The car is only worth that much at best, so that is not really an option for me. The trouble code is P0A09, with sub-code P0A09-591. I'm bringing it back home today until I can figure out what to do next.
    I researched that code a bit, looks like it may or may not be a failed inverter. Any opinions on what is going on, or additional checks to make?

    I also found some information on replacing the inverter with a salvaged unit. It looks to be not horribly complicated, but wanted some expert opinion on whether that is something a part-time mechanic might tackle. I'm a mechanical engineer and have rebuilt motorcycle engines and some moderately involved car maintenance, so I am comfortable with complex repair projects, but no experience with hybrid electrical systems. I can get the protective equipment and tools needed from work, but don't want to get in waist deep if it's best left to professionals.
     
  2. Beachbummm

    Beachbummm Senior Member

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    ebay/junk yard/craigs list..parts are everywhere be sure to change the invertor pump too and bleed all the air out..dyi videos on youtube
     
  3. JTM2955

    JTM2955 Active Member

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    Have you ever had your invertor water pump changed? I wonder if it cooked the invertor due to lack of coolant flow?

    $4800 to change? Ouch!


    LG-D851 ?
     
  4. jadziasman

    jadziasman Prius owner emeritus

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    Most likely that it's inverter failure. Wire harness'/connectors within the engine bay rarely fail
    unless the vehicle has been in a serious accident.

    Your 12V aux battery had an extremely low voltage because the DC/DC converter in the inverter was/is inoperative
    and could not charge it.

    Time for you to shop around for a used inverter from a salvage yard. Can't be too difficult to replace - plug and play.
     
  5. Patrick Wong

    Patrick Wong DIY Enthusiast

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    1. Buy a new 12V AGM battery now, and fully charge it prior to installation. You definitely need that, regardless of whatever other problems your car may have.
    2. Install the battery. See whether the car becomes READY or not. If it does, use a digital multimeter to measure voltage across the 12V battery. If it measures ~13.8VDC, then the inverter is working properly.
    3. If the voltage reading is much lower then the inverter is not working and you need to replace it. As previously suggested, a used inverter would be fine, certainly affordable at ~$200 or so, and you can replace it yourself. Make sure the part number is the same as the original equipment inverter because it is unclear whether you might have a problem with the inverter/hybrid vehicle ECU interface by using a different inverter model number.
    4. Get factory repair manual info at techinfo.toyota.com so that you are fully aware of the safety precautions to be taken when working on the high voltage circuits. There are four main safety precautions: disconnect the 12V battery first, remove the orange traction interlock switch on the traction battery case, measure the voltage on the inverter terminals connecting to the traction battery cables before disconnecting the cables to make sure the electrolytic capacitors have discharged to zero voltage, and wear insulating gloves. You can also follow the troubleshooting tree regarding P0A09 and test the wiring harness prior to replacing the inverter, to make sure a broken wire is not the problem.
     
    #5 Patrick Wong, Jul 27, 2015
    Last edited: Jul 27, 2015
    m.wynn likes this.
  6. Eric H

    Eric H New Member

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    Vehicle:
    2007 Prius
    Model:
    N/A
    Thanks for all the fast feedback! Here's the latest.
    • I believe the inverter cooling pump was a recall item. If that is true, then it has been replaced 2-3 years ago (I need to dig through my service records to verify).
    • I picked the car up from the shop, it appears to work fine now (so far). It started right up, no warning lights of any kind, including the exclamation point triangle.
    • Hybrid battery was fairly low, down to last 2 purple bars, but charged up to 2 bars short of full within the 2-3 mile drive home.
    • Checked 12 V battery voltage via the maintenance mode menu, looks normal at ~14 VDC.
    • Drove it out a few more miles to the store later, hybrid battery ran down a few ticks and charged back up a few ticks.
    • Checked 12 V battery with a DVM, 14.1 VDC.
    It seems odd that the inverter would completely conk out, them come back to life and perform normally and not generate any more warnings. I don't trust it enough to drive it the 27 mile trip down to work. Any other suggestions on what to check would be much appreciated.
     
  7. bisco

    bisco cookie crumbler

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    you want to check your 12v with the car off. after a few hours to remove surface charge. it should be 12.5 or better. i like to pop the hood in the evening so i don't activate the electronics by opening the driver door, and check it at the jump point in the morning under the hood.
     
  8. Eric H

    Eric H New Member

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    Checked the battery this morning with car off after it was sitting all night, 12.55 VDC.

    Took a gamble and drove it to work, 27 miles, no problems. Gas mileage was a little on the high side, 55.7 MPG whereas I normally get between 45-50, but traffic was light so conditions were ideal for good mileage.
     
  9. Beachbummm

    Beachbummm Senior Member

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    the prius heals itself, they have gremlins but the good kind...
    I had a flat tire once by the time I got the spare out it was fixed like magic...