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2nd DIY Inverter coolant pump replacement: No inverter touched

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by rrg, Apr 7, 2019.

  1. rrg

    rrg Active Member

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    This is for my Gen 3 2011.

    Before I write the short and easy way I did this, I need help.

    Can some one confirm where the two hoses from the reservoir (Top and Bottom) go to???

    I need that for the write up as well.

    There is a long one that wraps around to the front and short one that attaches to the inverter.
    I got them mixed up in my original attempt to do this.

    I can not find clear pictures anywhere on-line.
    Thank you so much in advance.
     
  2. AzWxGuy

    AzWxGuy Weather Guy

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    The top hose on the reservoir goes to the right side (facing) port on the inverter and the bottom hose follows beneath this path around the lower front of the inverter and plugs into the top port on the pump. I always try to leave one end of a hose connected or take good pictures beforehand.

    Two pump replacements?! Just bad luck or recycled vs. OEM new?
     
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  3. Raytheeagle

    Raytheeagle Senior Member

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    The bottom hose goes directly into the suction of the pump and the upper hose is the return from the inverter.

    Second pump already:whistle:?

    Just replaced the inverter water pump on our 2010 Friday as preventative maintenance :).

    So I’m familiar with the job;).

    Good luck and keep us posted (y).
     
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  4. NutzAboutBolts

    NutzAboutBolts Senior Member

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    Damn already replaced yours? I’m still running on my original lol and it’s close to 190k miles. I’m gonna wait till they throw a code before I change mine.
     
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  5. Raytheeagle

    Raytheeagle Senior Member

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    From what I can tell, you should be fine in that line of logic;).

    Tore the pump apart yesterday and here are some pics:
    F861FBDA-2A30-4198-B087-03AF7764669A.jpeg E4D5D81B-1902-4E09-8C17-A77D6C3407FE.jpeg 33D5F040-40A1-451A-87E0-550AC0974973.jpeg 3DB2E082-EDAF-4566-B766-0BA73A1AB644.jpeg 4EA8303B-5E06-4B69-ABBC-0B19BEF0A8AD.jpeg 1689DE66-AEA3-4DED-A97A-86B8EC105080.jpeg 8C80663E-D2CD-43DC-AB1F-34CDD37BEA77.jpeg 791F42C2-8E97-4D84-8BA1-F253C5D5AC6E.jpeg

    This pump impeller is more robust on the fins than the engine water pump and I did not note any resistance on the magnetically driven impeller like that of the engine water pump:).

    But the fuel pump that we preventatively replaced at the same had the suction filter full of dirt / debris:

    074F5C47-1482-44E9-B513-95ABEBD8C16B.jpeg 52CD6FDB-A096-42FF-B49A-4BDFF3F8277C.jpeg

    So that would be one I would consider doing;).

    But @The Critic and I are not videographers so no videos from us:(.

    Maybe something you’ll do in the future (y).
     
  6. rrg

    rrg Active Member

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    NOTE: THE DIY - PROCEDURE I PROMISED Part 1:

    This procedure takes the removal of six 10mm screws and two hoses. The plastic clips from the shield don't count in my book.

    I live in the very salty environment as you can see by the rust. I have 155K but the cold and rust have done a number on my pump.

    I got the P0A93 code and POC73 code on my scan guage. (NOTE: The problem that cuased these codes is the coolant all leaked out.)

    The car showed a danger triangle and it said OVER HEAT. Next while still running the car went into limp mode. The gas peddle was not fully responsive. I would press it but it would not move faster. The car ran but not very good and the mph on the dash did not feel like it was the correct speed. Very strange feeling. The dash image where the car battery and electric motor and arrows showing energy flow STOPPED working. No regenerative No engine moving arrows. The car did keep running.

    Got to work and saw no coolant in the reservoir. Bone dry.

    Next I chose to replace the pump and rusted spring clips on most hoses.

    Remove the under car shield look up and remove the connector. I used a screwdriver to push the connector and press the tab with the other hand. Here I show the connector that you need to press remove but you can't see the TAB from the bottom. Small hands will help. (no jokes from the peanut gallery please.)
    Here is the @#$%% of a connect that is hard to remove.

    pump2.JPG

    Look at the next picture to see the tight spot from below.
    If you get the connector off you can move on to do the rest.
    Next, losen but do not remove the two 10mm screws in the red circles. See image.
    That is because you also want to loosen the top third screw in yellow from above or you will have a tough time getting traction to turn the screw from above.

    pump1.JPG
    Move to the top next.
    We remove 3 inverter hold down screws to make room to reach the 3rd top pump screw with a socket.
    We only move the inverter back to use a long extension socket with a 10mm,
    Move/push it 2 inches back toward the coolant tank. I used a piece of wood 2" wide.
    pump3.JPG pump4.JPG pump5.JPG

    Go back to the bottom after you loosen the top pump screw.

    Now get ready to remove the two bottom screws but be ready to catch a bracket that holds the 2 threaded nuts together. Here it is removed.
    1bracket.JPG

    Be ready to catch the bracket that is attached to these screws.
     
    #6 rrg, Apr 8, 2019
    Last edited: Apr 8, 2019
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  7. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    If you've got the room, tip of a knife blade right here and pry out often works:

    upload_2019-4-8_16-35-26.png
     
  8. rrg

    rrg Active Member

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    Part 2:
    Ok now remove the bottom hose of the Coolant Reservoir, it's the long one that wraps around to the front of the inverter down to the pump.

    HERE IS THE TRICK,
    Bend the corner of the bracket to make room to move the pump past the radiator hose. Here is a picture of it bent.
    pumpbend.JPG

    Now just pull the pump out and it will hang under the car like this with one side of the hoses disconnected,
    hang1.JPG
    Follow the exact postion of the hoses when you connect the new pump. There are paint marks on the hoses.
    Old and new pump ready for swap.
    1oldnew.JPG

    Next reverse all steps.
    I filled the coolant and drove the car. So far that is all I have done and I hear the noise again from the car when the ICE shuts down. Little gurggling and high pitch noise. YAY

    6 screws and two hoses. That is it. Thank goodness no inverter wires were disconnected or harmed during this operation.

    Oh yea, special Thank You to AzWxGuy who gave me the correct hose location that I messed up.
     
    #8 rrg, Apr 8, 2019
    Last edited: Apr 8, 2019
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  9. NutzAboutBolts

    NutzAboutBolts Senior Member

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    Good to know, the fuel pump will be a possible in the future when we replace it. I’ll let you know :)
     
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  10. Raytheeagle

    Raytheeagle Senior Member

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    I’m willing to stop by for moral support;).

    Just let me know the random meeting time and location:).

    I’ll be there (y).
     
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  11. Raytheeagle

    Raytheeagle Senior Member

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    When @The Critic and I did this on Friday, we had a devil of a time with the bracket and the inverter pushed out of the way:(.

    Not sure how you do this without the inverter shoved off to the side :cool:.

    But always willing to learn(y).
     
  12. NutzAboutBolts

    NutzAboutBolts Senior Member

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    Lol
     
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  13. The Critic

    The Critic Resident Critic

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    How did you manage to get the pump bolted back into place? As it is, it is difficult to thread the bolts thru the main bracket and onto the secondary bracket with the nuts. Returning (bending) the main bracket into just the right shape must have been tricky.
     
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  14. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    Cancer be damned, there is something wrong with this picture:

    upload_2019-4-10_14-17-1.png
     
  15. Peter123

    Peter123 Active Member

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    Where is the fuel pump? On the gas tank?
    If they plug up over time, they will need replacing.
    That sounds like a future @NutzAboutBolts Video.
     
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  16. Raytheeagle

    Raytheeagle Senior Member

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    The fuel pump is in the gas tank;).

    So the car smells a bit once the pump is extracted :eek:.

    But based on the suction filter, it was worth the effort (y).
     
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  17. rrg

    rrg Active Member

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    From the bottom of the car looking up I used one hand to hold down, postion the bracket for the screw and a second hand to start and thread by hand to get the bolt started. Very tight spot, I know.
     
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