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3 error codes after head gasket job

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by YellowBlue, Dec 12, 2023.

  1. YellowBlue

    YellowBlue New Member

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    Hi all,
    Getting P0301, P0403 and P0352 after head gasket job, hybrid system failure message and it does not start at all.
    Gasket job was not done professionally, but carefully, with youtube videos.
    It was leaking coolant into cylinder 1, but the engine was working smoothly when cold prior to disassembly.
    So I doubt there is anything wrong with rods, etc.
    Replaced oil pan, there was no metal in there - all clean.
    Disassembled, and re-surfaced head using sand paper on glass surface, after watching tons of youtube videos.
    Cleaned injectors, intake manifold, pipes.
    Cleaned EGR/EGR cooler, replaced all gaskets.
    Installed new spark plugs (checked all spacing, etc) and new coils.
    Reinstalled chain properly, but after cranking the engine when I was trying to tighten the harmonic balancer - chain marks went out of sync with marks on gears. (btw i ended just tightening the balancer with milwaukee M18) +I googled, chain going out of sync on makrs appeared to be expected after rotation. I sealed the valve cover and re-assembled all. connected hybrid orange plug+battery. Shows hybrid system fail, and does not even crank. No 'ready' light.
    Potential problems - please see if I'm right or wrong:
    a) maybe I did not re-surface head enough? there were no low points though after long...long sanding...
    b) should i be closing the coolant reservour cover to pressurize it? i tried starting without the cap, to bleed it...
    c) could EGR just not be on tight somewhere, leaking air?
    d) could there be a timing chain tensioner not firing back into correct spot?(i did pre-tension it prior to inserting) should i just drain oil and disassemble it all again?
    e)could there be a general air leak if i sealed something incorrectly between head/valve cover, top...
    f) could there be some kind of fuse problem?
    Thank you all...any advice would be very appreciated!
     
    #1 YellowBlue, Dec 12, 2023
    Last edited: Dec 12, 2023
  2. YellowBlue

    YellowBlue New Member

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    (forgot to say, i also changed PCV valve, but did not change water pump - it spins fine)
    also correction: the message is 'CHECK HYBRID SYSTEM", I misspoke above. Thanks
     
  3. ASRDogman

    ASRDogman Senior Member

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    Does it turn the engne over and try to start?
    Did you disconnect the 12v battery for a minute or two to clear the codes?

    I doubt it is something machanical with the engine. Are you sure you reconnected everything?
    Double check all the connections. It's easy to miss a connector or not plug it in all the way.
    Check for damages wires...
     
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  4. The Critic

    The Critic Resident Critic

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    All ground cables connected?

    Did you get any coolant in the HV connector on the compressor?

    How long did the vehicle sit for? Possible high voltage battery is too discharged? These cars are getting old and the HV battery can be toast if it is allowed to sit for months.
     
  5. bdc101

    bdc101 Member

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    It's not a mechanical problem... check all electrical connectors that you touched. Get under the car and check the back of the motor too. But most of all... check the orange disconnect connector on the battery. Make sure that not only is the lever rotated back all the way, but that you push it in after you rotate it all the way. (I say this because I made this mistake and it took me a couple hours to figure out, like a moron)
     
  6. Mr. F

    Mr. F Active Member

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    P0301:
    Were the spark plugs sourced from a dealer, auto parts store, or directly from Denso? If not, they may be counterfeits and causing misfires. Swap the plug from cylinder 1 with other cylinders and see if the code moves with the plug.

    P0352:
    Coils should be from Denso or a dealer only, no aftermarket replacements from auto parts stores. The code could be indicating a bad coil on cylinder 2, try swapping the coil to cylinder X and seeing if you now also get P035X (where X is either 1, 3, or 4).

    P0403:
    EGR valve connector not pushed in all the way.

    These are just the simplest explanations based on the work that has been described as done. There are other things that could be wrong (gnawed wiring, faulty ECM, etc.), but are less likely. I highly recommend using Techstream for diagnosis.
     
    #6 Mr. F, Dec 12, 2023
    Last edited by a moderator: Dec 13, 2023
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  7. Tombukt2

    Tombukt2 Senior Member

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    If you don't have a ready light that's what you're working with. I doubt there's any mechanical issues you haven't even gotten it to tell you if there's any mechanical issues because the engine hasn't even attempted to start as it's not gotten to ready until that happens nothing's going to happen so when you sit in the car push the brake and hit the button what do you hear do you hear the relays in the back click on the battery The HV battery we're talking about The big clunk clunk click? No hmm maybe check the plug and make sure that it's seated like mentioned above and even better than that maybe take a reading of the HV battery or connect the capable scan tool and it might tell you the base voltage of the battery Dr Prius will for instance. We don't discuss here how long the car sat or was out of service original hybrid battery or? These things are important We did this with a Gen 3 persona and it was down for a few months and then had almost these exact same problems trying to get it to restart.
     
  8. Tombukt2

    Tombukt2 Senior Member

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    And just to be clear in the 13 persona we have fake all kinds of stuff not spark plugs but coils are not original so on and so forth and have had no problems engine running smooth as glass no issues at all with that. So I wouldn't worry too much about fake coils and not original inverter pumps and all that sort of thing they'll work long enough for you to find out that they're no good and you need to do something else been there done that here too.
     
  9. YellowBlue

    YellowBlue New Member

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    Thank you for your response! It sat for 2 months. I had trickle charge on it so battery is good and it lit up with error lights when i tried to start:) But maybe it could be a hybrid battery discharged?
    Also, I taped the HV connector with electrical tape prior to disconnecting pump hoses. (and i drained the coolant prior to all work anyhow).

    The engine does not do anything whatsoever - silent. Does not turn or anything.
    but i do hear that electrical sound as it powers something as prius usually does when you approach it with key in pocket. ((unless it is done by 12V battery and not hybrid one). Maybe it is hybrid battery that sat for 2 months with no charge?
    well...i will check - thank you!

    hmm...i just inserted the orange connector all the way and rotated the handle. so...it might be the hybrid battery???? oh boy...it is a revelation then...i did not know there is an extra 'push' there. will try next week and report (away for a week) THANK YOU

    disconnected 12V and reconnected a few times - codes re-appear. someone above already suggested that the orange connector of hybrid battery might be the issue - so i inserted and rotated the handle. but they sayd there may need to be another push...will try that next week when i get back to it.
    The engine doesn't even start..no 'ready' light, pumping gas pedal ields nothing.
    but i do hear that electrical sound as it powers something as prius usually does when you approach it with key in pocket. ((unless it is done by 12V battery and not hybrid one)

    I do hear that usual sound when relay does something once you approach the car with key in pocked, and then i hear that electrical sound when pressing the brake. But no 'ready' light....
    So the hybrid battery could discharge in 2 months? that is weird, because i used to travel far, prius used to sit 3,4 even 6 months. - and then only 12V battery was discharging....always could start it again.
    maybe it is the orange plug or something with it - will check, and will re-check all plugs again. Or maybe a fuse....

    Interesting suggestions.
    All was purchased from amazon, not original, but with thousands of good reviews ( i believe people...)
    good idea to swap - thank you!! will try. would the engine at least try to crank though, if it was just spark plugs or coils? would it at least display 'ready'? it does not do any of that...
    btw my codes are P0301, P0403 and P0352.
    I did not have 304, but 352 is something about EGR too i think.
     
    #9 YellowBlue, Dec 12, 2023
    Last edited by a moderator: Dec 13, 2023
  10. YellowBlue

    YellowBlue New Member

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    I'm using a cheap 17 dollar scanner one from amazon, (autel ms300). it has the option to erase, but the codes re-appear after erasing, and after disconnecting and reconnecting the 12V battery and orange plug of hybrid battery again and again.
     
  11. YellowBlue

    YellowBlue New Member

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    i checked the orange plug. So it is constructed in a way that when you swing back the lever, it pushes and locks it kinda. I can't push it in further. So maybe your plug was different, or maybe this is not the issue then...Thank you for suggesting though!
     
  12. Mr. F

    Mr. F Active Member

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    The service plug on your vehicle should not be any different than that on another Gen 3 Prius. Check the linked short for the correct removal and installation.
     
  13. Brian1954

    Brian1954 Active Member

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    What scan tool are you using to read the trouble codes?

    Are the three trouble codes listed as current, pending, or history?

    I am assuming that you had the 12v battery disconnected, so that would have reset (cleared) any "old" trouble codes from the ECUs. What I do not understand is how you can get a P0301 trouble code if you can not even crank over the engine.
     
  14. YellowBlue

    YellowBlue New Member

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    Mr. F - THANK YOU - this actually did it! the push was to the right, and i mistakenly thought that it had to be pushed inside further (and wasnt able to, of course)Once I locked it properly, the car started! Thank you so much, and have a good holiday season!!!!
     
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  15. YellowBlue

    YellowBlue New Member

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    Hi all, wanted to say that the folks who suggested electrical problem, and especially the folks who suggested checking the hybrid orange plug - were right! The car started once i latched the orange plug properly (push and then push to the right).
    So...the codes remain, but i assume my scanner isnt able to delete history. The car works perfectly, drives perfectly, does not feel like there are any misfires or egr problems. THANK YOU ALL
     
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  16. bdc101

    bdc101 Member

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    Wow, I learned that lesson the hard way too. Glad it was such an easy fix!!
     
  17. ASRDogman

    ASRDogman Senior Member

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    Glad you got it going!
    If you disconnect the 12v battery for a minute or two, it will clear codes.
    Though you might want to get a reader that CAN clear the codes.