2005 Prius Died While Driving - Diagnostic Help Needed

Looks like good news. Got the new pump in, reset DTCs and everything looks back to normal. Will do a test drive this weekend to be sure, but looks good.

FWIW here's what I did, based on a combination of sources online. The video from luscious garage was quite helpful as an overview.

1) removed two inverter bracket bolts at front to slide the inverter over a few inches. Removed drivers side bracket from inverter.

2) removed bolt from back of fuse box near firewall to let it move a little to help with clearance.

3) removed 1 bolt and 1 nut securing pump bracket. Removed one bolt from bracket over stud through pump bracket to lift off and out of the way.

4) lifted pump assembly up as far as possible and unplug from wiring if not done already, clamped off both hoses with vise grips. Opened hose clamps with needle nose pliers and pulled back past end of pump inlet/outlets. Used small flat screw drivers to help carefully break seal and pry hoses off.

5) It's tight, but once hoses were off and set aside could maneuver pump assembly out between inverter and fuse box with both having some give.

6) Normally I guess you'd have to remove the bracket from the pump and transfer to the new pump, but mine from Amazon came with a new bracket attached.

7) As recommended in one thread I read, I used a 12V battery and some test leads to briefly spin up the new pump to make sure it's good.

8) Wiggle new pump assembly down in to where you can reconnect the hoses, plug in wiring connector and reset over the stud.

9) work pump bracket in under fuse box leg, replace bracket over stud and replace its bolt, replace nut and bolt that hold pump bracket down.

10) replace inverter bracket and bolts, and bolt at top of fuse box.

11) remove inverter coolant tank cap, top up coolant to make up for loss. Power car to ign on, listen for pump and look down into tank for fluid movement. Replace cap.

12) connect miniVCI and use techstream to read and clear DTCs. I had C0200, C0205, and C1242 related to ABS errors from when the AM2 fuse blew. When first started up ABS, VSC, BRAKE, and (!) warning lights were lit on dash. All cleared after resetting DTCs. If you don't have a means to reset, I believe they will clear after several restarts. Maybe require some driving in between as ABS may not rerun it's diagnostics until you are moving over some low speed?

All said and done it took me about an hour. All nuts bolts were either 10mm or 12mm. A long socket extension helps get at the ones down on the pump bracket in particular.

Rob

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Good to know, thanks! I assumed that would be a pain, but given how tight it is in there I can see now how it's probably faster.




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