2012 gen 3 head gasket repair. P0016 and cannot clear "check hybrid system. Maintenance required"

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Louhazosc, Jul 17, 2025 at 10:29 PM.

  1. Louhazosc

    Louhazosc New Member

    Joined:
    May 17, 2025
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    Location:
    Maine, USA
    Vehicle:
    2012 Prius
    Model:
    One
    Hey guys,

    Did a head gasket repair. Everything went fine except the one thing I didn't like was every time I'd go to put the tensioner in, it would release before being seated. After a few attempts and pressure i got the bolts on but it was fully released.

    I had the engine set to top dead center, timing marks lined up etc.

    Did a hard reset disconnecting the battery and orange plug. Wife drove it today for 60 miles with no issue. then got a P0016 code - cam and crankshaft not aligned. So I replaced both the cam and crankshaft sensor cause I did hit the valve cover with some brake fluid. Also cleaned the MAF sensor while I was there.

    Now we have nothing. It continues to say "check hybrid system. Maintenance required" Did another hard reset. Battery disconnected, plug out. No good. It actually rattled for a few seconds and immediately shut down. No idea what the rough rattle was.

    So....do I go back in and start over? I really just don't wanna take all that apart and see the timing chain is just fine. Lot of work but I will. Can't think of anything else.

    Also had an issue with our fixd code reader so wasn't able to clear the p0016.

    Im lost at this point

    extra info: 200k miles. Car was sitting for 7 months. New tank of gas. head was machined and cleaned and valves resurfaced. New water pump, thermostat, timing chain, tensioner (but released as stated), cleaned egr, air intakes, new orings...all the things you do on a head gasket.