Force close air blend door?

Discussion in 'Gen 4 Prius Care, Maintenance and Troubleshooting' started by Jbbnbsmith, Aug 11, 2025 at 7:08 PM.

  1. Jbbnbsmith

    Jbbnbsmith New Member

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    Hi all,

    I have the dreaded error codes 41 and 48 and am getting hot air whenever the internal combustion engine runs, but nice cold AC when I am electric. My Prius is a 2016 and I am trying to find a cheap workaround. I pulled my glove box and I can see that one part of the actuator seems to be working (diverting air to various vents and defrost and recirculation) but the door is stuck open to the engine heat exchanger.

    It seems I should be able to manually close that door, right? I thought I had found the damper that would do it, but it didn't seem to work. Am I even in the right place, or is it farther back behind the cabin filter assembly? I'm not sure exactly where I should be looking for the damper.

    If anyone can point me toward some diagrams or pics that would be great! I've seen complete dash tear out videos and that's a bit beyond my comfort level. But I'm find doing a temporary zip tie to get me through the Summer, and then taking it off in winter. I just need a little guidance.

    Much thanks in advance!
     
  2. Jbbnbsmith

    Jbbnbsmith New Member

    Joined:
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    Location:
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    Vehicle:
    2016 Prius
    Model:
    ----USA----
    Update: Resolved. I used a flat head screw driver to manual turn the gear until the damper was in the closed position. I was able to do this by only removing the glove box. Obviously the actuator is still broken, but now I have my AC back. When the weather get cold I will repeat the process to turn it the other way. Not ideal, but it only takes about five minutes, and I really don't want to pay $1000 or more to replace a $150 actuator.
     
    bisco likes this.
  3. bisco

    bisco cookie crumbler

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    great macguyver, well done!