Smoke Under Hood Driver Side Near Fuse Box and Inverter - Multi Function Display Flashing 2005 Prius

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by prius2serve, Mar 1, 2017.

  1. prius2serve

    prius2serve New Member

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    I parked my newly acquired 2005 Prius with 275k miles after a 3 hour drive, left the key in it and power on, came back 3 minutes later and smelt something but could not identify the source. I got in the car and saw smoke coming out from under the hood in the area where the fuse box and inverter coolant pump is on the front left drivers side.



    I tried pressing the power button and the dash warning lights, red triangle, all of them, everything beeping, Flashed erratically. I popped the hood, got out with a flash light, and everything looked okay, I couldn't see what melted or caused the smoke. The smell was a strong plastic type of burnt smell.

    After the dash lights settled down there was one interesting light sequence. The the combination meter where the squares that usually indicate the position of the transmission buy lighting around the D, N, or R etc… all light up at once and flash with no other lights. The multi Function display turns on and can be operated to go through the menus.

    It was dark and I had no tools other than a crecent wrench, and screw drivers. I happen to have a friend in the area with a flatbed and he picked us up and got it back to my garage at home; a life saver!
    I plan on inspecting it when I get home today. It was a tough way to break down I’m excited and ready to tear into the car.

    I spent the last night and morning reading other related threads on priuschat.com trying to prepare for the diagnostic and repair of my awesome new Prius.

    Should I pull all fuses and check with ohm meter and look for evidence of burning or melted material?

    Also, in regards to the inverter coolant pump, I am not aware if this Prius ever had the Inverter coolant pump replaced while Toyota was covering it. Is this something to look at? inspect? or identify if it's defective?

    Would an inverter coolant pump smoke?


    As a side but possibly related note. I bought the car a few days ago and the radio did not work. So I replaced the fuse under the hood and it worked for one drive. When I shut the car down and started it up again the radio would not turn on. It might have a short somewhere.

    When I would hit bumps there was a big clunk rattle on the front left driver side in the wheel well or behind it in the engine compartment. The clunk was alarming but let alone that it is the same area where the smoke was coming from.

    One more thing, the horn does not work and I have not looked into it yet.



    Edit to add video Links
    Video 1


    Video 2
     
    #1 prius2serve, Mar 1, 2017
    Last edited: Mar 2, 2017
  2. jerrymildred

    jerrymildred Senior Member

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    Bummer!! Sounds like something loose has rubbed through a wire. It should be visible if you can get your eye on it. But car wiring is often so buried, it's hard to chase down shorts like that. At least there was smoke, so that might give you something obvious if you can spot it. Hopefully no collateral damage.

    Interesting that it smoked. I wonder if they put in an oversized radio fuse and when it blew, you put in the same size not noticing it was wrong. I think that's where I'd look first -- and at that rattle.
     
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  3. prius2serve

    prius2serve New Member

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    Thanks Jerry! Ill check the fuse and start digging in to find it when I get home tonight and report findings.
     
    #3 prius2serve, Mar 1, 2017
    Last edited: Mar 2, 2017
  4. bisco

    bisco cookie crumbler

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    reading the trouble codes might be a good idea as well.
     
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  5. prius2serve

    prius2serve New Member

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    The rattle was the black plastic fender well rattling. I could not find any melted wires last night. I will put my code reader on it today and see if it will give any codes.
     
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  6. prius2serve

    prius2serve New Member

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    Setup Bluetooth ODBII Port scanner with android tablet
    Prius ECU would not connect - figured main fuse blown.
    Started checking fuses manually with meter

    EM2 15amp fuse blown
    Replaced EM2 15amp fuse in engine room main fuse box



    dash lights came back on, power on, multi dash lights on.
    Will not go into gear

    Code Reader connected to Prius ECU - via torque android app.

    Prius threw Codes:
    Active codes:
    P1116
    P1121
    P1123

    Pending codes:
    P1116
    P1121

    [​IMG]

    Googled all codes together and found this info:
    Looked up coolant control valve 16670-21010:
    16670-21010 | eBay
    Got this interesting tidbit on Prius chat:
    2007 Prius P1116 code and coolant control valve issues | PriusChat
    Re: TSB EG001-08- Also, note that the valve, 16670-21010 has an MSRP of $66. A couple gallons of SLLC will cost around $50.

    Subscribed to All Data diy 1 year $29 info service for some documentation quickly (not sure how good it is yet) to get info
    but google did the trick so I have not even logged into the all data ... bummer I spent the money!

    Mike Dimmick said
    Reading the description in the manual, the P1116 code indicates that there is a problem with the coolant tank outlet sensor. Did they try replacing the sensor? Edit oops it looks like they did. Perhaps the wiring is making a bad connection.
    See attached pages.
    P.S. It should not cause any damage to the engine.
    Just to state that this is the 'coolant heat storage tank
    sensor', i.e. the thermos. The sensor is supposed to tell the computer that it's getting hot coolant back from the thermos. The code is logged if there is less than 1 degree Celsius increase after opening the valve, or if the engine coolant sensor reads more than 25 degrees C higher than the thermos outlet temperature sensor.

    If this doesn't happen, chances are pretty good that the sensor has stopped working. It can also indicate that the coolant isn't flowing properly due to a blockage. There are also three other codes relating to this sensor - P1115 indicates an intermittent open circuit or short, P1117 indicates a permanent short circuit, and P1118 indicates open circuit. If the valve doesn't open properly, it should log P1121 (Coolant Flow Control Valve Position Sensor Circuit Stuck). Codes P1120, P1122 and P1123 indicate problems with the valve position sensor.

    http://www.justanswer.com/uploads/skyvisions/2008-05-30_223901_prius.pdf?r=aw|78888|0&awc=7742_1488481092_51d32fe2b95b4642dfe4b10feb5174a3
    P1116
    Got priuschat link check engine light: codes p1116 and p1121 | PriusChat
    Says: p1116 is about the coolant temp sensor, and p1121 is for the coolant flow control valve.
    make sure all the air in the system is bleed

    I pulled the back seat up and part of the trunk panels to access the HV Battery.
    I pulled the Orange HV plug with 100amp fuse out
    and let it sit for 15 minutes.
    Plugged it back in and the car started and went into gear!!!!!.

    I still have not gotten to the bottom of it.
    I have no clear idea where the short is or what caused the short , smoke, or error codes.
    I am going to take it for a drive and will upload the video with details.

    all the yellow/orange lights on the dash.
    [​IMG]


    Update:

    Got Prius on the highway and it drove perfectly with the CEL and other orange lights on the dash. Then 30 miles into it the Red triangle lit up and I re-ran the fault code scanner on the tablet.
    [​IMG]
    A new code came up P0A93 - Which I googled and it says the Inverter coolant pump failed. (the scanner was still showing P1116, P1121, P1123). A few minutes later the other codes disappeared. Now the only code is the P0A93.

    [​IMG]

    The temperature reader was up around 180F and peaked at 195F when I got back home.

    I ordered a Inverter collant pump on eBay .

    [​IMG]

    I hope this is it. I need to figure out if I have a short somewhere or if the underlying cause was the bad pump. .

    I also found the horn that was not working and there was no fuse for the horn. I need to add a fuse and see if it works again.


    Thanks a million!!!!
    D​
     
    #6 prius2serve, Mar 2, 2017
    Last edited: Mar 2, 2017
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  7. jerrymildred

    jerrymildred Senior Member

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    Sounds like you're making headway.
     
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  8. prius2serve

    prius2serve New Member

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    Yes, it's coming along! I am now waiting for the inverter pump to arrive in the mail anytime before the 7th of March.
    I also have to look into the radio and the horn.
    In the mean time I might leisurely start the process of removing the headlight to get to the bad pump so when the new one arrives I can simply disconnect it and replace it with the new one and button everything back up quickly.
     
  9. m.wynn

    m.wynn Senior Member

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    Good chance the smoke was simply from the bad pump's motor cooking. The location is right, so as long as the smoke didn't come from within the inverter, you should be good. You're not getting P0A94, so I'd guess your inverter is fine. If you're not going to drain and fill the inverter loop at the same time, I'd top it off (just to the full line) and bleed by running a piece of vinyl tubing from the bleeder back into the reservoir. Then ready the car for several minutes until the gurgling noises quiet and the pump runs smooth. Final top off to the full line and you're done. Lots of demos on how to do this around here. And the pump you ordered is the correct one.

    Regarding your P11XX codes, P1121 is the one - you need to replace the 3-way coolant valve, especially since you have Cali emissions testing. The valve malfunctioning is not a performance issue other than occasional lack of cabin heat, so a Prius owner in a state without emissions testing and/or cold weather could ignore it indefinitely. Once the valve is replaced and the engine coolant loop properly bled, the P1116 and 23 will normally go away, too. Again, there are some excellent tutorials here. Getting the engine coolant loop filled and bled properly is tedious but not difficult. It just takes some time.

    A positive of both of these issues is that it's a great opportunity to get both coolant loops changed out and not have to think about them again for 50(inverter) and 100k(engine) miles.
     
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  10. RRxing

    RRxing Senior Member

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    Good troubleshooting - Keep us informed on your progress.

    P.S. - You should look into getting your windshield replaced at some point ;)
     
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  11. prius2serve

    prius2serve New Member

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    Hey RRxing, thanks for bringing that up. as aside, I priced it out with one auto glass guy and he mentioned $220 for a sound insulated windshield that has some sort of acoustic layer in the glass and $180 for a standard loud windshield.
    Does anybody know the difference between the 2 windshield types?
     
  12. prius2serve

    prius2serve New Member

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    The subscription to AllDataDIY.com is paying off. I found a out the bulletin for the hybrid water pumps turned into a Safety Recall, SC-COU
    SC-C0U 01/15/2013 Recall - Hybrid Electric Water Pump Replacement
    Toyota_SC-COU_Hybrid_Water_Pump_191297511.jpeg

    I am going now to check my vin and see if it is eligible.


    Question:

    Safety recalls don't expire until work is complete because it's a federal traffic safety board law regulation right??? Does anyone know the details on this so I can be armed with the correct information if I go to the dealer for this.

    (I already ordered the part and can easily perform the repair but I might just call the dealer Monday and see if they can fit me in and get it done. I'd shave a few days off downtime for the pruis since the part is not due to arrive until Monday at the earliest and Wednesday at the latest. )



    Thanks
     
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  13. prius2serve

    prius2serve New Member

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    Wow M.Wynn, Thank You!!!

    Really solid perspective and advice I can count on.
    You explained it in a way that resolved the uncertainty for me in regards to this issue.
    Sincerely, Thanks.

    I'm now going to go order the 3 way coolant valve and will update.

    :)
     
    #13 prius2serve, Mar 4, 2017
    Last edited: Mar 4, 2017
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  14. m.wynn

    m.wynn Senior Member

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    I feel pretty ridiculous that I never thought of the C0U when considering your issue! It seems like pretty much every Gen 2 in the U.S. is eligible or has had it performed. I'll be very surprised if yours isn't covered.

    Also, the 3-way valve is one of the most common Gen 2 mechanical issues. I did our family '07 myself a few years back. In the vast majority of cases, the owner seems to be on the hook for the repair. However, there have been a few reported cases of strictly Cali residents getting theirs done under their 10/150 hybrid warranty. Not sure why this has been just a Cali thing when states like NY seem to be on a very similar CARB program. Anyway, it's not an isolated failure part. Toyota sells scores of them.
     
    #14 m.wynn, Mar 4, 2017
    Last edited: Mar 5, 2017
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  15. RRxing

    RRxing Senior Member

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    I don't know by how much the acoustic layer in the windshield reduces interior noise, but for that small of a price difference, go with the sound insulated.
     
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  16. prius2serve

    prius2serve New Member

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    My hybrid water pump came in the mail And I installed it.

    I drove it for an hour or so and the code went away.
    Now after 1/2 a day of driving the computer says it failed again!!!!'

    Red triangle and everything!


    What can it be?

    The coolant temp is 186degrees farengeight
     
  17. m.wynn

    m.wynn Senior Member

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    P0A93 again?... If so, I'd guess you didn't get the inverter loop bled well enough. Did you run a plastic hose from the bleed valve in front of the inverter into the the reservoir while you idled the car in ready mode? You need to do this for several minutes until you see no more air bubbles in the hose and the pump is running pretty much silently. This guy does a good job showing the procedure starting at around 11 minutes:



    Also, I think the coolant temp reading you're showing is for the engine loop and not the inverter. I don't believe there is a coolant sensor in the inverter loop. There are temp sensors in both the inverter and transaxle (5 total, I think...) but none monitors coolant. If any of this is bogus, someone will correct me but I'm pretty sure I'm remembering all this correctly. I'm also assuming you understand the engine coolant and inverter coolant loops are two completely separate, sealed loops.
     
    #17 m.wynn, Mar 9, 2017
    Last edited: Mar 10, 2017
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  18. prius2serve

    prius2serve New Member

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    I got it all fixed thanks to the great help and support of the Prius chat forum members!!!!

    I decided to tear it all down again because I was replacing the coolant control valve. Upon inspection (It takes a lot to admit this) I found that the Inverter coolant pump was not fully plugged in.

    I replaced the Coolant Control Valve and plugged in the Inverter pump and put everything back together. It worked perfectly. I have not had any temp or check engine issue since!!!
    Thanks Again,

    IMG_6932.jpg IMG_6927.jpg IMG_6933.jpg

    IMG_6932.jpg

    IMG_6927.jpg

    IMG_6933.jpg
     
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  19. SFO

    SFO Senior Member

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    Curious if you were eligible for this C0U recall or not?
     
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