Toyota Prius hybrid heater repair
After a minor accident and subsequent auto body repair the heater was no longer working in the cabin. The heater did not work when the engine was turned off. The heater on this car is organized as follows.
While the gasoline engine is running, the antifreeze is circulating through the engine mechanical pump. When the engine is shut off, and the car runs on electric power. The electric pump turns on and pumps the antifreeze into the radiator. On the test vehicle, the owner complained that it freezes. And when the gasoline engine was running, it was warm inside, but when I turned off the engine, the warm air was quickly cooled down. It was clear that the electric pump was not working.
The operation of the electric pump is controlled by the electronic control unit of the internal combustion engine. At the right moment it switches a relay which starts the electric pump. It was necessary to check the entire circuit. The developers put the ability to activate the electric pump when scanning the climate control system. this is the fastest way to check the circuit. But the test was inconclusive. The pump didn’t turn on, the relay didn’t turn on either. The test only confirmed that the electric pump was not working. We were not able to localize the problem immediately. Electric pump control diagrams are very different for different Japanese, European and American markets. For Japanese domestic market control circuit doesn’t even have a protection system (no fuse in the circuit).Electric pump is switched by a low current relay (winding resistance R300 Ohm, control current 30 mA), which is integrated into the relay and is installed in a fuse box in the engine compartment. Where is the control relay installed, I did not know at that time. So first remove the wipers and get to the pump. The pump turned out to be working. So no control. Using wires I figured out where the relay was installed. When dismantling the relay unit, the problem was revealed quite unexpectedly. Electric pump control relay coil was sawed with a hacksaw! Why, during the body repair, sawed the relay. Was only left to guess.
I could only find the relay from a donor. To find an analogue is problematic. Ordering takes 2-3 weeks. And the regular relay from Toyota has significant differences in characteristics. Install temporarily relay is not possible. But the owner quickly enough found the parts and after replacement got the long-awaited heat. This is how after repairing “bodywork” car owners get additional problems. But this is the reality of Russian repairs.Have a nice repair. Vladimir Bekrenev d. Khabarovsk.
Only registered users can add Комментарии и мнения владельцев.You have no rights to leave Комментарии и мнения владельцев.
Briefly about Prius cooling systems
The following cooling system parameters should be monitored while operating your Toyota Prius:
- the level of antifreeze in the expansion tank, according to the marked lower and upper limit;
- Matching the extreme freezing point of the antifreeze to the current climate conditions;
- Coolant circulation in the electric draw circuit.
Under the hood of the Toyota Prius 30 Accent on the cooling system of the hybrid, due to the risk of failure of the inverter responsible for converting the DC to AC, with subsequent powering of the electric motor. In the process of operation it is found that the cooling pump of hybrid system of Toyota Prius 20 serves about one hundred thousand kilometers. If this element fails, heat dissipation is lost and as a result the inverter fails.
The first replacement of antifreeze in Prius XW20, according to the official recommendations on maintenance, is done at 150,000 km of run, further on with the frequency of 80,000 km.
The factory coolant used is a pink Super Long Life Coolant. It is allowed to mix it with other types of antifreeze only to get to the service station where it will be completely replaced.
Changing the antifreeze in Toyota Prius
Toyota Prius coolant volume:
In circuit with internal combustion engine: 5.5 liters for left-hand-drive models and 5.3L. with the right one;
Electric motor cooling system. 2.7 л;
If you have a Thermos in your Prius, you’ll need an extra two liters.
Hybrid Vehicle Repair and Maintenance Techniques. Sergey Gordeev’s school. Lesson 19
Last lesson we ended with, “The cause of bloated elements and failed components is often a clogged or faulty BBQ cooling fan. Accordingly, it requires special attention. Located in the rear left fender of the vehicle. You can check the efficiency of the fan with the scanner in the mode of active tests of actuators”.
A functioning electric motor is not an indication that the cooling system is in good working order. It is necessary to estimate a degree of a contamination of an impeller of the fan. There is no need to disassemble anything to check the impeller when repairing the BBP because the duct will already be removed. The fan can be viewed with the naked eye.
If there are any deposits on the impeller it must be cleaned. If when you check the fan itself not all speeds turn on it means that there is a problem with the transistor that controls rotation speed.
Selecting the rotation speed of the air intake cooling fan Air intake cooling fan
In fact, this is a very uncommon problem. Most of the time they just forget to connect it. The transistor itself is located in the BBQ cooling duct. The wiring harness connector is blocking the transistor connector, so it is not plugged in.
Here are the basic details. What to do after the BB is installed in the car?
Reinstall the breaker and put the terminal on the auxiliary battery. Connect the scan tool and turn on the ignition. If everything is assembled correctly. there shouldn’t be any malfunction icons on the panel and monitor (unlike Prius 10). There is no need to initialize the high-voltage battery control unit because it has already been done (by resetting the power from the HV control unit). To check this, let’s go into the date of the control unit of the BBU and check the value of Delta SOC. If you see 20%, you can go to equalization. It can’t be less than 20%. If it is still greater than 20%, the repair of the VVB is not done correctly.
The transistor responsible for controlling the rotation speed of the BBB fan The location of the transistor connector
It’s worth noting that the “initialization” item from the BB control unit firmware is not deleted, but quite active. It means you can reset the Delta SOC value without leaving the car. For this reason it is enough to turn off ignition for 30 seconds. The process is simple enough, so let’s not dwell on it.
How to start the equalization process? To do this, select “Onboard equalizing charge” directly in the main menu of the battery control unit. In the window that opens we see the name of the chosen procedure and its purpose. charging of rechargeable batteries for leveling the cells.
Press “Enter” and go to the next window, which lists the conditions under which the process can start successfully. There are five in total.
The car is on (READY inscription on the instrument panel is on).
The gearbox position lever is set in park mode.
Temperature of the BBB elements ranges from 10 to 45 ° C above zero.
The difference between the readings of the temperature sensors of the cells should not be more than 2 degrees. This is the case when it is not possible to start equalization because the temperature sensor on the element is not fixed.
Check if all the listed conditions are fulfilled and press “Next”. In the next window we will see a short instruction. It informs that the equalization process is about to start. It can take up to 30 minutes. When the equalization process is complete, the gasoline engine will stop and the energy flows on the monitor from the engine to the BB will stop. After that you need to turn the car off and leave it with the ignition on for about 10 minutes to cool the BB.
Initialization and equalization selection menu The first window when starting the equalization
Then press Next and you will see the message that the procedure was successful. The first sign that equalization is on will be the BB cooling fan running at maximum speed regardless of the temperature sensors readings. The second sign is that the charging does not stop (charging is not switched off) of the BVB even at 75% of the charge level.
After ending of equalization the engine will really stop (if air conditioner is not on). Then according to the manual we have to switch off the car and switch on ignition. I do not recommend this because as long as the vehicle is not switched off the battery cooling fan keeps on full blast despite the end of the equalization process. As soon as we turn the ignition off and on, the fan speed will again be linked to the temperature sensors readings. In hot summer weather, the temperature of the elements can increase significantly. In that case it’s better to close all windows and doors right in the process of equalization and run the air conditioning system at maximum power.
After completing the equalization, leave the car to work until the temperature of the cells drops to 45 ° C. In this case, cooling is more effective and allows you to test our work in motion. If the temperature of the cells will be more than 50 ° C, it makes no sense to check on the run. the output power of the high-voltage battery will be limited and we will not see a real picture of the state of the cells under load.
Equalization Start Conditions Equalization Instructions
ТОЙОТА ПРИУС 20 | КАК СОХРАНИТЬ БАТАРЕЮ НА ПРИУСЕ | КАК ПРАВИЛЬНО ИСПОЛЬЗОВАТЬ ВВБ 5 ПРОСТЫХ ПРАВИЛ
Do not forget that the process can be quite long. The combustion engine will be running under load. And so you need to be sure of three things: first, the engine cooling system is serviceable. So, the fans turn on at the right moment and cool the radiator; the coolant level is normal; the pump works.
Secondly, the amount of fuel in the tank will allow the vehicle to run for a long time without stopping the fuel supply. It often happens that customers arrive with the low fuel light on.
Third, the exhaust hood is connected and the room is ventilated, or the car is outside. After cooling the cells to 45 ° C, turn off the car. Turn it on again and go to the test.
Now let’s look at the high-voltage battery installed in a Toyota Estima body 10. The battery is located just under the third row of seats. It is covered from above by a big metal cover and cladding, so it is quite difficult to guess that there is a battery there.
The disconnect switch is on the back left side of the BB. (Design, principle of operation. everything is like a Prius body 11, in case anyone has forgotten the previous lesson.) In order to take out the opener without dismantling the car interior, in the metal housing is made a technological opening covered with a rubber curtain. To find it, you need to open the trunk door, pull out the trunk floor hiding the tool kit and jack, pull out the left backing. Behind the left liner, next to the warning sticker, there is a curtain that hides the circuit breaker.
Battery location in Estima Battery disconnector behind the curtain
To the right of the disconnect switch is the same connector with a plug to connect the BB charger.
There are air vents under the third row of seats towards the front of the car to cool the battery. In any case they should not be covered with anything. Unfortunately, not all car owners are aware of this.
Exactly from these grates we continue the disassembling of the car interior in order to dismantle the BB. They are fastened only with clips and cover the bolts fixing the back sofa. Having disassembled grids we unscrew the seat of the third row and move it forward along the salon, having preliminarily moved the second row of seats up to the stop forward. It is not necessary to remove the back sofa from the passenger compartment.
Charging connector Ventilation grilles Folded rear couch Removing the cover
Further we unscrew plastic plugs, hiding under there brackets for rear seat fastening. We remove rear seat passengers’ legs blowing grates (if it has a rear heater). Then pull the carpet out from under the side panels and pull it back. Clips of fastening to the casing can be not removed.
Then unscrew all bolts fixing the metal cover in a circle. Using the release, remove the two orange clips and pull the cover out of the car.
Note that the bolts securing the shell and the third row of seats go straight out into the street. Which means they are constantly corroding. To avoid damaging the threads, be sure to use a lubricant when installing the bolts in place. This will save you time or time of another technician when disassembling the HVB.
You should also pay attention to the upper brackets, to which is bolted the metal cover. You will often see cracks where the brackets are attached to the body, and water from the wheel arches can get into them. They may need to be sealed.
Toyota Prius 20 fuses and relays
Toyota Prius 20 represents the 2nd generation of the Toyota Prius range produced in 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010. The model has been restyled in the meantime. In this publication you will find information about location of electronic control units, fuses and relays of Toyota Prius 20 with diagrams and their locations. Note the cigarette lighter fuse.
This car was shipped all over the world, there are models with both left and right hand steering. Therefore, the execution of the blocks and the purpose of the elements in them may be different from that presented. Match the schematics with your own, which are stamped on the cover of the unit.
Cleaning the Prius HVB fan
Hi all.Read here about battery maintenance, the copper terminals have not yet reached, but to clean the fan was easy to do, just disassemble the right rear, 2 screws and a lot of pistons.
I took off the fan by disconnecting 2 plugs, unscrewed 3 bolts and it was in my hands,
Opened the case hit it with a screwdriver and that’s what came out of it.
When reassembling saw the cracked from old age noise, decided to freshen it up a bit, heated it up with a hair dryer and added a couple of sheets.
Reassembled in reverse order, they say that this procedure prolongs the life of the batteries, and eliminates unpleasant odors.
Yes, even in my car was not working back camera, there was already a Chinese from the time it just oxidized
Of course we throw it away and buy another Chinese one for 1000 rubles. 20 minutes and it works.
Yes, more things came from the Chinese, this cover on the key. it looks chic and nice to hold in your hand.
Replaced the tail light bulbs on diodes.T20 base
By the way after the replacement of the plugs fuel consumption has decreased by half a liter and the car starts and stops more softly.
Cleaning the intake fan of a Prius 20
Bad smell in the car or search for a dead rat
Today our Hybrid Service guest Yevgeny from Yekaterinburg drove a silver Prius with 20 body.
And came with a rather interesting and unusual request: “Help me find a dead rat in my car!”.
To our open mouths in amazement, he explained that he parks his car next to the garbage cans. There are a lot of rats living and eating in those bins. In the cold season they, “having eaten”, go to sleep under the hoods of nearby cars on warm engines. Traces of their life can be seen under the hood almost every morning.
And then one day there was a bad smell in the car. Gradually, the smell got stronger and more unpleasant. It got to the point where Eugene’s wife refused to get in the car one fine morning, saying that everyone at work was looking at her askance because there was a very unpleasant smell coming from her outer clothing.
Eugene thought the reason for the foul odor was clear. a rat had died somewhere in the car! He spent days looking for it, but could not find the remains of the little rodent. That’s how we ended up with it.
When we looked inside the car, we immediately smelled a pungent, unpleasant odor. But we already knew the reason for this smell. We didn’t take off the door trim and the roof, as Evgeny asked us to do, but we took off the cooling fan of the air intake. You can see it at
The name of the disease is related to the 1976 outbreak of a severe respiratory disease in Philadelphia, which had the type of pneumonia. In July 1976, more than 4,000 attendees at the American Legion convention in Philadelphia, Pennsylvania, USA. This was the organization’s 49th annual convention. After the convention was over safely, the participants and their families left for their homes. Three days after the convention, on July 27, 1976, one of the attendees suddenly died of a pneumonia-like illness. Three days later, a Pennsylvania internist noticed that three of the pneumonia patients he was treating were also attending an American Legion convention. On the same day a nurse at a nearby hospital discovered similar illness in three other convention attendees. But it was not until August 2, 1976, that state officials linked the illness to the convention. By this time, 18 Legionnaires had already died. In all, 221 people became ill during this outbreak, 34 of whom died. Analysis of previous cases of pneumonia of unclear etiology following isolation of a pathogen of the genus Legionella proved that the mass illness at the American Legion convention was not the first case of pneumonia caused by bacteria of the genus Legionella. Despite this fact, the disease was called “legionnaire’s disease,” and only later was the classification of legionellosis proposed. A gram-negative bacillus assigned to the genus Legionella was first isolated by J. D. MacDade and C. Mac-Dade and C. In 1977, six months after the outbreak described above, Shepherd reported. The bacterium was isolated from a lung fragment of a man who died of legionellosis. Scientists believe that the disease outbreak was triggered by legionella colonies multiplying in the ventilation system of the hotel where the participants were staying.
Conclusion: if you smell something bad in your car, don’t look for a dead rat! Pay close attention to the cooling fan of the VVB and the evaporator of the air conditioner system. They are the most favorable environment for the reproduction of these dangerous bacteria.
Well, in the case of Eugene everything ended well: the fan impeller was cleaned, washed and steamed. The unpleasant smell is gone (though the car seats and roof lining will remind you of it for a long time).
Sergey Gordeev © Legion-Autodata (forum nickname. FERMER) Sverdlovsk Region., Beloyarsk district with.Kochnevskoe, ul.Sadovaya, v.33. 7 (902) 444-23-35