Canada - Hybrid Controls - MIL ON/DTC's P0AC0/P0A1F/P0A7F/P0AFA

Bulletin
3198

Issue Date
June 25, 2009

Market
Canada

Title:
M.I.L. "ON" DTC P0AC0, P0A1F, P0A7F, AND/OR P0AFA

Component
ENGINE ELECTRICAL

Models
'04-'09 Prius

INTRODUCTION:
Some vehicles may exhibit a M.I.L. "ON" condition with one or more of the following Diagnostic Trouble Codes (DTCs):
- P0AC0 - Hybrid Battery Pack Current Sensor Circuit Range/Performance
- P0A1F - Battery Energy Control Module
- P0A7F - Hybrid Battery Pack Deterioration
- P0AFA - Hybrid Battery System Voltage Low

Improvements have been made to the HV ECU and battery ECU hardware to correct these conditions.







APPLICABILITY:


PRODUCTION CHANGE INFORMATION:







This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.







WARRANTY INFORMATION:







PARTS INFORMATION:







REQUIRED TOOLS & EQUIPMENT:

NOTE
Additional Techstream units may be ordered by completing the order form on ETAS and faxing it to (416) 431-8342.

INSPECTION PROCEDURE:
1. Using ETAS Techstream, check for Diagnostic Trouble Codes (DTCs).
2. Are only codes P3000 (Information Code 123), P0AC0, P0A1F, P0A7F, or P0AFA present?
- YES - Continue to step 3.
- NO - Diagnose other DTC(s) first.

3. Review the Freeze Frame Data (FFD) for P3000 (Information Code 123), P0AC0, P0A1F, P0A7F, or P0AFA DTC(s).












Inspect the Battery State of Charge (Figure 1) and Battery Block Voltages 1-14 (Figure 2).

4. Is the Battery State of Charge 0.0% or do ALL Battery Blocks equal 0.00V?
- YES - Proceed to step 5.
- NO - This TSB does NOT apply.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2004 or 2005
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: Hybrid Control System: Diagnostic Trouble Code Chart

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2006/2007/2008/2009
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: P112 Hybrid Vehicle Control: Hybrid Control System: Diagnostic Trouble Code Chart

5. Clear the DTC(s) and road test the vehicle.
Do the DTC(s) reset?
- YES - This TSB does NOT apply.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2004 or 2005
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: Hybrid Control System: Diagnostic Trouble Code Chart

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2006/2007/2008/2009
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: P112 Hybrid Vehicle Control: Hybrid Control System: Diagnostic Trouble Code Chart

- NO - Perform the Repair Procedure.

REPAIR PROCEDURE:
1. Replace the HV ECU.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2004/2005
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: Hybrid Vehicle Control ECU: Replacement

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2006/2007/2008/2009
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: P112 Hybrid Vehicle Control: Hybrid Control ECU: Removal
- Keyword: P112 Hybrid Vehicle Control: Hybrid Control ECU: Installation

2. Replace the battery ECU.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2004/2005
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: Battery ECU Assy: Replacement

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2006/2007/2008/2009
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control System
- Keyword: P112 Hybrid Battery Control: Battery ECU: Removal
- Keyword: P112 Hybrid Battery Control: Battery ECU: Installation

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.