Toyota Prius Gen 4 to Gen 3 Engine swap issues!!!

Discussion in 'Gen 3 Prius Main Forum' started by Debo160, Apr 21, 2022.

Page 1 of 2
  1. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    What's up Prius Chat!!


    I have a 2011 Prius that I did a gen 4 swap into.(Well I had it done) The new engine has 42K on it.

    After getting everything together the car runs and drives. But It has a voltage leak. I don't have the code at the

    moment, but i will get it. When you drive the car it might shut down randomly. It states that the hybrid system is

    over heating (The LCD on the dashboard). After a long time of not having tune ti jump on it with my mechanic. I

    sent it to toyota. I explained my issue and they basically told me what I told them. And wanted to charge me

    200 for the information that they had already received from me. Without being rude I asked where is the

    fault/leak. Oh this car has a engine in it that doesn't fit in this car. Yeah I got that but I need to figure the issue

    out. What's the issue and why is it shutting down. Becasue if I know where we can repair it and move on. They

    said the car shouldn't be driving because of the issue, Ok I understand that but again (WHAT THE ISSUE?) Oh

    we might have to do more diagnostics to find out the problem? Why did I bring this here again? I don't have any

    more knowledge than when I brought it in. SMH so im here to ask some of you guys that may have

    experienced this issue before. In my book hybrid system would be Hybrid battery the inverter and the orange

    cable. I have tried a different battery and a different inverter. Just trying to figure it out. They (toyota) told me

    basically to junk the car. But I know better. Please any information you have would be great.


    Thanks folks
     
    #1 Debo160, Apr 21, 2022
  2. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    12,555
    5,084
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    For starters, condolences on the outrageous incompetence on the Toyota Stealership. They're warranty specialists and don't understand actual vehicle repair, only how to replace the most expensive parts to maximize their profit margin at Toyota corporate's or customer's expense.

    As for diagnosis, anything else come up after the engine swap beyond a voltage leak error code? And which voltage leak error code?

    Also when you're driving and the car dies, does it happen randomly or it is associated with the car hitting a pot hole or rough patch of road? Or does it happen during a specific speed, or during acceleration or braking? Also any rainy or stormy weather? And are you original owner/clean title?

    Also if you can hook up an OBD2 reader and an app, or Toyota Techstream on old windows computer to give us some details on what part of hybrid system is overheating?
     
    #2 PriusCamper, Apr 21, 2022
  3. ASRDogman

    ASRDogman Senior Member

    Joined:
    May 29, 2018
    7,493
    3,882
    0
    Location:
    Florida
    Vehicle:
    2010 Prius
    Model:
    Two
    You'll certainly need the code. Is it the battery overheating? Which would mean the fan in
    not working, or blocked. Easy enough to check.
    Or is the inverter overheating? Which probably would mean the pump. Do you see coolant flowing
    when you put the car in "ready" mode? If it's not circulating, likely the pump. If it is, the pump is probably
    working.
    These are only guesses.... with the code you'll get better answers.
     
    #3 ASRDogman, Apr 21, 2022
    Mendel Leisk likes this.
  4. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    12,555
    5,084
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    Does Gen4 have same method of verifying inverter pump is working same as all previous generations?
     
    #4 PriusCamper, Apr 21, 2022
  5. Mendel Leisk

    Mendel Leisk MMX GEN III

    Joined:
    Oct 17, 2010
    59,871
    41,149
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    I’ve heard this here before. Not just a code, a text warning on the dash?

    I’d second this:

     
    #5 Mendel Leisk, Apr 21, 2022
  6. tony_2018

    tony_2018 Member

    Joined:
    Jun 12, 2019
    227
    67
    0
    Location:
    78717
    Vehicle:
    2012 Prius
    Model:
    IV
    agreed.
     
    #6 tony_2018, Apr 23, 2022
  7. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    Sorry it has been a crazy week. But after pulling techstream back up I had the following codes.

    P0A2B-250 Drive Motor "A" Temperature Sensor Circuit Range Performance

    P0AA6 - Hybrid Voltage System Isolation Fault

    The car does run and drive but again just trying to track it all down.
     
    #7 Debo160, Apr 26, 2022
  8. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    12,555
    5,084
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    I wonder if @SFO has the write up from the service manual for these codes? If he does and sees this, he'll likely post them here for you.
     
    #8 PriusCamper, Apr 26, 2022
    SFO likes this.
  9. EH6TunerDaniel

    EH6TunerDaniel Member

    Joined:
    Mar 16, 2022
    55
    29
    0
    Location:
    Texas
    Vehicle:
    2010 Prius
    Model:
    III
    I would bet your cooling system needs to be burped.
     
    #9 EH6TunerDaniel, Apr 26, 2022
    Last edited: Apr 26, 2022
  10. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    These are the 2 codes that popped up on techstream. While drive the car will just shutdown. Shutdown meaning the car will lose all power

    and state that the hybrid system is overheating. Once it cools down you can drive it again until it gets hot. But you could be anywhere and

    this happens. When you press the gas there is no power until the hybrid system cools off.
     
    #10 Debo160, Apr 27, 2022
  11. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    Yes. Both pumps have also been changed. We put it in maintainance mode to bleed/burp the systerm but the car will actually over heat if

    it's in maintenance mode after a while.
     
    #11 Debo160, Apr 27, 2022
  12. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    Im not sure but they were both changed
     
    #12 Debo160, Apr 27, 2022
  13. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    I thought about that too. We had a couple battery's and it didn't matter the same result was going to happen. If the car is setting still or

    moving it's going to overheat. We also changed the inverter. No change.
     
    #13 Debo160, Apr 27, 2022
  14. SFO

    SFO Senior Member

    Joined:
    Feb 7, 2017
    5,302
    4,247
    0
    Location:
    Northern California
    Vehicle:
    2007 Prius
    Model:
    N/A
    Knowing the freeze frame data or INF for a DTC may help narrow down the issue; not all DTCs have associated INFs (detail codes)

    Were you able to retrieve the INFs or subcode(s) for DTC P0AA6 by clicking on the bluish snowflake icon?

    [​IMG]

    [​IMG]

    The gen3 and gen4 manuals are in the wild for DLing, but are not currently hyperlinked like the gen2.
     
    #14 SFO, Apr 27, 2022
  15. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    Ok the detail codes are: 526 and 614
     

    Attached Files:

    #15 Debo160, Apr 28, 2022
  16. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    27,314
    17,928
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    You can (roughly) refer to this (Gen 2 Gen 2 Gen 2) diagram to see the area of high-voltage connections to look in for a leak identified with a 614 code. I haven't found an equally nice diagram for Gen 3.

    There are a few changed details between generations, and Gen 3 doesn't have an A/C Inverter section inside the inverter assembly, but otherwise, this roughly shows what you're looking at.

    [​IMG]
     
    #16 ChapmanF, Apr 28, 2022
    PriusCamper likes this.
  17. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    Ok im back after taking some time off of this one. But it looks like some light might be at the end of the

    tunnel. We ended up changing the main orange cable. After this the 526 code went away. Im

    not sure if it will or wont show back up. But now im about to change the other 2

    orange cables in hopes of a successful driving vehicle. Wish me luck as we tear in this week. Im not sure if

    this is the solution but what would cause 3 orange cables to have leakage issues?
     
    #17 Debo160, May 30, 2022
    Last edited: May 30, 2022
    johnny gompers and ASRDogman like this.
  18. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    AHHHHHHHH!!! ok that's a no go!! 614 and 526 are both back!! I guess the next step is to pull the AC

    compressor and see if there is water and if everything needs to be resoilder/reflowed. If this doesn't work im

    going to be leaning toward the transmission. It's the only thing left that has a orange cable. Im ready to drive it

    and sell the other ones. To many projects not enough time. Any feedback would be excellent.
     
    #18 Debo160, Aug 24, 2022
  19. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    27,314
    17,928
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    Do you have a megger to test for leaks with? That would be a whole lot less invasive than pulling the compressor and experimenting with reflowing stuff.

    In a Gen 3, I guess I can kinda sorta believe the compressor could be implicated with a 614 code. Because the Gen 3 compressor inverter circuitry is inside the compressor (in Gen 2 it was in the inverter assembly), even though leakage in the compressor motor windings would still give you 611, the Gen 3 cable to the compressor, and the input side of the compressor's built-in inverter, would still be part of the 614 area.

    I'd call the transmission more of a long shot. You should really have a 613 if it's that.
     
    #19 ChapmanF, Aug 24, 2022
  20. Debo160

    Debo160 Junior Member

    Joined:
    Oct 9, 2016
    41
    12
    0
    Location:
    MORTH CAROLINA
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    What's a megger? If you don't mind explaining
     
    #20 Debo160, Aug 25, 2022
(You must log in or sign up to post here.)
Page 1 of 2