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started smelling burning on long drives, and now the AC doesn't work

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by yokonzo, Jul 15, 2024.

  1. yokonzo

    yokonzo Junior Member

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    I have had to do a few long drives on highways and twice me and my girlfriend started smelling burnt plastic, pulled over to see if we could locate the scent but found nothing; This is all I know of the issue. it's gonna be pretty hard to sell a car in this heat that has no AC, does anyone know what I should start looking for?
     
  2. Tombukt2

    Tombukt2 Senior Member

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    Melting plastic doesn't really add up I guess an untrained nose could think freon oil mix might be plastic that would indicate you're evaporator is leaking and then shortly your air conditioner should fail usually in evaporator leak should leak out fairly quickly so if you still have cold air after all these smells it's probably not leaking gas refrigerant
     
  3. yokonzo

    yokonzo Junior Member

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    You're probably right, I'm very familiar with the plastic smell since I work with burning plastic, but never freon, it may be the evaporator then. I'm definitely not getting cool air anymore I think, and I'm also not getting the smell anymore. But to be fair I haven't really pushed my engine for an hour straight going 80 like the last time it happened so I don't wanna totally rule out the possibility that the engine was overheating and messed something else up as well . But evaporator I will definitely look at
     
  4. pasadena_commut

    pasadena_commut Senior Member

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    No codes? If the A/C only stops when there is a code it is likely a failed or failing inverter pump. Especially if it works when the ambient temperature is low and codes when it is high.

    The evaporators sometimes go bad on these cars. Actually I think it is a valve on the evaporator, but the difference is of no significance since the whole thing needs to be replaced. (On the Gen 3 they moved that valve into the engine compartment so it could be serviced separately.) PITA to replace an evaporator oneself and $$$ to pay somebody else for it. If it is the usual evaporator issue all the refrigerant will leak out.

    Or it could be a leak or some other typical A/C issue.

    In any case, if the A/C is not working as in, only cools poorly or not at all, do not run it. That may damage the condenser. More $$$.
     
  5. TMR-JWAP

    TMR-JWAP Senior Member

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    The acrid smell of burning plastic is often caused by the inverter cooling water pump failing electrically. Eventually, this will blow the AM2 fuse and kill power to the dash and shut the car off. Quite the thrill when at highway speed!!

    The pump is located directly behind the driver side headlight. It has potting material on the bottom, which is the material that heats up and burns when the pump motor is failing. I've had a few of these pumps that have had gooey areas underneath from the potting material heating up.

    On another note, loss of the AC is also one of the early signs of the ICWP failing. If the pump isn't circulating coolant adequately, the inverter starts heating up. Since the inverter supplies power to the air conditioning compressor, the car will cut it off to help prevent overheating the inverter (reduces the current load).
     
    #5 TMR-JWAP, Jul 15, 2024
    Last edited: Jul 15, 2024
    Tombukt2 likes this.
  6. rjparker

    rjparker Tu Humilde Sirviente

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    If you could smell burning plastic it was probably in the hvac assembly under the dash. It could have been the blower or one of several air routing doors. Almost all compressor fails would have trouble codes as would many of the inside hvac devices.

    The problem with the inside assembly is it requires an almost complete dash removal, a several thousand dollar job at most places.

    I would invest $150 at a dealer to get it properly diagnosed and then report back for options.
     
  7. yokonzo

    yokonzo Junior Member

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    Yeah just confirmed I'm getting no codes
     
  8. TMR-JWAP

    TMR-JWAP Senior Member

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    My scenario will give NO codes, until the inverter gets hot enough to trigger the over temp P0A93 to let you know there's a problem
     
  9. pasadena_commut

    pasadena_commut Senior Member

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    If the A/C shut off because the inverter was too hot there should be a code. There won't be a code from the inverter pump having hot spots.
     
  10. yokonzo

    yokonzo Junior Member

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    I will get back to thread tomorrow folks, currently sheltering from a tornado
     
  11. yokonzo

    yokonzo Junior Member

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    So I'm back, finally got around to tinkering, I went through most of the interior paneling and see no burnt wires, checked the sight glass and it seems clear, freon cycles through when started up, I can't get to the bottom of this, I may have to wait till my next paycheck and see if I can get a professional to look at this car