Charging Issues - System Malfunction

Hello everyone,

I purchased a Prius Plugin 2012 half year ago, and I've been facing some issues on charging. I'm reaching out to seek advice and gather insights regarding this problem.

During the first week of owning the car, I didn't encounter any issues while charging. I used the aftermarket charging cable that came with the PIP, as well as an 220V wall mount EV charger at my home with a Type 2 to Type 1 adapter, and everything worked fine.

However, after a week of normal usage, I had an incident when I arrived home and plugged in the EV charger. Initially, the charging socket orange LED on the car lit up, and the EV charger's relay clicked, indicating that charging had begun. But after a second, the relay clicked again, signifying that charging had stopped. At this point, the orange LED on the car flashed ten times before turning off. When I pressed the Power button in the car, the dashboard displayed the error message: "CHARGE RESULT: CHARGE STOPPED DUE TO SYSTEM MALFUNCTION." The error code shown was P3203. After clearing the error code, the car operated normally, including regenerative braking.

Over the next two months, I tried various methods of charging at home, but I consistently encountered the System Malfunction P3203 error as above. I noticed that if I approached the car without the key fob, causing the interior lights not to turn on, the charging process would work normally.

Additionally, if I parked the car after I drove home and immediately plugged in the charger, the P3203 error would occur. I had to wait for the battery cooling fan at the back to stop before being able to start charging.

I have already replaced the 12V battery from the dealer and had it checked by the dealer. However, they informed me that without the original Toyota charging cable, they couldn't diagnose the issue. The cost of purchasing a Toyota charging cable from the dealer is £700, which seems unreasonable to me, so I haven't bought it and nothing checked by the dealer.

My EV charger, a PodPoint Solo, is located around 30 meters away from the main switch.

I have inspected the charging socket on the car and all the pins are fine. I believe it's not the source of the problem.

Now for a successful charge, I need to ensure that the car is locked, lights are off and the fan is not running inside the car. Even if I plugged the charging cable and both the car and EV charger's charging lights are on, it doesn't mean that charging is in progress. The first three hours are spent waiting charge nothing. During this waiting period, if I unlock the car door, the P3203 error appears. After approximately three hours, the charging process eventally begins. If I press the Power button at that moment, dashboard shows the charging time remaining. Since the EV charger operates at 220V, it takes around 1.5 hours to complete charging. In total, I need approximately 5 hours to charge my PIP.

I would appreciate any suggestions or recommendations on how to proceed with troubleshooting this issue. Should I consider replacing any charging components in the car? Any advice or experiences shared would be greatly appreciated.

Thank you all for your time and assistance.

 

Thanks vvillovv, I try to make it clear.

I got the error code from an OBD2 bluetooth scanner on iphone, which is not recognized by DR Prius. According to the OBD2 scanner's app, P3203 is a problem on the car charger circuit. I just ordered a Dr Prius supported OBD2 for the traction bettery check.

The home plug charging cable and the wall mount EVSE are both 230 volts which is the UK home power supply standard. I took photos of them and posted below.

Charging the car with both EVSEs will have the same problem and same error code.

If the car is fully charged, it will show having 13.8 miles on EV.

Home Plug Charging Cable

Wall mount EVSE

Using wall mount EVSE with Type 2 to Type 1 adapter to charge

 

Thanks for you advice vvillovv.

The Type 2 to Type 1 adapter is just a very simple rewire hub. Nothing to do with the voltage change. So the second pic in the #1 post is using 230V to charge.


I cleaned the 2 traction battery fans and the passenger seat air inlet. No noticeable blockage.

Air inlet at back seat

Traction Battery Bay

Left Fan

Right ventilation hole behind the fan

 

I got the OBD2 finally. Below is the screenshot just after a 5 miles ride in HV mode and before plugging in the charger. Seems the traction battery temperture is OK. Then I plugged the charger it showed the System Malfunction message and error P3203 again.

The charging timer is not active.

 

I know nothing about PIP battery running tempreature and SOC. I am more familiar with my phone battery temperature.
I collected some battery data of my today driving which showed below. Sorry many pics makes this post so long.

Here is yesterday charging time. I plugged the Prius to the charger at 17:30, red arrow on below picture. The car actually start drawing current at 22:30, green arrow. The charger plugged but idling time become even longer. Maybe something is getting worse.

Today morning had a good start

System shows 12.9 miles after full charge

Dr Prius screen after turned on car Power

After a 37miles highway run, 10.3 EV miles left

After a 37miles highway run, 10.3 EV miles left

After a 37miles highway run, 10.3 EV miles left

After one of a pure EV 2.9 miles trip

After one of a pure EV 2.9 miles trip, maybe 5.4 miles EV left

After one of a pure EV 2.9 miles trip

After driving back home 37 miles

After driving back home 37 miles

After driving back home 37 miles

 

The OBD2 I bought is this one Car & Motorcycle Code Reader Check Engine Fault OBD2 Scanner For IOS Android | eBay
The Dr Prius screen for the cells of my car is very simular on both iPhone or Android.

I took a video of the charging error. The first shot is at the charging socket. Second shot is at the battery bay. Then follow by the error message on the dashboard screen. I hope the relay sounds in the video can give a clue.

About the chinging timer, I am quite sure it is not activated. If activated, the orange LED at the charging socket will be off after a few second instead of 10 blinks error. But I also tried to plug and replug the socket. This time I discovered something new. After 3 consecutice plug and replug, the orange charging LED did not blink 10 times. It became long lit that show the car was charging. I leave it there for 10 minutes. Then I turn on the car I found it really started charging!!





The charging finished within 2 hours. I know the error will happen again next time. How strange.

 

Thanks for your reply. DrPrius can clear the error code every time. The error code comes again after each unsuccessful charging.

Here is an update after the Easter holiday and some checking at the user manual. I mainly focus on the security alarm system and door lock, since the error usually occur when I unlock the door. And I noticed for a successful charging, I have to plug the charger 30 seconds after I locked the door. In the user manual said the security system will be activated 30 second after the door locked. So the problem should be related to the door lock and security system. Therefore I do the following procedure:

Lower the driver window
Switch off the car
Lock the door
Wait 30 second, the red security system led on the dashboard begin to flash
Plug in the charging socket, wait for the orange charging light goes on
Start the car (because the driver window is opened, I can press the start button when the door is locked.)
Check the charging status on the dashboard
If not charging, turn off the car
Open the door from inside, alarm start to sound
Close the door
Use remote key to lock the door, alarm goes away
Now the orange charging light should still on
Start the car again to check the charging status, this time the dashboard will show time to complete charging.

I have to do the above steps to charge my Prius. Up to now works fine for 4 days and I am happy with this solution.



If not charging, the dashboard will show negative charging power and no finish time.



Dashboard screen of a successful charging when the car door is locked.