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Don't let this happen to you. Inverter coolant warning.

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by PartsNinja, Dec 2, 2014.

  1. PartsNinja

    PartsNinja Junior Member

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    I joined this board because I saw a community that looks out for each other and shares knowledge. That is what I am here to do. I don't have an axe to grind and I am not out to hurt anyone's feelings. But I want to do my part with a warning for my fellow owners. Here are just the facts as they are with no names.

    I have a little over a hundred thousand miles on my 2010 Prius. I love the car and want to keep it going with regular maintenance. I know that the plugs and coolant are rated for around the mileage I have now (100k for the coolant, 120k for the plugs). So I brought it in to get a coolant drain and fill for both systems and the plugs changed. About two weeks went by and then I got a check engine light. The code they pulled was a P0A01 which is a code for the inverter cooling. The explanation provided to me by the tech is that if there is a temperature difference inside the inverter (indicating a blockage in the coolant passages) that it sets this code. When this happens, it is un-serviceable and the entire inverter must be replaced. I had Toyota contacted to see if they would grant me some kind of good will warranty being that I am barely 5k miles out of warranty for the inverter. They were ready and willing. But then after looking at my service records, they noticed that a "coolant additive" had been put in during the coolant service. They mentioned that they had seen several of these in the past few months or so where a code was set after an additive was mixed with coolant. They had to decline the goodwill warranty. So basically I am between the dealer (who I happen to work for which only makes it harder) and the chemical company who made the "additive" that was added to the coolant.

    So my warning is this. IF you have anyone (Toyota dealer or not) service the inverter, DO NOT let them put any kind of additive or chemical in the coolant. This will void your warranty and blow any chance of good will from Toyota that you might have. I don't care what song and dance they give you to sell it (and they will trust me). You want Toyota coolant ONLY put back in your inverter. I hope this comes out well for me. But more than likely I will be buying an inverter because of this. And even at Toyota employee price, it is very high.
     
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  2. Yakoma

    Yakoma Active Member

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    If I were you, I'd want more than a code to convince me that I need to buy a new inverter because of a coolant additive. Sounds bogus to me. I'm no engine expert, but it seems that if the inverter is working and it passes inspection, I'd keep driving it. Unserviceable by Toyota? So what...do it yourself or take it to some other shop. And who put the additive in? Toyota dealer or someone else? If the dealer, then they owe you the inverter. And if they don't own up, why would you want to work for them anyway?
     
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  3. dorunron

    dorunron Senior Member

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    I sympathize with the op but it has been posted many times on this board to only use "Toyota Super Long Coolant" in the radiator and the inverter. That does not include any "additive" of any sort.

    I feel for the op, but if you don't follow the manufacturers recommendation concerning types of fluid use you then run the risk of the warranty being cancelled or withheld in your case.

    As said above, if Toyota did this, then they should foot the bill. But if someone else did it, it then falls under the owner's responsibility.

    There are members on this board that do use different fluids in their Prius, but they do it at their own risk.

    Honestly, it would not surprise me if you have air in your system which is causing the problem and setting the code. Before I gave up on this, I would do some investigation under the hood. The dealer can say whatever they want, but it does not hurt to get a second opinion and check things for yourself. I would begin by checking the fluid levels and go from there.

    Ron (dorunron)
     
  4. bisco

    bisco cookie crumbler

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    you can get a used inverter installed for cheap money, it's not a big deal these days.
     
  5. bisco

    bisco cookie crumbler

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    i would be curious to know if your companies policy is to put an additive in everyone's coolant.
     
  6. Former Member 68813

    Former Member 68813 Senior Member

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    Sure, and charge extra for that to make more bucks. Sometimes, it backfires. One more reason to DIY.
     
  7. fotomoto

    fotomoto Senior Member

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    Your workplace owes you a new inverter.
     
  8. IMkenNY

    IMkenNY Im just being nosy

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    It there any chance this code could come up from a air pocket that needs to be purged?
     
  9. dorunron

    dorunron Senior Member

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    Here is the definition of the code that is being referred to. I would say "YES", a air pocket could cause the DTC to register and the light to ignite.

    P0A01-726 Motor Electronics Coolant Temperature Sensor Circuit Range / Performance - Inverter cooling system - Cooling fan system - Power management control ECU - Inverter with converter assembly - Water pump with motor assembly - Wire harness or connector - IGCT No. 3 fuse Comes on

    As shown above, it could be a number of things, but when you consider the OP had the inverter serviced, it makes sense that a air pocket might be present if it was not drained and refilled properly. Gen III is more forgiving than Gen II, but it still would not surprise me that a air pocket would set the code.

    Ron (dorunron)

    Source:
    1. priuschat.com/attachments/2010-prius-dtc-codes-pdf.33416/
     
  10. dorunron

    dorunron Senior Member

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    It is also possible that the OP may simply have a bad inverter pump. Without a proper diagnosis, it really is best guess IMO.

    Ron
     
  11. GregP507

    GregP507 Senior Member

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    Sounds like a potential lawsuit against the guy who put in the additive, which Toyota blames as the cause of the failure.

    I'm assuming someone has already thought of flushing out the coolant, resetting the code, and giving it another try?
     
  12. PartsNinja

    PartsNinja Junior Member

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    Hi guys.

    @dorunron I wish I had read it on here or talked to you first! Honestly all I asked for was a drain and fill. The other stuff got put in without my asking or knowledge. But I understand that the service person and the tech meant no harm and didn't know what would happen. In spite of that, it did happen and right now I am the hot potato between the chemical rep and the service manager. If neither one decides to do the right thing, I just have to eat it and move on. Or I could be a pain and get fired (not an option).

    @bisco You are the man. I never even thought about a used one. If I end up stuck, I might look into one. I just hope they are cheap enough to justify the risk of buying used. For your other post, gosh I hope we didn't put it into another Prius. We just started up with this chemical company, so it might not have made it into a customer hybrid. But you bet I asked. Time will tell and nobody will say. I guarantee one thing, after the stink I raised, it won't be going into anyone else's Prius.

    @dorunron and IMKenNY and GregP507 We thought that maybe it was just an air pocket or something. Hence the difference in temps. But the guy that did the job is one of our best. He wouldn't leave it unburped. As far as DIY, this thing doesn't have a purge like some of the later ones. I am not the handiest of guys anyway (or I would be in the shop instead of in front of a computer). So I let the guys drain and fill it again, reset the codes and let it ride. I didn't make it 10 miles and it lit up again (along with the smell of hot coolant, never a good thing). The coolant is nice and pink and doesn't look like Jello. The level is normal. None of the hoses are kinked. The pump functions normally. It is definitely blocked somewhere internally. The guys tell me that the cooling passages in that inverter are very, very small. One of the guys mentioned trying some kind of back flow to see if it pushes the blockage back out. But nobody seemed real excited about trying that. So the suggestion died pretty quick. One thing all of them told me (now) is that unlike regular coolant that gets exposure to oil and trans fluid etc, inverter coolant stays pretty clean. I should have just left it the heck alone. It's my first hybrid so live and learn I guess.

    Guys I appreciate all the suggestions and sympathy. That's why I love this board. Even before I bought this car (I am about to make my second payment), I lurked here quite a bit. Great bunch of folks. I just hope that my voice adds to the others as a cautionary tale.
     
  13. IMkenNY

    IMkenNY Im just being nosy

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    I find it hard to believe the additive that is showing no signs of jelling in the reservoir and is used in a engine heater core environment would cause this problem. A foil or plastic seal from said additive or antifreeze bottle is more believable.

    A back flush at this point would be well worth a try and if that didn't help I would try using a Airlift II to purge the system , its $80 on Amazon.

    Link to Airlift II on Amazon:
     
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  14. JC91006

    JC91006 Senior Member

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    Does the OP work at a Toyota dealer or just a regular car dealer? Why was an additive used in the first place? It's best to get a 2nd opinion. Could the car have been damaged when you bought it? It seems fairly new to you.
     
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  15. bisco

    bisco cookie crumbler

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    o/p, did you get the inverter recall?
     
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  16. dorunron

    dorunron Senior Member

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    +1 on the inverter recall. There was a recall earlier this year on the Gen III Prius. I remember it plainly because the new one I have now had to be done before I picked it up.

    Getting back to the op's original post, I do understand everything that has been said so far. This may be far reaching, however has anyone checked to make sure the thermostat is functioning properly. The code you published relates to temperature variables being out of tolerance for normal operation. It can be caused by more than one part of the system. It is obvious that the Prius is NOT a simple machine, but rather a very complex machine with many systems that interact with one another along with computers driving and controlling said systems.

    Before I spent money on a used inverter, I would take the time to continue to check the little things. These things even being small can create problems. Without a proper diagnosis, you will never determine the exact problem.

    My best advice would be to seek out a different technician to inspect the Prius properly. It is obvious that the dealer you are using is not up to speed on the Prius. This is not unheard of on this board. I myself work with two different dealers (stealers) here in Houston to keep our beloved Prius on the road. When one struggles, I turn to another. Maybe the OP should try this rather than spending more time and money trying to solve a problem that may be very simple.

    A great example of this would be something that I am dealing with right now on our current Prius. There is a noise coming from the front end. It occurs when you go over the reflectors on the roadways. I have found more than one of the Gen III Pri that make the same noise as ours. It seems that it stems from the wheels on the car. I say that because the stock 15" wheels on the new Pri that are on the lot's today don't exhibit this noise when driving them. But Pri equipped with the wheels that are on our Prius do exhibit this symptom. With all that said, it boils down to slowly and methodically troubleshooting said problems until a solution is found.

    In the op's case, the car worked normally for a long time. Since the drain and refill a DTC code is now present in the system. It is possible that the code is related to the work that was done. It is also possible that a part in one of the many systems has failed which has NOT been properly diagnosed or found at this time.

    Bottom line: Do some more investigation into the problem and try a different technician. Sometimes a different set of eyes and minds can solve the problem that stumps many. I have found this to be true more than once. I say that because when one dealer (stealer) can't solve my problem, the other one does.

    Don't give up. Your Prius can be fixed properly. But until the Prius is properly diagnosed, everyone is still guessing.

    Best of luck to you.

    Ron (dorunron)
     
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  17. GregP507

    GregP507 Senior Member

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    Not accusing anyone of shoddy diagnostic techniques, but it's extremely easy to replace components until things start working and then blame the problem on all the components that were replaced. There's not much financial incentive for the dealer to do otherwise. It's sometimes left to a basic sense of good-will, which isn't always in good supply.
     
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  18. PartsNinja

    PartsNinja Junior Member

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    I hope this is my last post about this and I can go back to fun stuff like lighted door sills and body kits. First off let me lead by saying that to their credit, the chemical folks said "fix it and we will take care of it". So kudos to them.
    @IMkenNY, thankfully I didn't have to worry about trying anything on my own. But good looking out with the back flush machine.
    @JC91006, The stuff was put it in without my knowledge. It probably works great in a regular gas engine radiator. But according to Toyota (who we have to call and open a case on certain DTCs), it is rotten in your inverter cooling system. They claimed that mine is not the first one they have seen. My thought was that someone needs to tell somebody. So I did... here.
    @bisco I looked into that when all this started and my code was not one that was included in the recall or the warranty extension. Trust me, I checked every angle to keep from losing all my Christmas money.

    Now for the fix (hopefully). I don't understand all of it. But I understand enough to get most of what the guys in the shop are telling me. If any of you techs want to chime in and clarify or correct, please do.

    This is the Intelligent Power Module or IPM. In my parts catalog, you have to order the whole inverter assembly. But evidently there is a bulletin now where you can get the component parts. This is one of those separate parts.
    [​IMG]
    See the coolant passage at the bottom right? Take a look how tight the passage is when you look down inside it.
    [​IMG]
    So yeah IMKenNY I bet it could be a foil top or debris in the flush machine or who knows. We probably never will. But the techline told us that replacing this part will solve my problem. So one of the guys changed it today (what a process that was to watch) and I will be riding it home tonight. Hopefully this is the end. But like I said, it could have never begun. No additives! Thanks for listening and I hope this helps someone!
     
    #18 PartsNinja, Dec 4, 2014
    Last edited: Dec 4, 2014
  19. Yakoma

    Yakoma Active Member

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    PartsNinja,
    Thanks for giving the PC community the heads-up on this. Good luck with yours.
     
  20. kc410

    kc410 Active Member

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    Thank you for taking the time to document the whole problem, right down to the fantastic end.
    Should be good for another 100K or 2.