Engine rattles tremedously after replacement of inverter

Sounds like the inverter isn't the problem. They rarely are.

Your new engine may only have 80k but it's not healthy.

 

Clean the egr circuit

 

but the original engine went 388k without cleaning it

 

...and blew up. No idea if somebody nursed it carefully through the last 280k of that.

 

Does an OBD scan show any diagnostic codes?

 

I’d cut my loses and buy a corolla or Camry and never look back if I’m in such situation after investing in multiple motors and inverters.

 

hmm... uber passengers stranded on highway. no wonder i still drive myself everywhere

 

120 degrees (Fahrenheit) is not an abormally high temp for sensor #2. In stop-and-go city driving on a warm day in particular.

I didn't know Dr Prius could do that btw. Thought it could read a few codes, could change when the Hybrid fan comes on, but didn't read the temp. I have read temp, though with ScanGuage.

I'd chime in with the others: check the EGR components and intake manifold, make sure they're free-flowing.

Ok, you say you've done all that. Not sure then.

One thing, I get the sense you want it to be something, and are willing to bend the data to make it that. That might lead you in the wrong direction: keep an open mind when troubleshooting, consider all the possiblities.

 

maybe time for tech stream?

 

I'm trying to understand your troubleshooting methodology.

In one sentence, the HV battery is bad, with what you believe is a high temp, so you crank the AC. 120F will not cause a battery to shut the car off, so I'm at a loss about that. Actually, I don't think any battery temperature will cause the car to shut down.

Your initial symptoms would tend to lead me to looking at inverter temperatures and the inverter cooling system. I'm trying to understand why you jumped right into swapping the inverter. Unfortunately, I would now venture something happened during a swap and either something isn't connected correctly or there's a broken wire/bad connection somewhere.

 

Sensor #2? Talking about hv bat temp sensor? Or another type of sensor?

 

Yeah sorry, getting esoteric: there's 3 sensors on the hybrid battery, spaced along the top. The midde one (#2) tends to be hottest, and I think the usual one monitored, for this reason.

 

120F on any battery sensor bad, in fact your hv bat went into protection mode and may have caused the limp. Hwy regen must have help the high temp build up quickly and if you had the heater on. Double check dr prius fan settings and lower the fan on threshold to speed up the hv fan intake. Then turn on AC so fan can pull air into the pack, fan is at speed 1 when any sensor is above 96F, speed 2 at 102F.

 

I was thinking the same. Guessing isn't the way to fix a modern car. It's too much work and too much money. Need data from a code reader for one thing.