CP) TOYOTA

T-SB-0013-14 Rev1 February 26, 2014 Technical Service Bulletin

MIL "ON" DTC POA80 Due to Dust or Debris in HV Battery
Cooling Fan

Service
Category Engine/Hybrid System
Toyota Supports a
Section — Hybrid/Battery Control System Market USA eeu
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2013 — 2015 Prius

REVISION NOTICE
June 24, 2015 Rev1:

+ Applicability has been updated to include 2014 — 2045 model year Prius vehicles.

* The entire bulletin has been updated.

Any previous printed versions of this bulletin should be discarded.

Introduction
Some 2013 - 2015 model year Prius vehicles may exhibit a MIL “ON” condition with Diagnostic

Trouble Code (DTC) POA80 stored due to dust or debris buildup in the HV Battery Cooling Fan. Use
the following Repair Procedure to address this condition.

Production Change Information

This bulletin applies to vehicles produced BEFORE and AFTER the Production Change Effective
VIN shown below:

MODEL REPAIR PROCEDURE VIN BREAK PRODUCTION CHANGE EFFECTIVE VIN
. A Before
Prius JTDKN3DU#D0356257
B On or After

Parts Information

PART NUMBER APPLICABILITY PART NAME arty
G92DH-47010 Before VIN Break

Fitter, HV Battery Intake, No. 1 1
G92DH-47060 On or After VIN Break
G9510-76010 All Battery Assembly, HV Supply 1

© 2015 Toyota Motor Sales, USA Page 1 of &

&) TOYOTA T-SB-0013-14 Rev1 February 26, 2014 Page 2 of 8

MIL “ON” DTC POA80 Due to Dust or Debris in HV Battery Cooling Fan

Warranty Information

OP CODE | PROCEDURE DESCRIPTION TIME OFP m1 T2

Clean HV Battery Cooling Fan,
Replace HV Battery Assembly, and 18

ed cs Install HV Battery Cooling Fan
Intake Filter
G9510-76010 8A 99
Clean HV Battery Cooling Fan,
EL1401 3 Replace HV Battery Assembly, 20

and Clean or Replace HV Battery
Cooling Fan Intake Filter

APPLICABLE WARRANTY

* This repair is covered under the Toyota Hybrid System Warranty. This warranty is in effect for
96 months or 100,000 miles, whichever occurs first, from the vehicle’s in-service date.

+ For California specification Prius vehicles sold, registered, and operated in California,
Connecticut, Maine, Maryland, Massachusetts, New Jersey, New York, Oregon, Rhode Island,
and Vermont, this repair is covered under the California Emission Warranty, which is in effect
for 120 months or 150,000 miles, whichever occurs first, from the vehicle’s in-service date.

* Warranty application is limited to occurrence of the specified condition described in
this bulletin.

Required Tools & Equipment

REQUIRED EQUIPMENT SUPPLIER PART NUMBER ary
Techstream 2.0* TS2UNIT
ADE 4
Techstream Lite TSLITEPDLRO1

* Essential SST.

NOTE
* Only ONE of the Techstream units listed above is required.

° Software version 10.10.018 or later is required.

° Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at
1-800-368-6787.

© 2015 Toyota Motor Sales, USA

TOYOTA T-SB-0013-14 Revi _—‘ February 26, 2014 Page 3 of 8

MIL "ON" DTC POA80 Due to Dust or Debris in HV Battery Cooling Fan

Required Tools & Equipment (Continued)

SPECIAL SERVICE TOOLS (SST) PART NUMBER ary
90002-03100-S (Small)

Electrical insulating Gloves* 00002-03200-M (Medium) 4
00002-03300-L (Large)

CAUTION

Always inspect Electrical Insulating Gloves before use for cracks, ruptures, tears, pinholes, or
damage. Do NOT wear if damaged.

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.

* Essential SST.

Repair Procedure

NOTE
There are 2 Repair Procedures for this condition depending on the VIN.
* Before VIN break, use procedure A.

* On or After VIN break, use procedure B.

Please confirm which repair applies to the vehicle you are working on by consulting the Production
Change Information table.

Repair Procedure A
1. Inspect the HV Battery Cooling Fan for dust or debris buildup.

Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2013-1201 4--2015-Pritts —————_—_o— — — =
Engine/Hybrid System — Hybrid/Battery Control System — “Hybrid/Battery Control:
Battery Blower: Removal”

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MIL "ON" DTC POA80 Due to Dust or Debris in HV Battery Cooling Fan

Repair Procedure A (Continued)

Is the HV Battery Cooling Fan clogged with dust or debris buildup? Refer to Figure 1 for an
example of a clogged cooling fan.

« YES — Proceed to step 2.

* NO— This bulletin does NOT apply. Troubleshoot the vehicle using the Repair Manual
procedure.

Refer to TIS, applicable model and model year Repair Manual:

2013 / 2014 / 2015 Prius:
Engine/Hybrid System — Hybrid/Battery Control System — “Hybrid/Battery
Control: Hybrid Battery System: POA80-123: Replace Hybrid Battery Pack”

2. Using vacuum, and compressed air, if necessary, clean any dust, lint, or debris buildup from the
HV Battery Cooling Fan blades, module, and ducts.

Figure 1. HV Battery Cooling Fan BEFORE Cleaning Figure 2. HV Batlery Cooling Fan AFTER Cleaning

NOTICE

¢ Do NOT attempt to clean the HV Battery Cooling Fan while it is installed in the vehicle.
Doing so may cause dust or debris to enter the HV Battery Case.

+ Failure to secure the fan blades while cleaning can result in electronic circuit failure due
to overturning.

© 2015 Toyota Motor Sales, USA

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MIL "ON" DTC POA80 Due to Dust or Debris in HV Battery Cooling Fan

Repair Procedure A (Continued)
3. Replace the HV Battery Assembly.
Refer to TIS, applicable model and model year Repair Manual:

2013 Prius:
Engine/Hybrid System — Hybrid/Battery Control System — “Hybrid/Battery Control:
HV Battery: Removal / Installation”

« 2014 Prius:
Engine/Hybrid System — Hybrid/Battery Control System — “Hybrid/Battery Control:
HV Battery: Removal / Installation”

+ 2015 Prius:
Engine/FHybrid System — Hybrid/Battery Control System — “Hybrid/Battery Control:
HV Battery: Removal / Installation”

4. Install the HV Battery Cooling Fan Intake Filter as shown (P/N G92DH-47010).

NOTE
The filter should be cleaned when dust begins to appear on the surface.

Figure 3.

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MIL "ON" DTC POA80 Due to Dust or Debris in HV Battery Cooling Fan

Repair Procedure A (Continued)

5. Clear any DTCs that have set during the Repair Procedure and test drive the vehicle to confirm
normal operation.

6. For severe usage vehicles, refer to Service Bulletin T-SB-0198-11, “HV Battery Cooling Fan

Maintenance for Severe Usage Vehicles," for additional HV Battery Cooling Fan maintenance
recommendations.

Repair Procedure B

1. Is the internal filter clogged with dust or debris buildup?

Figure 4.
S
1 | Rear Seat Cushion Assembly 3. | Rear Side Seat Back Assembly RH
2 | Rear Door Scuff Plate RH 4 | Hybrid Battery Intake Filter
NOTE
The seat back does NOT need to be removed even though it’s not shown in the Figure above.

© 2015 Toyota Motor Sales, USA

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MIL "ON" DTC POA80 Due to Dust or Debris in HV Battery Cooling Fan

Repair Procedure B (Continued)
+ YES — Continue to step 2.

+ NO — This bulletin does NOT apply. Refer to TIS, applicable model and model year
Repair Manual:

2013 / 2014 / 2015 Prius:
Engine/Hybrid System — Hybrid/Battery Control System — “Hybrid/Battery
Control: Hybrid Battery System: POA80-123; Replace Hybrid Battery Pack”

NOTE
See step 2 for hybrid battery blower removal for battery intake duct access and inspection.

2. Check the physical condition of the internal filter.
A. If the filter is damaged, replace the HV Battery Intake Filter No. 1 (P/N G92DH-47060).

B. If the filter is physically OK, clean using vacuum and make sure no contaminants enter the
HV Battery cooling system including fan.

CAUTION

* Clean the HV battery intake duct No. 1 with vacuum. Do NOT use water or fluid
when cleaning.

Do not use a wire brush or a scrub brush for cleaning the HV Battery Intake Filter No. 1
due to a concern that the brush may damage the part.

Refer to TIS, applicable model and model year Repair Manual:

* 2013 / 2014 / 2015 Prius:
Engine/Hybrid System —- Hybrid/Battery Control System — “Hybrid/Battery
Control: Battery Blower: Removal”

3. Replace the HV Battery Assembly.
Refer to TIS, applicable model and model year Repair Manual:
+ 2013 Prius:
Engine/Hybrid System = Hybrid/Battery Control System — *Hybrid/Battery Controt:
HV Battery: Removal / Installation”

* 2014 Prius:
Engine/Hybrid System — Hybrid/Battery Control System — “Hybrid/Battery Control:
HV Battery: Removal / Installation ”

* 2015 Prius:
Engine/Hybrid System — Hybrid/Battery Control System — “Hybrid/Battery Control:
HV Battery: Removal / installation”

‘© 2015 Toyota Motor Sales, USA