NHTSA ID Number: 10132091
Manufacturer Communication Number: T-SB-0153-13
TSB/Document Date: 2018-04-02
Summary
Some 2004 ? 2009 model year Prius vehicles may exhibit a MIL ?ON? condition with Diagnostic Trouble Code (DTC) P0A80 or P0A7F stored due to dust or debris build-up in the HV Battery
Cooling Fan. Use the following repair procedure to address this condition.
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TSB/Document ID: T-SB-0153-13
Replacement Service Bulletin Number:
MFR Communication Date: 2013-10-08
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
T-SB-0153-13
October 8, 2013
MIL "ON" DTC P0A80 or P0A7F due to Dust or Debris in
the HV Battery Cooling Fan
Service
Category
Engine/Hybrid System
Section
Market
USA
Applicability
YEAR(S)
MODEL(S)
2004 – 2009
Prius
ADDITIONAL INFORMATION
Introduction
Some 2004 – 2009 model year Prius vehicles may exhibit a MIL “ON” condition with Diagnostic
Trouble Code (DTC) P0A80 or P0A7F stored due to dust or debris build-up in the HV Battery Cooling
Fan. Use the following repair procedure to address this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EL1312
Clean HV Battery Cooling Fan,
Replace HV Battery Assembly, and
Install HV Battery Cooling Fan Intake Filter
1.9
G9510-47031
8A
99
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 (starting with ’05 MY), Maine, Massachusetts, New Hampshire (’05 MY – ’09 MY),
New Jersey (starting with ’05 MY), New York, Oregon (starting with ’08 MY), Rhode Island
(starting with ’05 MY), 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.
Parts Information
PART NUMBER
PART NAME
QTY
G92DH-47020
Filter, HV Battery Intake, No. 1
1
G9510-47031
Battery Assy, HV Supply
1
© 2013 Toyota Motor Sales, USA
Page 1 of 5
T-SB-0153-13
Page 2 of 5
October 8, 2013
MIL "ON" DTC P0A80 or P0A7F due to Dust or Debris in the HV Battery Cooling
Fan
Required Tools & Equipment
REQUIRED EQUIPMENT
QTY
Compressed Air or Vacuum
1
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
TIS Techstream
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite
1
TSPKG1
TSLITEDLR01
NOTE
• Only ONE of the Techstream units listed above is required.
• Software version 8.20.019 or later is required.
• Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at
1-800-368-6787.
PART NUMBER
SPECIAL SERVICE TOOLS (SST)
QTY
00002-03100-S (Small)
Electrical Insulating Gloves*
00002-03200-M (Medium)
00002-03300-L (Large)
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
* Essential SST.
© 2013 Toyota Motor Sales, USA
1
T-SB-0153-13
October 8, 2013
Page 3 of 5
MIL "ON" DTC P0A80 or P0A7F due to Dust or Debris in the HV Battery Cooling
Fan
Repair Procedure
1. Inspect the HV Battery Cooling Fan for dust or debris build-up.
Refer to the Technical Information System (TIS), applicable model year Prius Repair Manual:
• 2004 / 2005 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Battery Blower Assy:
Replacement”
• 2006 / 2007 / 2008 / 2009 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Battery Control:
Battery Blower: Removal”
Is the HV Battery Cooling Fan clogged with dust or debris build-up? Refer to Figure 1 for an
example of a clogged cooling fan.
Figure 1.
• YES – Proceed to step 2.
• NO – This bulletin does NOT apply. Install filter screen assembly and troubleshoot the
vehicle using the applicable Repair Manual procedure.
Refer to TIS, applicable model year Prius Repair Manual:
P0A80:
• 2004 / 2005 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid Battery System:
P0A80 Replace Hybrid Battery Pack”
• 2006 / 2007 / 2008 / 2009 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Battery Control:
Hybrid Battery System: P0A80; Replace Hybrid Battery Pack”
© 2013 Toyota Motor Sales, USA
T-SB-0153-13
October 8, 2013
Page 4 of 5
MIL "ON" DTC P0A80 or P0A7F due to Dust or Debris in the HV Battery Cooling
Fan
Repair Procedure (Continued)
P0A7F:
• 2004 / 2005 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid Battery System:
P0A7F Hybrid Battery Pack Deterioration”
• 2006 / 2007 / 2008 / 2009 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Battery Control:
Hybrid Battery System: P0A7F; Hybrid Battery Pack Deterioration”
2. Clean dust and debris build-up from the HV Battery Cooling Fan with compressed air
and/or vacuum.
NOTICE
Do NOT allow the cooling fan to spin freely during cleaning. This may damage the cooling
fan motor.
3. Replace the HV Battery Assembly.
Refer to TIS, applicable model year Prius Repair Manual:
• 2004 / 2005 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “HV Battery: Removal &
Installation and Disassembly & Reassembly”
• 2006 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Battery Control:
HV Battery: Removal / Installation”
• 2007 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Battery Control:
HV Battery: Removal / Installation”
• 2008 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Battery Control:
HV Battery: Removal / Installation”
• 2009 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Battery Control:
HV Battery: Removal / Installation”
© 2013 Toyota Motor Sales, USA
T-SB-0153-13
October 8, 2013
Page 5 of 5
MIL "ON" DTC P0A80 or P0A7F due to Dust or Debris in the HV Battery Cooling
Fan
Repair Procedure (Continued)
4. Install the HV Battery Cooling Fan Intake Filter as shown.
NOTE
The filter should be cleaned when dust begins to appear on the surface.
Figure 2.
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-0098-13, “HV Battery Cooling Fan
Maintenance for Severe Usage Vehicles,” for additional HV Battery Cooling Fan maintenance
recommendations.
© 2013 Toyota Motor Sales, USA
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