NHTSA ID Number: 10164333
Manufacturer Communication Number: T-SB-0153-13-Rev
TSB/Document Date: 2019-09-03
Summary
TSB: REVISION NOTICE July 02, 2019 Rev1: ? The Applicable Warranty section has been updated. Any previous printed versions of this bulletin should be discarded. 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 buildup in the HV battery
cooling fan. Follow the Repair Procedure in this bulletin to address this condition.
T-SB-0153-13
Rev1
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
REVISION NOTICE
July 02, 2019 Rev1:
The Applicable Warranty section has been updated.
Any previous printed versions of this bulletin should be discarded.
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 buildup in the HV battery
cooling fan. Follow the Repair Procedure in this bulletin 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 2005 model year), Maine, Massachusetts, New Hampshire
(2005 – 2009 model year), New Jersey (starting with 2005 model year), New York, Oregon
(starting with 2008 model year), Rhode Island (starting with 2005 model year), and Vermont,
this repair is covered under the California Emission Warranty, which is in effect for 180
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.
© 2019 Toyota Motor Sales, USA
Page 1 of 5
T-SB-0153-13
Rev1
October 8, 2013
Page 2 of 5
MIL ON DTC P0A80 or P0A7F Due to Dust or Debris in the HV Battery Cooling
Fan
Parts Information
PART NUMBER
PART NAME
QTY
G92DH-47020
Filter, HV Battery Intake, No. 1
1
G9510-47031
Battery Assy, HV Supply
1
Required Tools & Equipment
REQUIRED EQUIPMENT
QTY
Compressed Air or Vacuum
1
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVi*
PART NUMBER
QTY
TSADVUNIT
Techstream 2.0
TS2UNIT
ADE
1
Techstream Lite
TSLITEPDLR01
Techstream Lite (Green Cable)
TSLP2DLR01
*Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
Software version 14.10.028 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
01413-00072 (Medium)
Insulated Glove Set, Rubber With Leather Protectors*
01413-00073 (Large)
1
01413-00074 (Extra Large)
*Essential SST.
CAUTION
ALWAYS inspect the insulated 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.
© 2019 Toyota Motor Sales, USA
T-SB-0153-13
Rev1
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 buildup.
Refer to TIS, applicable model year 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 buildup as shown?
YES — Continue to step 2.
Figure 1. Clogged Cooling Fan
NO — This bulletin does NOT apply.
Reinstall the filter screen assembly
and troubleshoot the vehicle
using the following applicable
Repair Manual procedure.
Refer to TIS, applicable model year 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”
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”
© 2019 Toyota Motor Sales, USA
T-SB-0153-13
Rev1
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)
2. Clean the dust and debris buildup from the HV battery cooling fan with compressed air
and/or a 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 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”
© 2019 Toyota Motor Sales, USA
T-SB-0153-13
Rev1
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.
© 2019 Toyota Motor Sales, USA
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TSB/Document ID: T-SB-0153-13-Rev
Replacement Service Bulletin Number:
MFR Communication Date: 2019-07-02
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:12V/24V/48V BATTERY
MFR Component System:
MFR Component Subsystem:
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