Hybrid Systems - MIL ON/DTC P0A80 Set
T-SB-0100-12July 13, 2012
MIL "ON" DTC P0A80 due to Dust or Debris in HV Battery
Cooling Fan
Service
Category Engine/Hybrid System
Section
Hybrid/Battery Control System
Market
USA
Applicability
Introduction
Some 2012 model year Prius vehicles may exhibit a MIL "ON" condition with Diagnostic Trouble Code (DTC) P0A80 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
Calibration Information
Parts Information
Required Tools & Equipment
Repair Procedure
1. Inspect the HV Battery Cooling Fan for dust or debris build-up.
Refer to the Technical Information System (TIS), 2012 Prius Repair Manual:
^ Engine/Hybrid System - Hybrid/Battery Control System - "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.
^ YES - Proceed to step 2.
^ NO - This bulletin does NOT apply. Troubleshoot the vehicle using the Repair Manual procedure.
Refer to TIS, 2012 Prius Repair Manual:
Engine/Hybrid System - Hybrid/Battery Control System - "Hybrid/Battery Control: Hybrid Battery System: P0A80-123: Replace Hybrid Battery Pack"
2. Clean dust and debris build-up from the HV Battery Cooling Fan with compressed air.
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, 2012 Prius Repair Manual:
^ Engine/Hybrid System - Hybrid/Battery Control System - "Hybrid/Battery Control: HV Battery: Removal / Installation"
4. Install the HV Battery Cooling Fan Intake Filter as shown.
5. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 3. Confirm if the Power Management ECU calibration has been updated. If the calibration ID listed is NOT the latest Power Management ECU calibration - go to step 6.
6. Flash reprogram the Power Management ECU.
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on the Technical Information System (TIS), Diagnostics � Tools & Equipment � Battery Diagnostics.
Follow the procedures outlined in Service Bulletin T-SB-0064-10, "Techstream ECU Flash Reprogramming Procedure", and flash the Power Management ECU with the NEW calibration .le update.
7. Install the Authorized Modifications Label.
A. Using a permanent marker, enter the following information on the label:
^ ECU part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This SB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 3. The Authorized Modifications Label is available through the MDC, P/N 00451-00001-LBL.
8. Clear any DTCs that have set during the repair procedure and test drive the vehicle to confirm normal operation.
9. 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.
© 2012 Toyota Motor Sales, USA