Repair
Gen 1 Prius code P3130: Inverter System Cooling Malfunction
NEWS FLASH!
Prius have two cooling systems: one for the engine and one for the high voltage inverter. They have two separate fill points (see pic: Carolyn’s left hand is pointing to the inverter reservoir, right to the radiator cap).
Technicians failing to fill both systems will cause overheating to whichever system is neglected (illuminating the Master Warning Light (red triangle) and the “check engine” light). I’ve seen this so many times that I’m starting to get angry!!! I mean, if you don’t know (or can’t figure out) that the car has two cooling systems, you have no business working on it!!!!
To be fair, inverter cooling systems are predisposed to another problem (besides unqualified techs) of failing water pumps. Gen 2 inverter water pump issues have been discussed previously: Prius Code P0A93: Inverter Water Pump Failure. But 2001, 2002, and 2003 Prius have the same problem. 
At the moment we have three Gen 1 Prius here with inverter cooling issues (with P3130 stored), to which I dedicate this blog.
When Gen 1 Prius inverters overheat, they set a trouble code P3130: Inverter Cooling System malfunction. The next step is to pop the hood and look at the reservoir. Does it have coolant? If not, there is problem #1. Of the three cars here, one was simply left unfilled (system overlooked); the second had the 
drain plug left loose and consequently lost all its coolant down the road (see pic of dried coolant trail).
If the car has coolant, the next question is whether it’s flowing. Remove the cap on the inverter reservoir (the one ATTACHED to the inverter) and look for turbulence. No turbulence? The car either has air in the system or the pump is stopped.
Find the pump (hint: it’s behind the driver’s headlamp assembly) and put your hand on it. Is it vibrating? Then there’s probably air in the system prohibiting coolant flow. (In this case the pump should also be noisy; you can massage the hoses to work the air out of the system; when it’s quiet and you confirm turbulence in the reservoir, you’re done.) It is possible that the motor is running but the impeller has broken free, in the case that you have vibration but no noise and no turbulence. I have never seen this, but it’s possible. Let common sense guide you.
No vibration? Check the power and ground to the pump, at the connector. I use a noid light; when it illuminates I know the pump is bad; otherwise troubleshoot the circuit.
Of the three cars here, one has a seized pump (it just went bad on its own, which is common); the one with the missing coolant was also disconnected from power (I will have to check it once I fill the system) with the pump actually tucked under the inverter (!) so it appeared to be missing; the third one—with the loose drain plug—has a powered pump that’s now seized from being run without any coolant in the system (which also cools the motor and probably lubricates it too).
To fill and bleed the cooling system LG charges $80 plus tax:
Labor: $60
1 Gallon Super Long Life Coolant: $20
To replace the pump costs $380 plus tax:
Labor: $240
Inverter Water Pump G9020-47022: $140
(Pic of three inverter water pumps today: two for cars and one for inventory)
Posted by Carolyn
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Gen 2 Prius MFD Screen Repair, $500
2004-2005 Prius multi-function displays have some weak soldering points, causing a failure well documented by our colleagues across the bay at Art’s Automotive:
Repairing the Multi-function Display via ArtsAutomotive.com
New screens from the dealer are unmercifully expensive, between $3000-$5000 depending on the model (navigation or no). Much more attractive—not to mention green—is the prospect of repairing the original screen.
Paul from Art’s, author of the earlier link, openly admits that he got his info from Hobbit, the east-coast Prius guru (pictured demonstrating the safety of Prius high voltage AC motor phases, from a class Carolyn attended back in 2006). His original account of repairing the screen is also available online:
Evaluation and repair of a failed Prius MFD via techno-fandom.org
Hobbit basically pinpoints his problem to a pair of joints on the top board, the most common point of failure. Like Art’s, we offer resoldering of these joints in house. 
(To be honest we hire Eric, our friend and IT computer science geek, to perform the very fine solders himself.)
The price for the service, including removal and reinstallation of the screen: $500
Admittedly there are other possibilities for failure. Because the diagnostic time necessary to chase those other potential soldering breaks quickly outpaces the value of an already repaired (or otherwise guaranteed) used unit, we offer a fall back solution: if the first soldering attempt does not work, we’ll replace the unit with a known-good one from Steve Woodruff of AutoBeYours, which comes with a 1 year warranty, at no additional cost.
In other words, if the initial repair doesn’t work, we’ll replace with a used unit, parts and labor, for the same price, $500. Of course we’re happy just to switch yours out with a replacement screen, if you prefer.
Use the contact page for appointments... or call us: 415-875-9030
Photo Gallery of Screen Repairs, for the curious:
Screen removed and on the bench, Carolyn disassembles for Eric:
Two screens that recently failed in two separate Prius, ready for attention:
Eric, the 21st century mechanic, working his magic:
Posted by Carolyn
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Gen 1 Prius Steering Rack Failure, Code C1513 Torque Sensor Malfunction
(This blog is one in a series on Gen 1 Prius common failures. Read the introductory blog here.)
CUT TO THE CHASE? LINK TO PRICES BELOW
Classic Prius, model years 2001, 2002, and 2003, employ a 12V electric motor for power steering assist. The following is an explanation of how the system is designed, how it fails, and how much it costs to fix.
The motor is integrated around the shaft of the pinion gear (input part of the steering rack) and the amount of assist is interpreted through a torque sensor, mounted at the top of the motor. The sensor has two pads, each with two “fingers” (think of the needle on a record player); as the steering wheel is turned the sensor flexes, changing where the fingers touch the pads, which corresponds to varying voltage values sent to the steering computer. The amount of flex translates the resistance to steering and, therefore, the amount of assist needed.
This sensor has a penchant for failure, triggering the “Problem” screen on the center display, illuminating “PS MAIN” for power steering (pic forthcoming), and setting trouble code C1513: Torque Sensor Abnormal/Malfunction. Out of range voltage values are saved in the computer’s “freeze frame” at the time of failure and confirm the code and that the sensor is bad. The component cannot be purchased separate from the rack.
Other symptoms include jerky steering assist (sometimes quite frightening). It’s possible for the code to set with no change to steering performance.
We have also experienced intermittent steering assist from cars with no codes or warning lights (but no less scary), which may originate from the torque sensor or internal failure of the assist motor windings. Regardless the rack must be replaced as a unit.
Toyota did issue a recall campaign for steering racks on early models (first three months of the 2001 model year run, produced between May 9th, 2000 and July 21st, 2000, which equates to less than 2000 units), with replacement covered by Toyota for free.
PDF of Toyota Special Service Campaign Y05, 2001 Model Year Prius Power Steering Gear, Letter to Dealers
(an interesting look at Toyota’s attitude towards Prius early adopters)
Of the cars we’ve seen with rack failures, none was produced during this small window (which makes you wonder what exactly they improved); in fact we’ve even seen a failure in a car that already had its rack replaced under this campaign (years ago). In short, while there is a chance your rack could qualify for free replacement, it’s not likely. We do however check to see if the campaign applies to any vehicle’s we diagnose with this condition.
Given the widespread failure of these components, we no longer entertain used replacements. We did replace a rack with a used one once, at the owner’s insistence, and it ended up being bad “out of the box” and proved a real PITA for everyone involved.
The good news is that new racks are readily available from dealer parts departments and can be replaced quickly and easily. The unit is mounted to the top of the vehicle subframe (on John’s hand, in pic); there are a few tricks to stay out of trouble (a cautionary note to other techs who may be reading), but LG charges 2.5 hours for R&R plus a front wheel alignment.
Prices
Price breakdown for the job:
Labor: $300
New Steering Rack: $1499
Front End Alignment: $85
Sales Tax: $142.41
Total: $2026.41
Posted by Carolyn
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Prius Tires
NOTE: This blog has been superceded: Click here for the latest one
The Prius doesn’t need much, but it does go through tires. The first generation—a small, heavy car thanks to its hybrid components—calls for Bridgestone Potenzas, which can be safely inflated to 50psi to maximize fuel economy and tread wear. After learning the hard way, many owners attest to getting the most for their money both in tires and gasoline with this product.
The second generation Prius comes stock with a different, more standard-sized tire, the Goodyear Integrity P185/65R15 86S, which lasts 40,000 miles at best (consistent inflation to 40psi and rotations every 5000 miles) and less than 30,000 miles at worst. It’s designed to get optimal fuel economy results for EPA certification (numbers listed on the label when the car is for sale), the top priority for Prius buyers, and therefore compromises on other performance specs such as endurance and traction. Given their short lifespan, Gen 2 Prius owners have been quickly posed with the question of tire replacement and how to improve on the original.
Being specialists, we have been vetting the plethora of choices for some time (OMG PriusChat) and have currently settled on the Goodyear Assurance FuelMax, in the standard size of 185/65R15 86T (slightly higher speed rating than original). I like this tire because it keeps with the OE brand of Goodyear; it’s specially designed to maximize fuel economy while tipping its hat to the most common complaints of poor traction and short tire life, all at a reasonable price.
LG does not maintain its own tire equipment, for lack of space and, frankly, lack of profit (tires are a highly competitive market and they don’t require our technical expertise to change). That said, we do advocate for informed, responsible tire choices and therefore carry the Potenza and Assurance FuelMax in stock (Potenzas are also the best for the Insight, and we carry that size too). Because the market is often slow to respond to hybrid trends, the correct tires are occasionally on backorder—problematic when you need tires now for a multiyear, high-dollar investment.
We purchase through Tire Rack at wholesale prices and mark them up to compensate for our expertise and the convenience of having them in stock. Individuals can also purchase from Tire Rack directly at a slight cost savings.
We sublet tire mount and balance to Larkins Brothers Tire a little over a mile away; they’re as green as any regular shop (which is to say, no greener than what’s required by law) but they’re honest, inexpensive, fast, and their employees seem well treated. (We also use Robert’s Tire around the corner when we’re in a rush, they’re a little more expensive and not quite as fast, but proximity allows us to leave the car and walk back to work and they’re equally capable and honest.) We do not mark up for installation ($25 per tire) but are willing to facilitate the service as a courtesy of getting it done while your car is already with us and not having to deal with a separate service facility.
All told, the cost of a tire, installed, is as follows:
Gen 1 Prius (model year 2001, 2002, 2003):
Bridgestone Potenza P175/65R14 RE92 XL - $108.80
9.5% Sales Tax - $10.34
Mount/Balance/Fees - $25
Total - $144.14/tire
Gen 2 Prius (model years 2004, 2005, 2006, 2007, 2008, and 2009 with the standard package)
Goodyear Assurance FuelMax P185/65R15 86T - $106.53
9.5% Sales Tax - $10.12
Mount/Balance/Fees - $25
Total - $141.65/tire
Gen 1 Insight (model years 2000, 2001, 2002, 2003, 2004, 2005, 2006)
Bridgestone Potenza P165/65R14 78S - $111.80
9.5% Sales Tax - $10.62
Mount/Balance/Fees - $25
Total - $147.42/tire
Tires are critical to safety: evidence pics from a 2006 Prius tire that literally wore through the steel belts and blew on the San Francisco Bay Bridge last Saturday. Many people swear by Costco; just yesterday a customer was telling me how he got 90,000 mile Michelins that originally lost on fuel economy (a common complaint with Costco tires) but is now getting 2 mpg better than original (which he and the salesman attributed to the treads “firming up") for $400 out the door (though he suggested this was a special sale price). Other popular choices are Yokohamas and Kumhos. Just last week I put a customer into Nexans because his car was a city workhorse and he didn’t mind current vehicle traction.
Obviously tires are high consumers of natural resources and the lifespan of the tire entails its own built-in fuel economy. Traction is another serious concern, in terms of safety and the resources entailed in repair and tow after an accident. The second generation Prius remains fairly new, and few have gone through enough tires to really know how long the replacements will last and what the lifetime fuel economy and other performance specs are. At some point the question is a Buridan’s ass, and there are as many tires available as there are advocates for buying them.
For more information on tire choices in the paradigm of fuel economy, check out:
Tire Rolling Resistance, Part 1 via TireRack.com
Tire Rolling Resistance, Part 2 via TireRack.com
Tire Rolling Resistance, Part 3 via TireRack.com
Posted by Carolyn
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Gen 2 Prius Leaking Water Pump
Second generation Prius have four water pumps, three electric and one mechanical. The mechanical pump is much like those on conventional four-cylinder engines: it is belt driven and bolted on with a handful of 10mm fasteners. Like regular cars, it also has the potential to leak. Initial signs are a pink crust under the weep hole; coolant residue eventually spreads around the shaft seal and down the front of the engine. We’ve never seen them bad enough to cause enough coolant loss to overheat the engine but there’s no question that the pump should be replaced. The good news is that the repair is straightforward and reasonably priced. Book time is just short of two hours, we charge an hour and a half.
Engine Mechanical Water Pump = $103.89
Toyota P/N 16100-29156-83
1.5 Gallons Super Long Life Coolant = $30.00
Sales Tax = $11.38
Labor = $180
Total = $325.27