Toyota2003–2009

Prius 1.5 Hybrid Synergy Drive: Common faults & known problems

Common faults & known problems

3 known faults documented in workshop bulletins. Of these, two concern the engine and fuel system and one the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

2 documented faults — symptoms, causes and workshop fixes.

Failure to start

Affects All models.

Symptoms

Trouble code stored: P0A0D.

Cause

Hybrid battery pack isolator incorrectly fitted after battery pack isolation.

Repair

Ensure hybrid battery pack isolator fitted correctly.

Data: Motorwise Workshop. Bulletin 2.

Unable to remove in-tank fuel pump

Overview

Affects: All models with in-tank fuel pump assembly retaining ring.
Remedy: Fit new part

Cause

Retaining ring for fuel pump assembly seized to fuel tank.

Repair

Cut through retaining ring to enable removal from fuel tank. Avoid damaging fuel tank threads.
Inspect fuel tank threads for damage. If fuel tank threads damaged or new retaining ring will not tighten: Fit new fuel tank.

Data: Motorwise Workshop. Bulletin 3.

Brakes

1 documented fault — symptoms, causes and workshop fixes.

Brakes squeal

Overview

Affects: All models.

Cause

Replacement brake pads fitted without anti-squeal shims.

Repair

Ensure brake pad anti-squeal shims are fitted.
Replacement shims available separately.

Data: Motorwise Workshop. Bulletin 1.

Glossary

Technical terms used in this guide.

In-Tank Fuel Pump: The fuel pump mounted inside the fuel tank
Trouble Code: A standardised fault code stored by a control module, read with a diagnostic tool

Frequently asked questions

What are the common faults with the Toyota Prius 1.5 Hybrid Synergy Drive?

This guide contains three workshop bulletins for the Toyota Prius 1.5 Hybrid Synergy Drive. Of these, two concern the engine and fuel system and one the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Prius 1.5 Hybrid Synergy Drive have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Toyota Prius 1.5 Hybrid Synergy Drive faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.