Engine & fuel system
5 documented faults — symptoms, causes and workshop fixes.
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 1.
Hybrid battery pack overheating
Foreign objects and/or debris in hybrid battery pack cooling fan reducing or stopping air flow. Fix: clean and lubricate.
Overview
- Affects
- All models, 2013→.
- Remedy
- Clean & lubricate
Symptoms
Engine malfunction indicator lamp (MIL) illuminated. Hybrid drive system warning lamp illuminated.
Repair steps
- Remove and clean hybrid battery pack cooling fan.
- Fit hybrid battery pack air intake aperture filter.
- Check operation and condition of hybrid battery pack. Replace if necessary.
Parts
| Part | Part number | Qty |
|---|---|---|
| Filter | G92DH-47010 | 1 |
Data: Motorwise Workshop. Bulletin 2.
Engine difficult to start after standing for 3hours or more
Cause
Unsatisfactory design of injectors.
Repair
- Inspect production number on injectors If production number 0692, replace injectors.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Injector | 23209-39145 | 4 |
Data: Motorwise Workshop. Bulletin 3.
Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P0401
EGR valve not operating properly due to build up of deposits. Fix: fit a modified part.
Overview
- Affects
- All models with 2ZR-FXE engine code, →12/12.
- Fault codes
P0401- Remedy
- Fit modified part
Repair steps
- Fit modified EGR valve.
- Re-route EGR valve wiring, leaving sufficient slack to allow for engine movement: Remove insulation tape from wiring harness Apply adhesive tape to area indicated.
- Re-program engine control module (ECM) with upgraded software. Note: To carry out an effective repair a software upgrade will be required - refer to manufacturer.
Parts
| Part | Part number | Qty |
|---|---|---|
| EGR valve | 25620-37120 | 1 |
| EGR valve gasket | 25685-37010 | 1 |
Data: Motorwise Workshop. Bulletin 4.
Engine overheating
Overview
- Affects
- All models with 2ZR-FXE engine code.
- Remedy
- Fit modified part
- Parts
- 1 part
Symptoms
Coolant loss with no signs of coolant leak. White smoke coming from exhaust.
Cause
Unsatisfactory design of cylinder head gasket.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Fit modified cylinder head gasket.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Cylinder head gasket | 11115-37080 | 1 |
Data: Motorwise Workshop. Bulletin 5.
Glossary
Technical terms used in this guide.
- MIL
- Malfunction indicator lamp — the engine warning light on the dashboard
- ECM
- Engine control module — the electronic unit that manages the engine
- Control Module
- A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
- EGR Valve
- The valve that meters exhaust gas back into the intake
- In-Tank Fuel Pump
- The fuel pump mounted inside the fuel tank
- Re-Program
- Update the software on a control module using the manufacturer's diagnostic tool
- Wiring Harness
- The bundled cables that carry power and signals around the vehicle
- Head Gasket
- The seal between the cylinder head and the engine block
Frequently asked questions
What are the common faults with the Toyota Prius 1.8 PHEV?
This guide contains five workshop bulletins for the Toyota Prius 1.8 PHEV. Of these, five concern the engine and fuel system. Symptoms, causes, repair steps and part numbers are shown where supplied.
Does every Toyota Prius 1.8 PHEV 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 1.8 PHEV faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.