T-SB-0036-16

Service Bulletin Details

Public Details for: T-SB-0036-16
Tsb: some 2010 ? 2014 prius and 2012 ? 2014 prius v model vehicles may exhibit a mil ?On? Condition with dtcs P0A94, P324E, P0A1A, or P3004, indicating a malfunction has occurred in the hybrid inverter assembly. To help identify the specif
- 2014 - 2013 - 2012 - 2011 - 2010 -
Models from 2014
Models from 2013
Models from 2012
Models from 2011
Models from 2010
T-SB-0036-16
May 12, 2016
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Service
Category
Engine/Hybrid System
Section
Hybrid/Battery Control System
Market USA
Applicability
YEAR(S)
MODEL(S)
2012 - 2014
Prius V
2010 - 2014
Prius
ADDITIONAL INFORMATION
Introduction
Some 2010 – 2014 Prius and 2012 – 2014 Prius V model vehicles may exhibit a MIL “ON”
condition with DTCs P0A94, P324E, P0A1A, or P3004, indicating a malfunction has occurred in
the hybrid inverter assembly. To help identify the specific components within the inverter
assembly that need to be replaced, follow the steps in this service bulletin to address
the condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
EL1602
R & R the Inverter Assembly with Converter
2.0
EL1603
R & R the IPM Transistor
2.9
EL1604
R & R the IPM Transistor and the
MG ECU
OFP
T1
T2
G9200-#####
8A
73
2.9
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.
Warranty application is limited to occurrence of the specified condition described in
this bulletin.
© 2016 Toyota Motor Sales, USA
Page 1 of 12
T-SB-0036-16
May 12, 2016
Page 2 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Parts Information
NOTE
Not all parts listed are needed for HV inverter repair, this list is for reference only. Refer to the
tables below for appropriate components based on the condition BEFORE ordering parts.
PART NUMBER*
PART NAME
G920H-47030
G920H-47040
Computer Sub-Assy, MG Control
w/Bracket
G920J-52010
Sensor Sub-Assy, Inverter Current
G9208-47090
Wire Sub-Assy, Inverter
04899-47021
Transistor Kit, Power Module
Intelligent (IPM)
04899-47060
Plug Kit, Inverter Drain
90430-18008
Gasket
G922L-47010
Cover, Inverter Signal Connector
91551-80618
Bolt, Flange
QTY
1
1
(Required with
any repair
procedure.)
1
(Parts not
required,
available in case
of breakage.)
Seal, Masking, No. 1
1
(Part included in
IPM Kit,
available in case
spare is
needed.)
08887-02809
Toyota Thermal Grease X-23-7884-4
2
(Used only for
IPM
replacement.
Product has
shelf life of 1
year, do NOT
use if stored past
1 year)
08826-00100
Seal Packing (or equivalent)
00272-SLLC2
Super Long Life Coolant
091X1-47020
* Part numbers are subject to change.
© 2016 Toyota Motor Sales, USA
1
T-SB-0036-16
May 12, 2016
Page 3 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
Techstream Lite
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite (Green Cable)
TSLITEPDLR01
1
TSLP2DLR01
NOTE
Only ONE of the Techstream units listed above is required.
Software version 11.10.034 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
00002-03100-S (Small)
Electrical Insulating Gloves*
00002-03200-M (Medium)
1
00002-03300-L (Large)
CAUTION
Always inspect Electrical Insulating 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.
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Oil Seal Puller*
09308-00010
1
Anti-Static Mat*
09890-47010
1
Squeegee*
09891-47010
1
Torque Wrench Adapter*
09961-00950
1
Inverter Case Separator*
09891-47020
1
* Essential SST.
© 2016 Toyota Motor Sales, USA
T-SB-0036-16
May 12, 2016
Page 4 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2010 – 2014 Prius Vehicles
Figure 1.
1. Confirm DTCs are present.
2. If multiple DTCs are present, save the freeze frame data.
3. After saving the freeze frame data, clear codes and confirm what DTCs reset.
4. If multiple codes return, follow the repair manual diagnosis procedure for the DTC with Freeze
Frame Data Occurrence Order value of “1”.
5. Check the position of the Part Number label
on the inverter.

Figure 2.
Type A Inverters:
Label is on side surface for all
part numbers.
Label is on upper surface for part
numbers: G9200-47140,
G9200-47141, G9200-47180 and
G9200-47181 only.

Type B Inverters:
Label is on upper surface.
6. Determine the repair components based on
inverter type and DTC detail code.
1
Upper surface
2
Side surface
© 2016 Toyota Motor Sales, USA
T-SB-0036-16
May 12, 2016
Page 5 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)
Use the correct table below to identify the parts required for repair. The correct parts are listed in
the bottom row of the table.
Prius Inverter Type A: Required Parts by DTC
DTC
DTC
DETAIL
CODE
IPM
REPLACEMENT
 MG-ECU
 CURRENT SENSOR
 INVERTER WIRE HARNESS
X
442
X
547
X
548
X
549
X
550
553
P0A94
X
X
554
X
555
X
556
557
MG-ECU
CURRENT SENSOR
INVERTER
IPM
ASSEMBLY
INVERTER WIRE HARNESS
X
127
172




X
X
564
X
585
X
587
X
589
X
590
X
© 2016 Toyota Motor Sales, USA
T-SB-0036-16
May 12, 2016
Page 6 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)
Prius Inverter Type A: Required Parts by DTC (Continued)
 MG-ECU
 CURRENT SENSOR
 INVERTER WIRE HARNESS




MG-ECU
CURRENT SENSOR
IPM
INVERTER WIRE
HARNESS
DTC
DTC
DETAIL
CODE
P324E
788
X
151
X
P0A1A
P3004
IPM REPLACEMENT
155
X
156
X
166
X
200
X
658
X
659
X
791
X
INVERTER
ASSEMBLY
131
X
132
X
800
X
801
X
PARTS & QUANTITY
(QTY)
FOR SPECIFIC DTC
REPAIR
04899-47021
08887-02809
04899-47060
QTY 1
QTY 2
QTY 1
G920J-52010
G920H-47030
G9208-47090
QTY 1
QTY 1
QTY 1
© 2016 Toyota Motor Sales, USA
G920H-47030 QTY 1
G920J-52010 QTY 1
04899-47021 QTY 1
G9200-49056
QTY 1
00272-SLLC2
QTY 1
T-SB-0036-16
May 12, 2016
Page 7 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)
Prius Inverter Type B: Required Parts by DTC
DTC
DTC
DETAIL
CODE
IPM REPLACEMENT
MG-ECU
 MG-ECU
 IPM
X
127
172
X
X
442
X
547
X
548
X
549
X
550
553
P0A94
X
X
554
X
555
X
556
557
P324E
 MG-ECU
 CURRENT SENSOR
 IPM
X
564
X
585
X
587
X
589
X
590
X
788
X
151
X
155
X
156
X
166
X
200
X
658
X
659
X
791
X
792
X
793
X
P0A1A
© 2016 Toyota Motor Sales, USA
INVERTER
ASSEMBLY
T-SB-0036-16
May 12, 2016
Page 8 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)
Prius Inverter Type B: Required Parts by DTC (Continued)
DTC
DTC
DETAIL IPM REPLACEMENT
CODE
P3004
MG-ECU



 MG-ECU
 IPM
MG-ECU
CURRENT SENSOR
IPM
INVERTER
ASSEMBLY
131
X
132
X
800
X
801
X
PARTS &
QUANTITY
(QTY)
04899-47021
08887-02809
04899-47060
08826-00100
FOR SPECIFIC 90430-18008
DTC REPAIR 00272-SLLC2
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
G920H-47030
04899-47060
08826-00100
90430-18008
00272-SLLC2
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
04899-47021
08887-02809
G920H-47030
04899-47060
08826-00100
90430-18008
00272-SLLC2
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
04899-47021 QTY 1
08887-02809 QTY 2
G920H-47030 QTY 1
G920J-52010 QTY 1
04899-47060 QTY 1
08826-00100 QTY 1
90430-18008 QTY 1
00272-SLLC2 QTY
*G9200-49025
(FOR
PRODUCTION
DATES OF
04/2009-10/2013)
QTY 1
*00272-49075
(FOR
PRODUCTION
DATES AFTER
10/2013) QTY 1
00272-SLLC2 QTY
1
Repair Procedure for 2012 – 2014 Prius V Vehicles
Figure 3.
1. Confirm DTCs are present.
2. If multiple DTCs are present save the freeze frame data.
© 2016 Toyota Motor Sales, USA
T-SB-0036-16
May 12, 2016
Page 9 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2012 – 2014 Prius V Vehicles (Continued)
3. After saving the freeze frame data, clear codes and confirm what DTCs reset.
4. If multiple codes return follow the Repair
Manual diagnosis procedure for the DTC
with Freeze Frame Data Occurrence Order
value of “1”.
5. Check the position of the Part Number label
on the inverter.
Figure 4.
6. Type A Inverters:
Label is on side surface for all
part numbers.
Label is on upper surface for part
numbers: G9200-47160,
G9200-47161, G9200-47162 ONLY.
7. Type B Inverters:
Label is on upper surface.
1
Upper surface
2
Side surface
8. Determine repair components based on inverter type and DTC detail code.
Use the correct table below to identify the parts required for repair, the correct parts are listed in the
bottom row of the table.
Prius V Inverter Type A: Required Parts by DTC
DTC
DTC DETAIL
CODE
IPM REPLACEMENT




MG-ECU
CURRENT SENSOR
IPM
INVERTER WIRE HARNESS
127
172
X
442
X
548
X
550
X
553
P0A94
X
X
555
557
X
X
564
X
585
X
587
X
589
X
590
X
© 2016 Toyota Motor Sales, USA
INVERTER ASSEMBLY
T-SB-0036-16
May 12, 2016
Page 10 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2012 – 2014 Prius V Vehicles (Continued)
Prius V Inverter Type A: Required Parts by DTC (Continued)
P324E
788
X
P0A1A
151
X
131
X
132
X
P3004
800
X
801
X
PARTS & QUANTITY
(QTY)
FOR SPECIFIC DTC
REPAIR
04899-47021
08887-02809
04899-47060
08826-00100
90430-18008
00272-SLLC2
G920H-47040
G920J-52010
04899-47021
08887-02809
G9208-47090
04899-47060
08826-00100
90430-18008
00272-SLLC2
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
QTY 1
G9200-49056 QTY 1
00272-SLLC2 QTY 1
Prius V Inverter Type B: Required Parts by DTC
DTC
DTC DETAIL
CODE
IPM REPLACEMENT
X
X
442
X
548
X
550
553
P0A94
X
X
555
557
 MG-ECU
 CURRENT SENSOR
 IPM
X
127
172
 MG-ECU
 IPM
X
564
X
585
X
587
X
589
X
590
X
P324E
788
X
P0A1A
151
X
© 2016 Toyota Motor Sales, USA
INVERTER
ASSEMBLY
T-SB-0036-16
May 12, 2016
Page 11 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2012 – 2014 Prius V Vehicles (Continued)
Prius V Inverter Type B: Required Parts by DTC (Continued)
131
X
132
X
P3004
800
X
801
X
PARTS & QUANTITY
(QTY)
FOR SPECIFIC DTC
REPAIR
04899-47021
08887-02809
04899-47060
08826-00100
90430-18008
00272-SLLC2
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
G920H-47040
04899-47021
08887-02809
04899-47060
08826-00100
90430-18008
00272-SLLC2
QTY 1
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
G920H-47040
G920J-52010
04899-47021
08887-02809
04899-47060
08826-00100
90430-18008
00272-SLLC2
QTY 1
QTY 1
QTY 1
QTY 2
QTY 1
QTY 1
QTY 1
QTY 1
G9200-49056 QTY 1
00272-SLLC2 QTY 1
Repair Procedure 2010 – 2014 Prius and 2012 – 2014 Prius V Vehicles
1. Repair the inverter. Refer to the Technical Information System (TIS), applicable model, and
model year Repair Manual:






2010 Prius:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
2011 Prius:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
2012 Prius:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
2013 Prius:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
2014 Prius:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
2012 Prius V:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
© 2016 Toyota Motor Sales, USA
T-SB-0036-16
May 12, 2016
Page 12 of 12
MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004
Repair Procedure for 2010 – 2014 Prius and 2012 – 2014 Prius V Vehicles (Continued)


2013 Prius V:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
2014 Prius V:
Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power Module
Intelligent Transistor: Removal / Installation”
2. Clear DTCs and confirm repair.
HINT
The link below contains best practices when repairing the inverter.
Quick Training Guide – QTG014B: Prius Inverter Repair Best Practices
© 2016 Toyota Motor Sales, USA