T-SB-0116-15 Rev

T-SB-0116-15
Rev1
November 19, 2015
Misfire While Driving With EGR Active
Service
Category
Engine/Hybrid System
Section
Intake/Exhaust
Market USA
Applicability
YEAR(S)
MODEL(S)
2012 - 2015
Prius PHV
2012 - 2016
Prius V
2010 - 2015
Prius
ADDITIONAL INFORMATION
REVISION NOTICE
August 11, 2016 Rev1:
Applicability has been updated to include 2016 model year Prius V vehicles.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2010 – 2015 model year Prius (2ZR-FXE equipped) vehicles, 2012 – 2015 model year
Prius PHV vehicles, and 2012 – 2016 Prius V (2ZR-FXE equipped) vehicles may exhibit a “runs
rough” and/or MIL “ON” condition with DTC(s) P0300, P0301, P0302, P0303, and P0304 (Misfire)
during light acceleration while the Exhaust Gas Recirculation (EGR) system is active. Replace the
Intake Manifold assembly to address this condition.
Parts Information
PART NUMBER
PREVIOUS
NEW
17120-37050
17120-37051
17120-37052
17120-37053
17120-37054
17120-37054
25634-37030
PART NAME
QTY
Manifold Assy, Intake
1
Gasket, EGR Pipe
1
© 2016 Toyota Motor Sales, USA
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Misfire While Driving With EGR Active
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
8A
88
17120-37050
17120-37051
170011
R & R Intake Manifold Assembly
1.5
17120-37052
17120-37053
17120-37054
APPLICABLE WARRANTY
This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
36 months or 36,000 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.
For California specification vehicles sold, registered, and operated in California, Connecticut
(starting with 08MY), Delaware (starting with 14MY), Maine (starting with 04MY), Maryland
(starting with 11MY), Massachusetts, New Jersey (starting with 09MY), Oregon (starting with
09MY), Pennsylvania (starting with 08MY), Rhode Island (starting with 08MY), Vermont and
Washington (starting with 09MY), this repair is covered under the California Long-Term
Emission Warranty. This warranty is in effect for 84 months or 70,000 miles, whichever occurs
first, from the vehicle's in-service date.
Prius (beginning with 04MY) and Prius PHV warranty coverage for all emissions components is
180 months or 150,000 miles, whichever comes first, from the vehicle's in-service date. Other
states that have adopted California Emission Coverage are Arizona (12MY only), Connecticut
(starting with 05MY), Delaware* (starting with 14MY), Maine, Maryland (starting with 11MY),
Massachusetts, New Jersey (starting with 05MY), New York, Oregon (starting with 08MY),
Pennsylvania* (starting with 08MY), Rhode Island (starting with 05MY), Vermont and
Washington* (starting with 09MY).
*In Delaware, Pennsylvania and Washington, California Emissions coverage for Prius and Prius
PHV is 84 months or 70,000 miles.
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
Techstream Lite
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite (Green Cable)
TSLITEPDLR01
TSLP2DLR01
* Essential SST.
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.
© 2016 Toyota Motor Sales, USA
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Misfire While Driving With EGR Active
Repair Procedure
1. Use Techstream to check for DTCs, and confirm the condition per the Introduction.
NOTE
This bulletin is ONLY applicable if the condition occurs during EGR operation while driving.
If the symptoms are different, this bulletin does NOT apply, proceed with normal
misfire diagnostics.
During a road test the EGR can be disabled by disconnecting the EGR connector to verify
the condition.
2. Remove and replace the Intake Manifold Assembly.
Refer to the Technical Information System (TIS), applicable model and year Repair Manual:

2010 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2011 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2012 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2013 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2014 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2015 Prius:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2012 Prius V:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2013 Prius V:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2014 Prius V:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”
© 2016 Toyota Motor Sales, USA
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Misfire While Driving With EGR Active
Repair Procedure (Continued)

2015 Prius V:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2016 Prius V:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2012 Prius PHV:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2013 Prius PHV:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2014 Prius PHV:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”

2015 Prius PHV:
Engine/Hybrid System – Intake/Exhaust – “2ZR-FXE Intake/Exhaust: Intake Manifold:
Removal / Installation”
3. Clear the DTC(s) and verify normal vehicle operation.
© 2016 Toyota Motor Sales, USA