T-SB-0204-12_Rev

T-SB-0204-12
Rev2
October 17, 2012
Headlamp Durability Enhancement
Service
Category
Vehicle Exterior
Section
Lighting (ext)
Market USA
Applicability
YEAR(S)
MODEL(S)
2010 - 2012
Prius
ADDITIONAL INFORMATION
REVISION NOTICE
February 21, 2018 Rev2:
 Applicability has been updated to include 2012 model year Prius vehicles.
 The Required Tools & Equipment section has been updated.
October 17, 2017 Rev1:
 The Repair Procedure section has been updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2010 – 2012 model year Prius vehicles may exhibit a condition where a halogen low beam
headlamp bulb lifetime is shorter than customer expectation. Follow the Repair Procedure in this
bulletin to address this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
EL1220
Install No. 4 Wire Harness With Headlamp
Alignment (One Side)
1.7
Combo A
Other Side
1.2
OFP
T1
T2
90981-13075
72
71
APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic 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.
© 2018 Toyota Motor Sales, USA
Page 1 of 9
T-SB-0204-12
Rev2
October 17, 2012
Page 2 of 9
Headlamp Durability Enhancement
Parts Information
PART NUMBER
PART NAME
QTY
04007-52147
Repair Kit, Headlamp Bulb
1
PART NUMBER
PART NAME
QTY
90981-13075
Bulb
2
82114-47010
Engine Wire No. 4
2
82999-52010
Sleeve Tube
2
82999-30010
Heat Shrink Tube
2
Headlamp Bulb Repair Kit Parts
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Kit*
00002-06020-02
1
Lance Canceling Tool M
09991-00510
1
Wire Crimper*
09042-2C100
1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
REQUIRED TOOLS & MATERIAL
QUANTITY
Nylon Ties
13
Measuring Tool (Metric Ruler)
1
Heat Gun
1
© 2018 Toyota Motor Sales, USA
T-SB-0204-12
Rev2
October 17, 2012
Page 3 of 9
Headlamp Durability Enhancement
Repair Procedure
1. Replace both of the headlamp bulbs.
2. AFTER confirming the headlamps work, verify headlight aim is visually correct and that there
are no signs of damage or alterations to wiring or headlamps.
NOTE
If a NEW bulb has been installed and the bulb is still inoperative, this bulletin does NOT apply.
Continue diagnosis using the applicable Repair Manual.
3. Remove the front bumper cover assembly.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 Prius:
Vehicle Exterior – Exterior Panels/Trim – “Exterior Panels / Trim: Front Bumper: Removal”
4. Remove the affected headlamp assembly.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 Prius:
Vehicle Exterior – Lighting (Ext) – “Lighting (Ext): Headlight Assembly: Removal”
© 2018 Toyota Motor Sales, USA
T-SB-0204-12
Rev2
October 17, 2012
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Headlamp Durability Enhancement
Repair Procedure (continued)
Figure 1.
1
6
8
2
5
7
3
4
8
1
Lance Canceling Tool M
5
Rem ove Violet Wire Harness from Connector
2
Headlam p Bulb No. 2 Connector
6
Front View
3
Engine ROOM Main Wire Harness (White-Black)
7
Cross Section
4
Engine ROOM Main Wire Harness (Violet)
8
Lock
5. Modify the existing headlamp harness and install the engine wire No. 4 harness.
NOTE
This wiring harness extends the factory headlamp wiring harness and will be placed between the
headlight socket and existing headlamp wiring harness. The harness will be cut with a special
crimping tool to make an adequate crimp. It is important to use the suggested crimp tool and follow
the instructions below to ensure a proper crimp.
A. Remove the green cap from the
headlamp connector by carefully using
a small screwdriver or pick to detach the
cap as shown.
Figure 2.
© 2018 Toyota Motor Sales, USA
T-SB-0204-12
Rev2
October 17, 2012
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Headlamp Durability Enhancement
Repair Procedure (continued)
B. AFTER the cap is removed, remove terminal 2 (violet wire) from the low beam headlight
connector wire using lance canceling tool M.
SST: P/N 09991-00510
(1) AFTER the terminal cap is removed,
gently insert lance canceling tool M
into the connector between the
terminal and the terminal lock
(see Figures 1 and 3), then gently
push the terminal lock to the
outward side of the connector.
Do NOT overstress the lock or it will
NOT properly hold the terminal
when reassembled.
Figure 3.
1
NOTICE
When inserting lance canceling
tool M, pry carefully outward just
enough to remove the terminal
from the wire side. Excessive
pressure may damage the lock or
bend the tool.
(2) As the lock is held outward, gently
pull on the violet wire from the back
of the connector to remove it.
C. Insert the terminal of engine wire No. 4
(white-black) into the headlamp bulb
No. 2 connector.
1
Terminal Lock
Figure 4.
1
2
3
1
Headlam p Bulb No. 2 Connector (Low Beam)
2
Insert Engine Wire No. 4 Into Terminal
(White-Black)
3
Engine ROOM Main Wire Harness
(White-Black)
© 2018 Toyota Motor Sales, USA
T-SB-0204-12
Rev2
October 17, 2012
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Headlamp Durability Enhancement
Repair Procedure (continued)
D. Cut the violet wire previously removed from the headlamp bulb No. 2 connector near
the terminal.
E. Remove the wire outer coat insulation
10 mm from the edge.
Figure 5.
1
4
3
NOTE
Measure the length of the wire carefully to
ensure the wire fits properly.
F. Remove 10 mm of the wire outer coat
insulation from engine wire No. 4
(white-black wire).
5
2
1
Engine ROOM Main Wire Harness (Violet)
2
Cut Here
3
Strip Off 10 m m of Insulation
4
Wire Insulation Coat
5
10 m m
Figure 6.
3
1
2
4
1
Strip Off 10 m m of Insulation
2
Wire Insulation Coat
3
Engine ROOM Wire No. 4
4
10 m m
G. Insert a section of heat shrink tubing (P/N 82999-30010) over the engine wire No. 4.
H. Insert the stripped, bare wires into the sleeve tube (P/N 82999-52010), ensuring the
wires overlap in the center of the crimp.
© 2018 Toyota Motor Sales, USA
T-SB-0204-12
Rev2
October 17, 2012
Page 7 of 9
Headlamp Durability Enhancement
Repair Procedure (continued)
I.
Using the wire crimper, apply a 2 crimp
to the center of the sleeve tube.
Figure 7.
SST: P/N 09042-2C100
NOTE
The wire crimper tool handles MUST be
fully depressed for them to release. Verify
proper alignment BEFORE applying
pressure to crimper handles.
J. Apply one additional crimp on both
sides of the center crimp as shown.
Figure 8.
1
c
2
K. Slide the heat shrink tubing over the
crimp and apply sufficient heat with a
heat gun to close the heat shrink around
the wire insulation.
1
Apply a 2 Crim p Here
2
Crim ped Sleeve Tube
Figure 9.
1
2
1
Heat Gun
2
Shrink Tube
L. Insert the headlamp connector back into the headlamp socket.
© 2018 Toyota Motor Sales, USA
T-SB-0204-12
Rev2
October 17, 2012
Page 8 of 9
Headlamp Durability Enhancement
Repair Procedure (continued)
M. Test for normal high and low beam headlamp operation with the headlamp temporarily
connected to the wiring harness.
6. Reinstall the headlamp assembly.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 Prius:
Vehicle Exterior – Lighting (Ext) – “Lighting (Ext): Headlight Assembly: Installation”
7. Install the engine wire No. 4 wire harness
on the driver or passenger side. Be sure to
attach nylon ties less than 100 mm apart.
Figure 10.
NOTE
 Each nylon tie should be located no more
than 100 mm from the next one.
 There should be no free play between the
factory harness and the engine wire No. 4
wire harness loom.
 The ties should face outside the vehicle.
 Be sure to trim the ties AFTER application.
1
Distance Between Nylon Ties Less Than
100 m m
Figure 11.
A. Driver Side Installation:
(1) Install the engine wire No. 4 harness
connector into the
headlamp assembly.
(2) Route the No. 4 harness at the inner
bumper reinforcement area following
the contours of the factory harness.
(Test first routing as necessary to
ensure fit.)
(3) Apply the nylon ties less than
100 mm from each other,
facing outward.
NOTE
Seven tie wraps are needed for the
left side. Ties number 6 and 7 are
located closer together than other ties.
Exact distance depends on routing.
1–7
8
(4) Trim the nylon ties AFTER installation.
© 2018 Toyota Motor Sales, USA
Nylon Ties
Front of Vehicle
T-SB-0204-12
Rev2
October 17, 2012
Page 9 of 9
Headlamp Durability Enhancement
Repair Procedure (continued)
B. Passenger Side Installation:
Figure 12.
(1) Plug the engine wire No. 4 harness
connector into the
headlamp assembly.
(2) Test fit routing the No. 4 harness by
following the contours, starting at
the upper part of the factory wire
harness area.
(3) Apply the nylon ties less than
100 mm from each other,
facing outward.
NOTE
Six tie wraps are needed for the
driver side.
1
Nylon Ties
2
Front of Vehicle
Figure 13.
(4) Trim the nylon ties
AFTER installation.
1
Distance Between Nylon Ties Less Than
100 m m
8. Reinstall the bumper cover.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 Prius:
Vehicle Exterior – Exterior Panels/Trim – “Exterior Panels/Trim: Front Bumper: Installation”
9. Adjust the headlamps.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 Prius:
Vehicle Exterior – Lighting (Ext) – “Lighting (Ext): Headlight Assembly: Adjustment”
10. Verify normal operation of ALL affected systems.
© 2018 Toyota Motor Sales, USA